Sterling Clothes Dryer SCD 10 User Manual

SCD 10 Compressed Air Dryer  
Part Number: 882.00280.00  
Bulletin Number: DH1-625.1  
Effective: 04/28/08  
Write Down Your Serial Numbers Here For Future Reference:  
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We are committed to a continuing program of product improvement.  
Specifications, appearance, and dimensions described in this manual are subject to change without notice.  
DCN No. ____________  
© Copyright 2008  
All rights reserved.  
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Table of Contents  
CHAPTER 1: SAFETY ...............................................................5  
1-1  
How to Use This Manual .............................................................................................5  
Safety Symbols Used in this Manual.....................................................................5  
General Safety Regulations ........................................................................................6  
Responsibility ..............................................................................................................6  
Warnings and Precautions ..........................................................................................7  
1-2  
1-3  
1-4  
CHAPTER 2: FUNCTIONAL DESCRIPTION ............................8  
2-1  
2-2  
2-3  
2-4  
2-5  
Models Covered in This Manual..................................................................................8  
General Description.....................................................................................................8  
Typical Features and Components .............................................................................8  
Options........................................................................................................................8  
Safety Features...........................................................................................................9  
Safety Circuit Standards........................................................................................9  
High Temperature Safety System .........................................................................9  
Airflow monitoring Safety System..........................................................................9  
Line Cord Plug (115/1/60 units only).....................................................................9  
Drying Hopper Air Trap ...............................................................................................9  
Remote Membrane Dryer for Low-Dewpoint Operation (Optional) ...........................10  
Microprocessor Controls ...........................................................................................11  
Identifying the Controller’s Buttons and Indicators..............................................12  
Understanding the Controller’s Parameters ........................................................13  
Restoring Factory Default Settings............................................................................14  
2-6  
2-7  
2-8  
2-9  
CHAPTER 3: INSTALLATION.................................................15  
3-1  
3-2  
3-3  
3-4  
3-5  
3-6  
Uncrating the Equipment...........................................................................................15  
Connecting a Hopper-Mount Dryer to a Hopper........................................................15  
Connecting a Floor-Mount Dryer to a Hopper ...........................................................16  
Making Electrical Connections ..................................................................................16  
Making Compressed Air Connections.......................................................................17  
Installing the Remote-Mount Membrane Dryer (Optional).........................................18  
CHAPTER 4: OPERATION......................................................19  
4-1  
4-2  
4-3  
4-4  
Auto-tuning the Dryer ................................................................................................19  
Setting the Alarm Value.............................................................................................19  
Start-up......................................................................................................................20  
Shut-down .................................................................................................................20  
CHAPTER 5: MAINTENANCE.................................................21  
5-1  
5-2  
5-3  
Preventative Maintenance Schedule.........................................................................21  
Cleaning and Replacing the Filters ...........................................................................21  
Replacing the Process Heater...................................................................................21  
CHAPTER 6: TROUBLESHOOTING.......................................22  
10 CFM Compressed Air Dryer  
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CHAPTER 7: APPENDIX.........................................................25  
7-1  
Returned Material Policy ...........................................................................................25  
7-2 Technical Assistance………………………………………………………………………26  
7-3  
7-4  
Technical Specifications............................................................................................27  
Dryer Operating Parameters ...............................................................................28  
Dimensions..........................................................................................................29  
Spare Parts List ........................................................................................................30  
10 CFM Compressed Air Dryer  
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Chapter 1: Safety  
1-1 How to Use This Manual  
Use this manual as a guide and reference for installing, operating, and maintaining your  
dryer. The purpose is to assist you in applying efficient, proven techniques that enhance  
equipment productivity.  
This manual covers only light preventative maintenance. No other maintenance should be  
undertaken without first contacting a service engineer.  
The Functional Description section outlines models covered, standard features, and safety  
features. Additional sections within the manual provide instructions for installation, pre-  
operational procedures, operation, and preventive maintenance.  
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup  
of the dryer. We can also provide the assistance of a factory-trained technician to help train  
your operator(s) for a nominal charge. This section includes instructions, checks, and  
adjustments that should be followed before commencing with operation of the dryer. These  
instructions are intended to supplement standard shop procedures performed at shift, daily,  
and weekly intervals.  
The Operation chapter includes a description of electrical and mechanical controls, in  
addition to information for operating the dryer safely and efficiently.  
The Maintenance chapter is intended to ensure that your dryer provides excellent, long  
service.  
The Troubleshooting chapter serves as a guide for identification of most common problems.  
Potential problems are listed, along with possible causes and related solutions.  
The Appendix contains technical specifications, drawings, schematics, parts lists, and  
available options. A spare parts list with part numbers specific to your machine is provided  
with your shipping paperwork package. Refer to this section for a listing of spare parts for  
purchase. Have your serial number and model number ready when ordering.  
Safety Symbols Used in this Manual  
The following safety alert symbols are used to alert you to potential personal injury hazards.  
Obey all safety messages that follow these symbols to avoid possible injury or death.  
DANGER! DANGER indicates an imminently hazardous situation that, if not avoided,  
will result in death or serious injury.  
WARNING! WARNING indicates a potentially hazardous situation or practice that, if  
not avoided, could result in death or serious injury.  
Caution!  
CAUTION indicates a potentially hazardous situation or practice that, if  
not avoided, may result in minor or moderate injury or in property damage.  
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Chapter 1: Safety  
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1-2 General Safety Regulations  
Read and follow the instructions in this manual before installing, operating or maintaining  
any equipment. Additional copies are available from the manufacturer.  
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. Only qualified persons should work on or with this equipment.  
Work only with approved tools and devices.  
Before removing, adjusting, or replacing parts on a machine, remember to turn off all air and  
electric supplies and all accessory equipment at the machine. You must also disconnect and  
lock out electrical and pneumatic power and attach warning tags to the disconnect switch and  
air shut off 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 on-current carrying parts of electrical apparatus, electrical 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. 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 properly.  
1-3 Responsibility  
These machines are constructed for maximum operator safety when used under standard  
operating conditions and when recommended instructions are followed in the maintenance  
and operation of the machine.  
All personnel engaged in the use of the machine should become familiar with its operation as  
described in this manual.  
Proper operation of the machine promotes safety for the operator and all workers in its  
vicinity.  
Becoming familiar with materials, inspection, and maintenance and total user responsibility  
will assist you in learning potential areas in need of observation for danger.  
Each individual must take responsibility for observing the prescribed safety rules as outlined.  
All caution, warning and danger signs must be observed and obeyed. All actual or potential  
danger areas must be reported to your immediate supervisor.  
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Chapter 1: Safety  
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1-4 Warnings and Precautions  
Our equipment is designed to provide safe and reliable operation when installed and operated  
within design specifications, following national and local safety codes.  
To avoid possible personal injury or equipment damage when installing, operating, or  
maintaining this dryer, use good judgment and follow these safe practices:  
; 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, remove all objects (tools, nuts, bolts, clamps, bars) from  
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 be  
adjusted only by authorized personnel, and the keys removed after setting.  
; Report unsafe operation, unsafe conditions, unusual dryer action, leakage, and  
improper maintenance immediately.  
; 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.  
; 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.  
; Never attempt to move the dryer while it is in operation.  
; Always allow time for the dryer to cool off before moving it or servicing the fuse or  
air filter.  
We have long recognized the importance of safety and have designed and manufactured our  
equipment with operator safety as a prime consideration. We expect you, as a user, to abide  
by the foregoing recommendations in order to make operator safety a reality.  
10 CFM Compressed Air Dryer  
Chapter 1: Safety  
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Chapter 2: Functional Description  
2-1 Models Covered in This Manual  
This manual provides instructions for installing and operating your 10 cfm compressed air  
dryer.  
2-2 General Description  
Mini compressed air dryers are designed to generate heated, dehumidified air at carefully  
controlled temperatures for use in plastic drying systems. Drying systems are sized to meet  
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. This dehumidifying dryer is used to  
generate very low dew point air, heated to a controlled temperature for drying plastic pellets  
and regrind.  
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, the manufacturer can advise you on necessary equipment  
and process time and temperature modifications required for your system.  
2-3 Typical Features and Components  
Electrical solenoid valve  
Compressed air filter, regulator, and gauge  
Drying temperature range of 120ºF to 400ºF  
Display of process temperature set point and actual settings  
Process thermocouple located in the process air stream just before the hopper inlet  
Nema 1 control enclosure:  
a. Fusing  
b. Power On light  
c. IEC process heater contactor  
d. Solid state relay  
e. Alarm light  
f. High temperature safety system  
g. Airflow detection system  
2-4 Options  
Options can tailor your dryer to meet the exact requirements of the drying task being  
performed.  
Floor-mount configuration  
Membrane compressed air dryer for low dew point operation  
220/1/50 operation  
230/1/60 operation  
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2-5 Safety Features  
This section includes information on safety devices and procedures that are inherent to the 10  
cfm compressed air 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.  
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 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 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.  
High Temperature Safety System  
A high temperature safety system will disable the dryer if the process temperature is too hot.  
The high temperature safety is designed so that if it fails, the failure causes a “safe”  
condition, and the dryer will not run. The compressed air continues flowing to cool down the  
system.  
Airflow monitoring Safety System  
If the airflow source to the compressed air dryer is below 35 PSI, the unit will shut down and  
not run. This is an indication that there is not enough pressure and flow for proper operation  
of the unit.  
Line Cord Plug (115/1/60 units only)  
The 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. Always disconnect  
power before servicing or moving this unit.  
DANGER! At no time should anyone remove the lockout or reconnect the twist plug,  
other than the person who installed the lockout or who unplugged the twist  
plug.  
2-6 Drying Hopper Air Trap  
Refer to the drying hopper Operation and Installation manual for proper operation of the  
drying hopper.  
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2-7 Remote Membrane Dryer for Low-Dew point Operation  
(Optional)  
Membrane 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 membrane 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 actually separates the water vapor from  
the air. 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 refrigerated air dryer.  
As a single stage unit, the dryer provides consistent performance from 60ºF to –20ºF 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 –40ºF with very low sweep  
requirements.  
Figure 1: Remote-Mount Membrane Dryer Airflow Schematic  
Water  
Air  
Dry Air  
Humid Air  
Purge  
Dry Air  
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2-8 Microprocessor Controls  
The 10 cfm compressed air dryer uses a microprocessor-based PID temperature controller for  
maintaining process air temperature. The controller is a modular, self-contained unit that you  
can remove from the mounting housing. All parameters except for the process air set point  
are factory set and adjusted. Normally, no field adjustment to the internal controls is  
necessary.  
Figure 2: Microprocessor Controller  
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Identifying the Controller’s Buttons and Indicators  
Button or Indicator  
Function  
During normal operation, the PV numeric LED  
indicator displays the process temperature at the To  
Process thermocouple. It also lists parameters during  
set-up and error messages if any errors occur.  
PV display  
During normal operation, the SV numeric LED  
indicator displays the set point temperature selected for  
the dryer. The dryer then maintains this set point  
temperature. This LED indicator also displays  
parameter and preset function values during  
configuration set-up.  
SV display  
This LED indicator displays the temperature units (ºF  
or ºC) that the dryer is configured to use.  
Temperature Unit display  
Level button  
The Level button is used to enter set-up. There are two  
set-up levels available: Operation and Adjustment.  
Mode button  
The Mode button is used to scroll through paramenters  
in set-up modes.  
Down Arrow button  
The Down Arrow button is used to decrease the set  
point temperature during operation. It also decreases  
the parameter values in set-up modes.  
Up Arrow button  
The Up Arrow button is used to increase the set point  
temperature during operation. It also increases the  
parameter values in set-up modes.  
The Alarm 1 indicator lights when the process  
temperature exceeds the set point temperature by more  
than the alarm deviation value. Alarm output de-  
energizes the heaters. Heaters re-energize when the  
temperature falls within the acceptable range.  
AL1 Alarm 1 indicator  
AL2 Alarm 2 indicator  
HB Heater Burnout indicator  
The Alarm 2 indicator is not used.  
(Optional) The Heater Burnout indicator lights when a  
heater burnout is detected. The heater burnout alarm  
remains On by setting the heater burnout latch. To  
reset, turn the power supply off and then on or set the  
heater burnout alarm vale to 0.0A.  
The Output 1 indicator lights when the controller  
signals the process heaters to be energized.  
OT1 Output 1 indicator  
OT2 Output 2 indicator  
STOP Stop indicator  
The Output 2 indicator is not used.  
The Stop indicator lights when the controller has been  
stopped.  
CMW Communications indicator  
The Communications indicator is not used.  
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Lights when the auto/manual mode is set to manual  
mode.  
MANU Manual Mode  
(Key)  
Lights when the setting change protect is ON.  
Understanding the Controller’s Parameters  
Set-  
up  
Parameter  
Function  
Level  
Can be set to “RUN” or “STOP.” When “RUN” is selected,  
the control is running. When “STOP” is selected, the control  
is stopped, and the Stop indicator lights. The default value is  
“RUN.”  
Run/Stop (r-S)  
Can be set from –1999 to 9999. This parameter is used to  
indicate how many degrees the process temperature will be  
allowed to exceed the set point temperature. An alarm output  
will de-energize the heaters. The default value is 25.  
Alarm Value (AL-1)  
Can be set to “ON” or “OFF.” This feature is used to  
automatically set the optimum PID parameters “proportional  
band,” “integral time” and “derivative time” for the set point  
value by changing the variables that had been modified  
previously. The default value is “OFF.”  
Auto-tune (At)  
Can be set from –199.9 to 999.9. This setting is used to offset  
an error between the set point and the actual temperature. The  
entire input range is shifted by a set figure preprogrammed by  
the operator. The default value is 0.  
Temperature Input  
Shift (Tns)  
Can be set from 0.1 to 999.9. This setting controls the amount  
in which the manipulated variable (MV) is proportionate to  
the deviated value or controller error. The default value is 8.0.  
Proportional Band  
(P)  
Can be set from 0 to 3999. Setting this feature gives the  
control an action that is proportionate to the time integral of  
the control error. By using this setting, proportional action is  
used in combination with integral action to offset the control  
error and the set point will begin to match the control  
temperature (PV or process value). The default value is 233.  
Integral Time (I)  
Can be set from 0 to 3999. Setting the derivative control  
provides the controller with the ability to correct for a future  
error in the previously set process output. The default value is  
40.  
Derivative Time (d)  
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2-9 Restoring Factory Default Settings  
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. Contact the Service department for detailed instructions.  
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Chapter 3: Installation  
3-1 Uncrating the Equipment  
The 10 cfm compressed air dryer has a handle at the top of the cabinet to use for lifting. For  
hopper-mount configurations, be sure to support the hopper when lifting and placing the  
dryer. Use caution and observe safety rules when lifting and placing your dryer. Be sure it is  
securely attached and additional bracing is used if necessary.  
3-2 Connecting a Hopper-Mount Dryer to a Hopper  
When mounting the dryer to an existing hopper, use the adapter and the self-tapping screws  
that are provided with the unit to mount the dryer to the inlet of the hopper. The adapter is  
pre-drilled with three holes that are used to mount it to the hopper.  
Note: In some cases, depending on the drying hopper model, an adapter may not be  
required. If an adapter is not required, attach the dryer to the hopper with the  
clamps provided, and install the exhaust filter to the drying hopper  
outlet/return line.  
Use the following procedure to mount the dryer to a hopper using an adapter (See Figure 3):  
1. Mark the holes in the inlet tube of the hopper for drilling.  
2. Use a 9/64” drill bit to pre-drill for the #8-32 screws that are provided.  
3. Spread silicone adhesive over the area where the adapter will mount to the hopper inlet  
tubing.  
4. Place the adapter onto the tubing and install the three screws to hold it in place. Allow  
sufficient time for the silicon to cure before you operate the dryer.  
5. Attach the dryer to the hopper with the clamps provided.  
6. Install an exhaust filter to the drying hopper outlet/return line.  
Figure 3: Typical Hopper-Mount Configuration  
10 CFM Compressed Air Dryer  
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3-3 Connecting a Floor-Mount Dryer to a Hopper (Optional)  
Use high-temperature flexible dryer hose or rigid tubing to connect the dryer to the drying  
hopper. Keep the delivery hose to the drying hopper as short as possible to minimize heat  
loss. We strongly recommend insulated hose for maximum energy savings. Make sure that  
hoses are not kinked or collapsed.  
Use the following procedure to connect a floor-mount dryer to a hopper:  
1. Using the clamps provided, clamp a hose adaptor onto the dryer and the hopper. (See  
Figure 4.)  
Note: Depending on the drying hopper model, the clamp and hose adapter may not be  
required. Connect the dryer hose with the hose clamp directly to the process air  
inlet of the drying hopper.  
2. Install an exhaust filter to the drying hopper outlet/return line.  
3. Drying hopper air inlet and outlet locations vary, but always connect hoses so the dry  
process air from the dryer enters the bottom of the drying hopper and flows out the  
top.  
Figure 4: Floor-Mount Configuration  
10 CFM Compressed Air Dryer  
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3-4 Making Electrical Connections  
The serial tag lists voltage, phase, and amp draw information. Line voltage must be within  
plus or minus ten percent of the voltage listed on the serial tag, or damage may occur. Never  
supply any voltage other than what the dryer is configured for.  
Fulfill all national, state, and local safety and electrical code requirements. A qualified  
electrician should make all electrical connections.  
Connect main power to the dryer. Install a fused disconnect with a lockout feature in the  
power main leading to the dryer. The power drop must include a ground wire. Make sure all  
electrical connections are tight.  
Note: Due to variances in 220-240 V connections, customers must supply the plug for  
these dryer models.  
3-5 Making Compressed Air Connections  
The compressed air supply must be regulated to 80 PSI (5.5 bars). Low air pressure will  
create poor drying performance. If the pressure in the system drops below 35 PSI, the alarm  
light will activate and the process heater and solenoid valve will shut off.  
Note: For maximum drying efficiency, we recommend a refrigerated compressed air  
connection. Not using refrigerated compressed air (to provide pre-conditioned  
compressed air to this unit) will affect drying performance and material drying  
capabilities.  
To achieve the lowest possible dew points, an optional remote-mount membrane dryer  
assembly is available. See Section 2-7 on page 10 for more information about the remote-  
mount membrane dryer assembly.  
Connect a minimum of 3/8” (9 mm) air line to the top of the filter regulator. Compressed air  
must be clean, dry, and free of oil. A shut-off is recommended for your in-plant air supply.  
In-line filters can handle small amounts of moisture; in-line desiccant filters or packed beds  
of granular absorbing polymer can remove oil mist and condensed oil.  
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3-6 Installing the Remote-Mount Membrane Dryer (Optional)  
The membrane drying kit can be mounted anywhere near the compressed air dryer. The kit is  
pre-assembled with a bracket that can be mounted to any flat surface with two screws. Use  
Figure 5 as a reference for this installation.  
1. Remove the large particle filter, including the close nipple, from the inlet of the  
compressed air dryer.  
2. Attach the large particle filter (including the close nipple) to the membrane drying kit.  
Note: The membrane drying kit must have the large particle and the coalescing filters  
in place and functioning properly to ensure full drying capabilities of the  
membrane. Both filters must be checked and cleaned regularly.  
3. Attach the 1/4” NPT elbow to the inlet of the compressed air dryer.  
4. Run the 3/8” hose between the outlet of the membrane drying kit and the inlet of the  
compressed air dryer. Use thread sealant on all threaded connections.  
Figure 5: Membrane Dryer Assembly  
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Chapter 3: Installation  
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Chapter 4: Operation  
Before beginning dryer operation, make sure that there is a good compressed air connection  
and that the main power is securely plugged in. Check the process hose and hopper exhaust  
filter for tight connections. Check all companion equipment, such as the drying hopper; verify  
that the loading system is ready for operation. The dryer will not run if a fault condition  
exists. Investigate the cause of any faults.  
DANGER! Always turn the dryer off before servicing. Do not attempt to check the  
alarms on the controller located within the unit enclosure unless you are a  
qualified electrician.  
4-1 Auto-tuning the Dryer  
Although the controller is calibrated at the factory, the unit should be auto-tuned prior to  
dryer start-up.  
Use the following procedure to auto-tune the dryer:  
1. Press the Level button one time to enter the Adjustment level.  
2. Press the Mode Key one time. The PV display will read “At.”  
3. Press the Up Arrow button to change the value to “ON.”  
4. Press the Level button to begin auto-tuning and return to the Operation level.  
The unit will automatically auto-tune. While this process is taking place, the SV  
display will blink the set point value. When the SV display stops blinking, the auto-  
tune process is finished.  
Note: It is recommended that the unit be auto-tuned when the pressure and airflow of  
the compressed air have been adjusted, and the dryer is running close to  
process temperature set point.  
4-2 Setting the Alarm Value  
The Alarm Value setting determines how many degrees the process temperature is allowed to  
exceed the set point temperature before the high temperature alarm is triggered and the heater  
turned off.  
Use the following procedure to set the alarm value:  
1. Press the Mode button two times to select the Alarm Value 1 parameter. (The PV  
display will read “AL-1”).  
2. Use the Up Arrow and Down Arrow buttons to change the value.  
3. Press the Mode button to accept the value and begin operation.  
Note: The factory default valve for this setting is 25.  
10 CFM Compressed Air Dryer  
Chapter 4: Operation  
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4-3 Start-up  
Use the following procedure to start the dryer:  
1. Turn on the disconnect switch in the power drop, close the slide gate at the bottom of  
the drying hopper.  
2. Close the slide gate at the bottom of the drying hopper.  
3. Fill the drying hopper with material.  
4. Turn the ON/OFF switch to “ON” to energize the display panel and turn on the  
solenoid and the heater.  
5. Use the Up Arrow and Down Arrow buttons to set the process set point on the  
temperature controller.  
Note: Consult the resin manufacturer for the recommended drying temperature.  
6. Press the Mode button one time to make sure the controller’s Run/Stop parameter is  
set to “RUN.”  
7. Use the Up Arrow or Down Arrow button to change the value to “RUN.”  
8. Press the Mode button to begin operation.  
9. After the proper pre-drying time for the initial hopper fill has elapsed, fully open the  
drying hopper slide gate.  
Note: To allow proper residence time during continuous processing, maintain the  
material level in the hopper at the midpoint of the air trap assembly.  
4-4 Shut-down  
Use the following procedure to shut down the dryer:  
1. When processing is complete, close the hopper slide gate and shut down any in-line  
companion equipment.  
2. Lower the process temperature controller set point to a value of 100º Fahrenheit.  
3. Allow at least one minute of run time so that the compressed air continues to flow  
through the unit and cool down the heating components.  
4. Turn the On/Off switch to “Off.”  
5. If needed, empty the drying hopper.  
6. For maintenance or a long-term shutdown, open the electrical disconnects at the dryer  
and at the power drop.  
10 CFM Compressed Air Dryer  
Chapter 4: Operation  
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Chapter 5: Maintenance  
This dryer is designed to be virtually maintenance-free. This unit is factory-sealed. Any  
service required on this unit must be performed by factory personnel at the manufacturer’s  
facility.  
WARNING! The 10 cfm compressed air dryer is sealed at the factory. Removing  
this seal and opening the box that houses the dryer will void your  
warranty. Please contact the manufacturer for assistance.  
5-1 Preventative Maintenance Schedule  
Weekly  
Inspect all filters for wear, and replace/clean if dirty or worn  
Check to make sure that all hose connections are air tight  
Monthly  
Lock out electrical power and inspect the main power supply for integrity.  
5-2 Cleaning and Replacing the Filters  
The 10 cfm compressed air dryer uses a large particle air filter in the process air system to  
clean the compressed air before it enters the drying cabinet. The optional remote-mount  
membrane dryer assembly features a coalescing filter in addition to the large particle air filter.  
Regular filter cleaning is essential to keep the dryer operating at peak efficiency.  
Use the following procedure to clean or replace the process air filter or the membrane dryer  
coalescing filter:  
1. Turn off and lock out electrical power to the dryer.  
2. Remove the clear bowl at the bottom of the filter. (See Figure 6).  
3. Discard the contents of the clear filter bowl.  
4. Visually inspect the filter element.  
5. If needed, clean the filter element with compressed air or replace it.  
Caution! Do not clean or wash the filter with water.  
6. Replace the clear bowl.  
Figure 6: Large Particle Filter  
10 CFM Compressed Air Dryer  
Chapter 5: Maintenance  
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5-3 Replacing the Fuse Outside of the Cabinet  
Note: If the compressed air dryer does not start when the ON/OFF switch is in the  
“ON” position, check the main power supply to ensure that it is properly installed. If  
the main power supply is correct, check the fuse. This is located on the front of the  
driver cabinet. Use the following procedure to check and, if needed, replace the fuse.  
1. Make sure that the main power to the dryer is shut off and locked out.  
2. Locate the fuse holder that houses the fuse for the dryer (see picture below for fuse  
holder location).  
3. Using a standard flat-head screwdriver, remove the insert that holds the fuse from the  
fuse holder.  
4. Separate the insert from the fuse.  
5. Using a multimeter, check for continuity between the two ends of the fuse.  
6. If there is no continuity, replace the fuse. See Spare Parts List for fuse part number.  
7. Insert new fuse into the fuse holder.  
8. Using a standard flat-head screwdriver, turn the fuse into the installed position within  
the fuse holder.  
Fuse Holder  
10 CFM Compressed Air Dryer  
Chapter 5: Maintenance  
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Chapter 6: Troubleshooting  
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 unit turned off, power disconnected, and with the machine tagged as  
out of service.  
Problem  
Possible Cause  
Possible Remedy  
Drying systems are designed  
for the material that was  
Material being dried differs  
from material specified at the originally specified.  
time of purchase.  
Different materials may need  
a longer residence time or a  
different drying temperature.  
Loss or reduction in drying  
capacity.  
Inspect for air leaks; replace  
as needed.  
Break in flex hose to drying  
hopper.  
Check resin manufacturer’s  
data sheet for proper drying  
temperature. Make sure plant  
personnel are aware of the  
correct process temperature  
set point.  
Process temperature set too  
high due to operator error.  
Material in drying hopper  
cakes, or meltdown occurs.  
High temperature alarm not  
set properly.  
Reset high temperature  
alarm.  
Process set point is out of  
acceptable range.  
Restore temperature  
controller to factory pre-sets.  
Function set for degrees  
Celsius (ºC), set point at  
degrees Fahrenheit (ºF).  
Verify correct Celsius or  
Fahrenheit settings.  
Nothing displays when the  
controller is turned on.  
Verify that the thermocouple  
is properly installed in the  
inlet tube.  
Process thermocouple not in  
airflow.  
The internal mechanism is  
not inserted properly into the  
No setting change possible on housing.  
Properly insert the internal  
mechanism into the housing.  
temperature controller.  
The power supply is not  
connected to its terminals  
properly.  
Properly connect the power  
supply to the power supply  
terminals.  
Supply a voltage of 85 to  
No power is supplied, or the 125 VAC to the power  
supplied power is not within supply terminals of the  
the specified range.  
controller or 220-240 V for  
higher voltage units.  
10 CFM Compressed Air Dryer Chapter 6: Troubleshooting  
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Problem  
Possible Cause  
Possible Remedy  
Check control power fuse for  
continuity. Turn disconnect  
switch and control power  
switch ON.  
Disconnect switch or Control  
Power switch not set to ON.  
Control Power fuse blown.  
The key protection switch is Set the key protection switch  
set to ON.  
to OFF.  
Compressed air source is no  
longer sufficiently above 35  
Check compressed air source  
for proper functioning.  
Alarm light is on and unit has psi.  
no air pressure.  
Regulator is set below 35  
psi.  
Check regulator for proper  
functioning.  
10 CFM Compressed Air Dryer Chapter 6: Troubleshooting  
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Chapter 7: Appendix  
7-1 Returned Material Policy  
Credit Returns  
Prior to the return of any material, authorization must be given by the manufacturer. A RMS number  
will be assigned for the equipment to be returned.  
Reason for requesting the return must be given.  
All returned material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking  
charge.  
All returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
No credit will be issued for material that is not within the manufacturer’s warranty period and/or in new  
and unused condition, suitable for resale.  
Warranty Returns  
Prior to the return of any material, authorization must be given by the manufacturer. A RMS number  
will be assigned for the equipment to be returned.  
Reason for requesting the return must be given.  
All returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
After inspecting the material, a replacement or credit will be given, at the manufacturer’s discretion, if  
the item is found to be defective in materials or workmanship. Purchased components are covered  
under their specific warranty terms.  
10 CFM Compressed Air Dryer  
Chapter 7: Appendix  
25 of 30  
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7-2 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 specifications, which will maximize your equipment’s performance  
and efficiency. To assist in expediting your phone or fax order, please have the model and serial  
number of your unit when you contact us. A customer replacement parts list is included in this manual  
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing  
excellent customer service.  
Service Department  
Call toll-free 8am—5pm CST [800] 423-3183 or call [262] 641-8610  
Emergencies after 5pm CST, call [847] 439-5655  
We have a qualified service department ready to help. Service contracts are available for most of our  
Sales Department  
Call [262] 641-8610 Monday—Friday, 8am—5pm CST, fax [262] 641-8653  
Our products are sold by a world-wide network of independent sales representatives. Contact our sales  
department for the name of the sales representative nearest you.  
Contracting Department  
Call [262] 641-8610 Monday—Friday, 8am—5pm CST  
Let us install your system. The Contracting Department offers any or all of these services: project  
planning; system packages including drawings; equipment, labor, and construction materials; and union  
or non-union installations.  
Sterling, Inc.  
2900 S. 160th Street  
New Berlin, WI 53151  
10 CFM Compressed Air Dryer  
Chapter 7: Appendix  
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7-3 Technical Specifications  
Average dew point: -10ºF (-23ºC)  
Average dew point with optional membrane dryer: -40ºF (-40ºC)  
Heating capabilities up to 400ºF  
Large particle compressed air filter  
Exhaust air cartridge filter  
1/16 DIN PID temperature controller  
High process temperature alarm light  
Automatic shutoff system to monitor compressed air supply  
Full load amps:  
12.5 @ 115V  
6.25 @ 240V  
1.5”, 2”, 2.5”, or 3” OD process air outlet (specify)  
Approximate weight: 25 lbs. (11.3 kg)  
10 CFM Compressed Air Dryer  
Chapter 7: Appendix  
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Dryer Operating Parameters  
Material  
Drying  
Temp, ºF,  
(ºC)  
Drying Drying Hopper Capacity,* lbs./hr (kg/hr)  
time in  
hours  
Initial  
Final  
0.4 cu. ft. 0.8 cu. ft. 0.9 cu. ft.  
moisture moisture (11 liter) (22 liter) (25 liter)  
content. content  
H20 in % H20 in % hopper  
drying  
drying  
hopper  
drying  
hopper  
ABS  
ASA  
CA  
CP  
EVA  
176 (80)  
212 (100)  
176 (80)  
167 (75)  
176 (80)  
2-3  
3
0.45  
0.15  
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)  
4.6 (2.1) 9.2 (4.2) 10.4 (4.7)  
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)  
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)  
5.6 (2.5) 11.2 (5.1) 9.0 (4.1)  
2-3  
2-3  
2-3  
3.5  
4-6  
4-6  
4-6  
4-6  
4-6  
0.7  
1.0  
0.15  
0.15  
Ionomere 194 (90)  
4.0 (1.8) 8.0 (3.6)  
2.8 (1.3) 5.6 (2.5)  
2.8 (1.3) 5.6 (2.5)  
2.8 (1.3) 5.6 (2.5)  
2.8 (1.3) 5.6 (2.5)  
2.8 (1.3) 5.6 (2.5)  
5.2 (2.3)  
6.3 (2.9)  
6.3 (2.9)  
6.3 (2.9)  
6.3 (2.9)  
6.3 (2.9)  
PA11  
PA12  
PA6  
PA6.6  
PA6.6  
GF35  
PBT  
167 (75)  
167 (75)  
176 (80)  
176 (80)  
176 (80)  
0.7  
0.7  
0.5  
0.5  
0.5  
0.07  
0.07  
0.05  
0.05  
0.04  
266 (130)  
248 (120)  
3-4  
2-4  
3-4  
1-2  
4
4
4
4-6  
0.25  
0.16  
0.5  
0.02  
0.01  
0.02  
0.01  
4.0 (1.8) 8.0 (3.6)  
4.6 (2.1) 9.2 (4.2)  
4.6 (2.1) 9.2 (4.2)  
9.0 (4.1)  
10.4 (4.7)  
10.4 (4.7)  
15.8 (7.1)  
7.9 (3.6)  
7.9 (3.6)  
7.9 (3.6)  
5.2 (2.3)  
PC  
PE Filled 185 (85)  
PE  
PEEK  
PEI  
PES  
PETP  
194 (90)  
302 (150)  
302 (150)  
302 (150)  
300-392  
(150-200)  
149 (65)  
176 (80)  
212 (100)  
194 (90)  
212 (100)  
284 (140)  
176 (80)  
302 (150)  
176 (80)  
158 (70)  
176 (80)  
176 (80)  
230 (110)  
194 (90)  
0.05  
7 (3.2)  
14 (6.4)  
3.5 (1.6) 7 (3.2)  
3.5 (1.6) 7 (3.2)  
3.5 (1.6) 7 (3.2)  
2.3 (1.0) 4.6 (2.1)  
0.25  
0.43  
0.25  
0.01  
0.02  
0.002  
PETG  
PMMA  
POM  
PP  
PPO  
PPS  
4-5  
2-3  
3-4  
2
2-3  
3-4  
1-2  
3-4  
3-4  
1-2  
2-3  
2
0.1  
0.25  
0.2  
0.1  
0.2  
0.1  
0.05  
0.3  
0.4  
0.3  
0.3  
0.3  
0.04  
0.02  
0.05  
0.05  
0.02  
0.05  
0.02  
0.05  
0.01  
0.10  
0.03  
0.03  
3.5 (1.6) 7 (3.2)  
7.9 (3.6)  
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)  
4.6 (2.1) 9.2 (4.2)  
7 (3.2) 14 (6.4)  
10.4 (4.7)  
15.8 (7.1)  
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)  
4.6 (2.1) 9.2 (4.2)  
7 (3.2) 14 (6.4)  
4.6 (2.1) 9.2 (4.2)  
4.6 (2.1) 9.2 (4.2)  
10.4 (4.7)  
15.8 (7.1)  
16.4 (7.4)  
16.4 (7.4)  
PS  
PSU  
PUR  
PVC  
SAN  
SB  
9.3 (4.2) 18.6 (8.4) 41.9 (19)  
5.6 (2.5) 11.2 (5.1) 25.2 (11.4)  
7 (3.2)  
4.6 (2.1) 9.2 (4.2)  
14 (6.4)  
31.5 (14.3)  
16.4 (7.4)  
TPE  
TPU  
3-4  
2-3  
0.4  
0.02  
5.6 (2.5) 11.2 (5.1) 12.6 (5.7)  
* Performance may vary based on initial quality of the compressed air supply to the dryer.  
10 CFM Compressed Air Dryer  
Chapter 7: Appendix  
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Dimensions  
12  
(305)  
13.4  
(339)  
12.25  
(311)  
15.7  
(398)  
6.8  
(172)  
7.3  
(185)  
10 CFM Compressed Air Dryer  
Chapter 7: Appendix  
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7-4 Spare Parts List  
Parts not included in this list must be replaced by the factory.  
Part No.  
Quantity  
Description  
35452  
1
1
1
2
1
Filter Regulator  
Fuse (110 volt)  
Fuse 220/1/50  
Fuse 230/1/60  
Hopper Mounting  
CLDMP  
725.00002.00  
725.00001.00  
725.00001.00  
CT92241  
CT94233  
1
Hopper Mounting  
Gasket  
10 CFM Compressed Air Dryer  
Chapter 7: Appendix  
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