Sterling 882.00290.00 6 Troubleshooting

6 Troubleshooting

6-1 Introduction

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 power off (or certified electrician should trouble shoot the unit) , line

fuses removed, and with the machine tagged as out of service.

The use of good quality test equipment cannot be over-emphasized when troubleshooting is

indicated. Use a good ammeter that can measure at least twice the AC and DC current that

can be encountered for the machine. Be sure that the voltmeter has at least minimum

impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales.

Popular combination meters, VOM and VTVM can be selected to provide the necessary

functions.

Before making haphazard substitutions and repairs when defective electrical components are

malfunctioning, we recommend that you check the associated circuitry and assemblies for

other defective devices. It is common to replace the obviously damaged component without

actually locating the real cause of the trouble. Such hasty substitutions will only destroy the

new component. Refer to wiring diagrams and schematics.

Locating mechanical problems, should they occur, is relatively straightforward. When

necessary, refer to the parts catalog section.

Alarm Message Cause Corrective Action Dryer Status

Make sure the process filter

is clean. Clean or replace if

necessary.

The process

temperature has

exceeded the alarm

set point. Double check the alarm set

point.

Check the positioning of the

thermocouple inside the air

inlet of the drying hopper.

The high temperature

snap switch of the

process heater box

has tripped. The tip of the thermocouple

should be centered to the

tube, and not touching any

metal part of the tube.

The drying temperature set

point is lower than dryer

capabilities. Check the dryer

specs.

Make sure all the hose

connections are tight.

HIGH TEMP

The high temperature

snap switch on of the

regeneration heater

boxes has tripped

Make sure the regeneration

timing cycle matches the

specs. If not contact Service

department.

- Dryer Shuts down:

- Process blower OFF.

- Process heaters OFF.

- Regen heaters OFF.

- Alarm light is ON

- Alarm horn is ON.

Dehumidifying Dryers 6Troubleshooting 42 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