Sterling 882.00290.00 4-3 System Operation Procedures

4-3 System Operation Procedures

Controller Operation (Without Optional Alarm Horn & Reset Button)

1. Turn the disconnect on the control panel to the ON position. Power is applied to the voltage

line fuses, line side of the control power switch and the temperature controller.

2. Turn the control power switch to the ON position. Power is applied to the programmable relay

and dew point controller. The valve will move to the start position as follows:

a. The valve motor rotates until the cam switch makes 2 transitions.

b. If the cam switch does not make a transition within 10 seconds, a valve

motor fault is generated. “VALVE MTR” is displayed on the relay screen,

the alarm light is activated. The valve motor, heaters, and blower shut off.

To restart the dryer, cycle control power to deactivate the alarm light and

restart the valve motor sequence.

Note: The relay screen which contains the Alarm Display Messages is

located inside the controller enclosure. For a list of Alarm Display

Messages, see Page 33. (Turning off the dryer resets the alarm)

WARNING! Do not attempt to check the Alarms on the Controller located within the

unit enclosure unless you are a qualified electrician!

c. The valve will normally complete one full cycle (revolution).

If the drying process shuts down due to an alarm, the dryer has been setup to

have the following operational features:

• The bed in process at power-down will remain in process.

• The bed in regeneration at power-down will remain in regeneration.

• The regeneration timing cycle will restart from the beginning.

3. Once the control power is on and no fault conditions exist, turning the OFF-ON-START switch

to the START position will start the dryer as follows:

a. The process heater is turned on and controlled by the E5CN controller.

b. The process/regen blower is started.

c. The regen heater is turned on and the regeneration timing sequence is

initiated. The regen heater is controlled by the E5C2 controller. For default

timing settings for regeneration, see the table below.

Model Heating Cooling

15 cfm

30 cfm 35 30

60 cfm 40 40

4. If either the left or right bed safety temperature switch opens, a regen heater fault is generated.

“HIGH TEMP” is displayed on the relay screen. The alarm light is activated. The regen heater is

turned off.

Dehumidifying Dryers Chapter 4: Operation 28 of 53

Contents

Main 15, 30, and 60 CFM Dryers With AP-0 Controls Shipping Information Table of Contents CHAPTER 1: SAFETY................................................................ 5 CHAPTER 2: FUNCTIONAL DESCRIPTION........................... 10 CHAPTER 3: INSTALLATION..................................................14 CHAPTER 4: OPERATION.......................................................19 CHAPTER 5: MAINTENANCE ................................................. 35 CHAPTER 6: TROUBLESHOOTING ....................................... 42 CHAPTER 7: APPENDIX..........................................................45 Chapter 1: Safety 1-1 How to Use This Manual DANGER! 1-2 Safety Tag Information 1-3 Warnings and Precautions 1-4 Responsibility Page Page Chapter 2: Functional Description 2-1 Models Covered in This Manual 2-2 General Description 2-3 Standard Features 2-4 Options 2-5 Safety Devices and Interlocks Page Chapter 3: Installation 3-1 Uncrating the Equipment Note: 3-2 Rigging and Placing the Dryer Note: USE FORK LIFT TRUCK USE Overhead Crane 3-3 Electrical Connections 3-4 Setup Procedures Checking for Proper Blower Rotation Drying Hopper Air Trap Considerations (If Equipped) Installing the Optional Aftercooler 3-5 Initial Start-up Pre-Startup Checks Chapter 4: Operation 4-1 Start-up The process blower starts. 4-2 Controller Description and Operation Page 8.8.8.8 8.8.8.8 Identifying Temperature Controller Keys Setting the Process Air Temperature Restoring the Process Air Temperature Controller (E5CN) Adjustment Level Note: Entering Operating Parameters to Select Modes The SV readout displays the different values for the parameter within a mode. The PV readout will display the different parameters within each mode. The SV readout displays the different values for the parameter within a mode. Figure 6: Settings for Process Temperature Controller (E5CN), Part No. A0567917 Process Air Dew Point Display Figure 7: Typical Dew Point Display Monitor; Part Number A0555757 AT Note: Setting the High Dew Point Alarm Restoring the Process Air Dew Point Meter (E5CK) to Factory Setup Redundant Safety Controller Display Optional Figure 8: Typical Redundant Safety Controller Display; Part No. A0568961 WATLOW Operating Parameters Entering Operating Parameters to Select Modes Figure 9: Setting List for Redundant Safety Controller (WATLOW), Part No. A0568961 4-3 System Operation Procedures Controller Operation (Without Optional Alarm Horn & Reset Button) Note: Page OMRON E5C2 Note: Alarm Display Messages 4-4 Auto-Tuning the Dryer HIGH TEMP PROC BLWR VALVE MTR Page Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule replacement date inspection System model # 5-2 Preventative Maintenance Servicing Process Air Filters Recommendations for Cleaning and Replacing Filters Figure 10: Air Filter Location and Disassembly Vacuuming Cleaning with Compressed Air Servicing the Dew Point Monitor 5-3 Corrective Maintenance Symptoms of Worn Desiccant + FIRST AID + In case of eye contact, immediately flush eyes with plenty of water for at least 15 minutes. SEE A PHYSICIAN IMMEDIATELY IF IRRITATION PERSISTS. Replacing Worn Desiccant Figure 11: Desiccant Bed Location and Disassembly Page Figure 13: Process Heater Location and Disassembly Procedures Replacing/Cleaning the Cooling Coils Figure 14: Cooling Coil Location and Disassembly 6 Troubleshooting 6-1 Introduction HIGH TEMP PROC BLWR Dehumidifying Dryers 6Troubleshooting 43 of 53 VALVE MTR 6-2 Determining Temperature Controller Errors or Sensor Errors Using a Thermocouple 7 Appendix 7-1 Warranty Warranty Liabilities Customer Responsibilities 7-2 Technical Specifications Annex B Information Aftercooler Design Specifications Entering water temp. F C 85F 50F (If used as Plasticizer trap) 29C 7-3 Drawings and Diagrams Figure 15: Standard Model (180F to 250F) Air Flow Schematic Figure 16: High Heat Model (180F to 400F) Air Flow Schematic Figure 17: Low Heat Model (120F to 250F) Air Flow Schematic 7-4 Spare Parts List Figure 18: Level 1 Spare Parts List (Electrical & Mechanical) Dehumidifying Dryers 7Appendix 50 of 53 Page 7-5 Returned Material Policy Credit Returns 7-6 Dryer Identification (Serial Number) Tag 7-7 Technical Assistance Parts Department Service Department Sales Department Contract Department