Instruction/ maintenance manual of the product stt 1600 Sterling
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Op er ating In struc tions De hu mid ified Air Dryer STT 1600 with Siemens S7 con trol unit 0 3 6 - 2 M S Ster ling Ma te rial Pro cess ing.
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Tech ni cal ser vice: Ser vice de part ment Tele phone: (800) 423-3183 Edi tion: 11/02 Or der con fir ma tion num ber: _ _ _ _ _ _ _ _ _ _ _ 0 3 6 - 2 M S STT 1600 2 Ster ling Ma te rial Pro cess ing 5200 West Clinton Ave. Mil wau kee, WI 53223 Tele phone: (414) 354-0970 Fax: (414) 354-6421 www.
Ster ling Ma te rial Pro cess ing re tains all rights to change the in for ma tion in these op er at ing in struc tions at any time with out no tice. We as sume no li a bil ity for any er rors or di rect or in di rect dam age re sult ing in con - text with these op er at ing in struc t ions.
TA BLE OF CON TENTS 1. Gen eral In for ma tion ............................................... 1-1 1.1. Warn ings and sym bols ............................................. 1-2 1.2. Ex pla na tions and in for ma tion ..................................
5. Main te nance ..................................................... 5-1 5.1. Main te nance in ter vals ............................................. 5-3 5.2. Cleaning/re new ing the air fil ters ..................................... 5-4 5.3. Ten sioning the V-belts .
10. Spare parts list ................................................. 10-1 10.1. Switching Cab i net and Op er ating Unit .............................. 10-5 11. Elec tri cal man ual ............................................... 11-1 o Con nec tion di a gram no.
1. Ge ne ral In for ma ti on » The se ope ra ting in struc tions are ad dres sed to all users of the de vi ce. The se ope ra ting in struc tions must be used by every per son char ged with work on the unit.
1.1. War nings and sym bols The fol lo wing war nings and sym bols are used in the se ope ra ting in struc tions: » This sym bol in di ca tes dan ger to life! Fa tal or se ri ous in ju ry is pos si ble if the cor re spon ding in struc tions, re gu la tions or war nings are not ob ser ved.
1.2. Ex pla na tions and in for ma ti on Va ri ous terms and de sig na tions are used in the se ope ra ting in struc tions to en su re cla ri ty. The re - fo re plea se note that the terms used in the text stand for t he cor re spon ding ex pla na tions lis ted be - low.
2. Sa fe ty in struc tions » The se sa fe ty in struc tions ap ply to all per sons wit hin the ran ge of ac ti on of the equip ment. Plea se in form all per sons wit hin the ran ge of ac ti on of the equip ment of the di rect and in di rect ha zards con nec ted with the equip ment.
2.1. For your sa fe ty Ge ne ral The ope ra ting per son nel of this equip ment must be at least 16 ye ars old. Plea se read the se ope ra ting in struc tions ca re ful ly be fo re ta king into ope ra ti on for the first time. Con tact us should que stions ari se.
Take care that the de vice is not stand ing on the mains ca ble. This will pre vent dan ger to peo ple and ma te rial! The dry ing cells must be filled with dry ing agent be fore setting-up the dryer (only STT 1600, STT 2400).
Main ten an ce Be fo re star ting main ten an ce work, ap point a su per vi sor. In form the re spon si ble per son nel be fo re main ten an ce work on the sys tem is start ed.
2.2. For the sa fe ty of the de vi ces Ne ver chan ge set tings wit hout ca re ful ly as ses sing the con se quen ces. Use only ori gi nal Ster ling spa re parts. Ob ser ve the main ten an ce in struc tions. Keep a re cord of all main ten an ce works and re pairs.
Ob serve that the dry ing cells must be filled with dry ing agent be fore setting-up the dryer (only STT 1600, STT 2400). This will pre vent dam age of ma te rial! Check 5 hours af ter first putt ing into op er a tion that the dry ing cells are sufficently filled with dry ing agent (only STT 1600, STT 2400).
3. Start-up » This chap ter is di rec ted at the ope ra tors of the equip ment. This chap ter as su mes ge ne ral skills in dea ling with dry ing sys tems and SPS (PLC) con trol units. This chap ter as su mes that the functio nal des crip ti on has been read and un - ders tood.
3.1. Control system The control system is switched on at the main switch. The control system is operated via a ”selection window” and the keyboard of the operator panel.
3.1.2. Flow chart 1 Indicator lamp 2 Valve system 3 Drying chamber 4 Drying blower 5 Return air filter 6 Drying hopper 7 Drying heater 8 Regeneration heater 9 Regeneration blower 10 Regeneration air f.
3.2. Switchi ng on the dryer Switch on the system by means of the main switch. & The control system carries through a self-test; after that , the name of the dryer and the operation status of the unit are display ed. F Unblock the control system: Keep the ACK key pressed until the LEDs of the keys K1 - K4 li ght up.
3.3. Vie wing the soft wa re-ver si on Press the “±” -key. & Lamp test: all LED’s must light up. The soft ware-ver sion will be dis played (op tional). 3.4. Passwords The entry of a password prevents unauthorised persons from having access to the data entered into the control system.
Login Press the key “F2" . En ter the pass word. Press the ENTER key. & If the pass word has been en tered cor rectly, the cor re spond ing pass word level is dis played. You can now en ter data into the con trol sys tem or mod ify data which have al ready been en tered.
3.5. Basic parameters Press the ”F1"-key. 3.5.1. Turning the devices on/off Select ” Main menu ”. Acknowledge with the ENTER-key. or Press the ”F2” -key. Dryer on/off ”on” = turn dryer on, ”off” = turn dryer off. Acknowledge with the ENTER-key.
Hop per X on/off (X = num ber of the dry ing hop per) “on” = re lea sing dry ing hop per X, “off” = bloc king dry ing hop per X Ack nowled ge with the EN TER-key. Hop per hea ter X on/off (X = num ber of the hop per hea ter) “on” = switch on hop per hea ter X, “off” = switch off hop per hea ter X Ack nowled ge with the EN TER-key.
3.5.2. Entering dryer values Select ”Dryer” . Acknowledge with the ENTER-key. or Press the ”F3” -key. Regeneration Heater Act. The regenerated heat temperature will be displayed. Used air Act. The current temperature of the used air will be displayed.
& If the unit ope ra tes with a re turn air coo ler (op tio nal): Re turn air cooler Tar get En ter the max. per mis si ble re turn air tem per a ture (65 °C max. (149°F max). Higher tem per a tures are not al lowed. Ac knowl edge with the EN TER-key.
3.5.3. Entering hopper values Select ”Hopper” . Acknowledge with the ENTER-key. or Press the ”F4” -key. Hopper entry X Target (X = number of the drying hopper) Enter the drying temperature for hopper flap X (when operating with supplement ary heating).
& If the unit ope ra tes with mo tor flaps (op tio nal): Gran ules X tar get: _ % = _ °C (°F) (X = num ber of the dry ing hop per) En ter the ma te rial tem per a ture at which the flap (op tional) on the dry ing hop per X should close. Con firm with the EN TER key.
3.5.4. Observing processing status Select ”Status” . Acknowledge with the ENTER-key. or Press the ”K1” -key. & The current operation status of individual assembly parts is displayed: e.g.: valve block mov ed in/mov ed out/error “moved in” = The upper drying cells are within the drying circuit; the lower ones are regenerated.
3.5.5. Setting date and time & This function is password protected. Press the “K3" -key. Enter the password if requested. Date Press the SHIFT key. By means of the arrow keys, select the desired week-day. By means of the arrow keys, select the shown date.
3.5.6. Viewing/changi ng language and contrast & This function is password protected. Press the “K4" -key. Enter the password if requested. Contrast Press the SHIFT key. By means of the arrow keys, select the adjustment which suits you best.
3.5.7. Changing parameters Select ”Parameters” . Acknowledge with the ENTER-key. or Press the SHIFT -key and the ”K1” -key. Run on time dry ing blow er -- 300 sec. Stan dard set ting: 300 sec onds, changes only af ter con tact ing Ster ling Ser vice.
3.5.8. Setting the timer Select ”Time r” . Acknowledge with the ENTER-key. or Press the SHIFT -key and the ”F1” -key. XX ON 00:00 OFF 00:00 (XX = day Mo-Su) Enter for each day the switching on time and the switching off t ime. Acknowledge with the ENTER-key.
3.6. Starting continuous operation When you have carried through all basic settings, you can start with continuous operation. F Make sure that hoppers which are not in use are separated from the dehumidified air supply. Make sure that the set drying temperatures are suited for the materials in the hoppers.
3.7. Viewing system runtime Select ”System runtime” . Acknowledge with the ENTER-key. or Press the SHIFT -key and the ”F2” -key. Sys tem runtime PLC #.## h r.-blw r. #.## h m.-blw r. #.## h & The runtime of the blowers and the PLC (SPS) is shown in hours.
3.8. Switchi ng the dryer off Select ”Main menu”. Acknowledge with the ENTER-key. or Press the ”F2” -key. Select ” Dryer off ”. Ack nowled ge with the ENTER-key. L Wait until the regeneration phase is finished and the blower has come to a standstill.
4. Er ror and er ror cor rec ti on » This chap ter is di rec ted at the ope ra tors of the equip ment. This chap ter as su mes ge ne ral skills in dea ling with dry ing sys tems and SPS (PLC) con trol units. This chap ter as su mes that the “start-up” des crip ti on has been read and un - ders tood.
& Alarm mes sages are dis played in plain lan guage on the screen of the op - er a tor de vice. The dis play of alarm mes sages in the op er a tor de vice can only be erased by press ing the ”ACK” key. The fail ure is not re paired. A fail ure is given by flash ing of the LED “alarm”.
View Press the ”F2" -key. All alarm mes sa ges with their num bers (see Texts), date, time and the supp le ment ”K”, ”G”, or ”Q” are dis play ed. & ”K” = co ming (a fai lu re oc cu red) Pres sing the “ à ”-key dis plays the alarm mes sa ge in plain text.
Num ber Press the ”F2" -key. To tal mes sa ges The num ber of all alarm mes sa ges is dis play ed. Wai ting mes sa ges The num ber of cur rent alarm mes sa ges is dis play ed. Press the ESC-k ey. De le te Press the ”F3" -key. & This functi on is pass word pro tec ted (Ster ling ser vi ce).
Over flow Press the ”F2" -key. & If the re are more cur rent alarm mes sa ges than can be sa ved, a war ning mes sa ge (= re si du al buf fer rea ched) may be gi ven. This functi on is pass word pro tec ted (Ster ling ser vi ce). Over flow w ar ning On/Off Press the SHIFT-key.
Text Press the ”F3" -key. All pos si ble alarm mes sa ges are dis play ed with their num bers (see Vie wing). For vie w ing the pos si ble alarm mes sa ges, press the ar row keys: PLC (= SPS) Bat te ry is Emp ty Re pla ce the SPS bat te ry. Main Sw itch is Off The main switch has been pla ced in the off po si ti on.
Check the blo wer. Va cu um sen sor de fec ti ve. Tem pe ra tu re Mea su re ment Re ge ne ra ti on Hea ter De fec ti ve Check the ca bles and the sen sor. Check the po wer supp ly. Short cir cuit check. Ex cess Tem pe ra tu re Re ge ne ra ti on Hea ter The re ge ne ra ti on tem pe ra tu re is too high.
Tem pe ra tu re Mea su re ment Dry ing Hea ter De fec ti ve Check ca bles and sen sor. Check the po wer supp ly. Short cir cuit check. Ex cess Tem pe ra tu re Dry ing Hea ter The dry ing tem pe ra tu re is too high. Check the sa fe ty tem pe ra tu re li mi ter.
Tem pe ra tu re Mea su re ment Gra nu les De fec ti ve Hop per X (X = num ber of the dry ing hop per) Check ca bles and sen sor. Check the po wer supp ly. Short cir cuit check. Ex cess Tem pe ra tu re Gra nu les Hop per X (X = num ber of the dry ing hop per) The ma te ri al tem pe ra tu re is too high.
5. Main ten an ce » This chap ter is in ten ded for per sons with skills in elec tri cal and me cha ni cal are as due to their trai ning, ex pe rien ce and re cei ved in struc tions.
F Plea se ob ser ve the main ten an ce sche du le. Be fo re star ting main ten an ce work, cle an the equip ment of oil, fuel or lu - bri cants. En su re that ma te ri als and in ci den tals re qui red for ope ra ti on as well as spa re parts are dis po sed of pro per ly and in an en vi ron men tal ly sound man ner.
5.1. Main ten an ce in ter val s 5 hours af ter first putt ing into op er a tion: Check dry ing agent in the dry ing cells, if nec es sary fil upl Daily: Check war ning signs on equip ment for good le.
5.2. Clea ning/re ne w ing the air fil ters Press the ”F2” -key. Se lect ” Dry er off ”. Ack nowled ge with the EN TER-key. L Wait un til the blo wers have stop ped tur ning. Switch off the dry er at the main switch. Dis con nect the po wer supp ly.
Re turn air fil ter /Re gen er a tion air fil ter Loosen the se cur ing nut on the fil ter hous ing and re move the hous ing lid. Re move the re turn air fil ter/re gen er a tion air fil ter. Clean the fil ter car tridge with com pressed air from in side to out or re new the fil ter.
Fil ter of the elec tri cal ca bi net Re mo ve the lid of the fil ter. Re mo ve the fil ter mat. Blow through the fil ter mat with com pres sed air from in si de to out si de or re new the fil ter mat. Cle an the fil ter hou sing. Use lint-free clea ning rags.
5.3. Ten sio ning the V-belts Press the ”F2” -key. Se lect ” Dry er off ”. Ack nowled ge with the EN TER-key. L Wait un til the blow ers have stopped turn ing. Switch off the dryer at the main switch. Dis con nect the power sup ply. F Open the up per panel by me ans of the pro vi ded switch ca bi net key.
”Re gen er a tion” Blo w er Re move the pro tec tive grid of the blower (pos. 3). Loosen the nut (pos. 1). Loosen and re move the screw (pos. 2). Slide mo tor with car rier flange plate (pos. 6) to wards the car rier flange hous ing (pos. 4). Re place ment: Re move de fec tive V-belts (pos.
”Drying” Blower Re move the pro tec tive grid of the blower (pos. 7). Loosen the nut (pos. 10). Loosen the screw (pos. 11). Re place ment: Re move de fec tive V-belts (pos. 32), put on new ones. Re-tensioning: Ad just belt ten sion by means of screw (pos.
High-pres su re blo wers w ith fre quency con ver ter ope ra ti on F Blo wers work wit hout V-belts! 5.4. Dis po sing of the dry ing agent En su re that dry ing cells are ex chan ged by Ster ling or re fil led only when emp ty. Dessicant must be dis po sed of in ac cor dan ce with all of fi ci al re gu la tions.
5.6. Chan ging the bat te ry of the con trol sys tem » This work may be car ried through only by qua li fied per son nel trai ned in the field of elec tri cal en gi nee ring. F The bat te ry may be chan ged only with the con trol sys tem swit ched on.
L Sto re ba ckup bat te ries in a dry and cool pla ce. Ba ckup bat te ries can be sto red for ap prox. 5 ye ars. If ba ckup bat te ries are not trea ted pro per ly, they can ig ni te, ex plo de and cau se se ve re bur ning.
5.6.1. Re set ting the con trol va lu es » This elec tri cal work is in ten ded to be car ried out only by trai ned per son nel. & Af ter chan ging the bat te ry or the PLC the con trol va lu es should be re set - ted. All con trol va lu es are set back to the stan dard set tings.
6. Functio nal des crip ti on This functio nal des crip ti on is in ten ded for all ope ra ting per son nel of the equip ment. Pre re qui si te for this functio nal des crip ti on is ge ne ral knowled ge of dry ers and SPS (PLC) s ys tems. En su re in each case that the ope ra ting per son nel are suf fi cient ly in form ed.
6.1. Dry er The dry er ope ra tes with de hu mi di fied air, i.e. the air is not only hea ted but also de hu mid i fied before flow ing into the dry ing hop per. This prin ci ple al lows plas tic gra nu les to be dried to a re si du - al moi stu re con tent as low as 0.
6.2. Dry ing hop per (op ti o nal) The ma te ri al is dried in the dry ing hop per. The de hu mi di fied air is for ced through the ma te ri al in the hop per, col lec ting moi stu re in the pro cess. The dry ing hop per must be di men sio ned ac cor - ding to its in ten ded use to en su re that the fi nal moi stu re con tent is at tai ned.
6.3. Re turn air cooler (op tional ) F A re turn air cooler is gen er ally re quired in cases in which the re turn air tem per a ture is over 65 °C(149°F). A re turn air coo ler im pro ves the ef fi cien cy of the dry ing cells. The re turn air coo ler re du ces the re turn air tem pe ra tu re to a de fi ned va lue.
6.4. Hop per hea ters (op tio nal) If dif fe ring dry ing tem pe ra tu res are re qui red in the dif fe rent dry ing hop pers, hop per hea ters must be in stal led on the dry ing hop pers. The dry ing tem pe ra tu re of each dry ing hop per can be set cen - tral ly at the dry er.
7. Trans port, As sem bly and Sto ra ge » This chap ter is in ten ded for all ope ra ting per son nel of the equip ment. Per son nel using the se in struc tions must be in struc ted in the re gu la tions for the pre ven ti on of ac ci dents, the ope ra ting con di tions and sa fe ty re gu la tions and their im ple men ta ti on.
7.1. Trans port and Pac king » Plea se en su re ade qua te car ry ing ca pa ci ty of the lif ting equip ment. Note that the dry er sys tem is top-he avy. Risc of topp ling! The equip ment pass a ri go rous ope ra ting test in the fac to ry and are pa cked ca re ful ly to avoid trans port da ma ge.
w ith a work shop cra ne Check if the eye lets are in stal led on the dry er hou sing. If this con di ti on is met, fas ten the trans port ca bles to the eye lets. If this con di ti on is not met, mount the eye lets and then fas ten the trans port ca bles to the eye lets.
7.2. As sem bly » Plea se en su re ade qua te car ry ing ca pa ci ty of the lif ting equip ment. Check the car ry ing ca pa ci ty of the point of in stal la ti on, par ti cu lar ly if in stal led on a plat form. The pla ce se lec ted for in stal la ti on should be as free of vi brat ions as pos si ble.
8. As sem bly in struc tions » These in stal la tion in struc tions are in tended for per sons with skills in elec tri - cal and me chan i cal ar eas due to their train ing, ex pe ri ence and re ceived in - struc tions.
8.1. Moun ting of the suc ti on de vi ce for re ge ne ra ti on ex haust air When plas tics are dried which pro du ce ha zar dous ga ses, en vi ron men tal ly sound dis po sal of the re ge ne ra ti on ex haust air must be pro vi ded. The throughput of the re ge ne ra ti on blo wer may not be chan ged.
8.2. Fill ing up the dry ing cells L At de liv ery the dry ing cells are not filled with dry ing agent. F Be fore fill ing up check that the screw con nec tion (B) is mounted. Re move the ten sion ring and the tin plate (A). Fill the dry ing cell with dry ing agent up to the noz zle (see fill ing level).
8.3. Con nec ti on of the air coo lers (op ti o nal) F A re turn air cooler is gen er ally re quired in cases in which the re turn air tem per a ture is over 65 °C (149°F). The re turn air coo ler can be con nec ted to a coo lant cir cuit or the wa ter mains net work.
8.4. Elec tri cal con nec ti on » Ob ser ve the ru les of the lo cal elec tri ci ty board. Check that the supp ly vol ta ge and the po wer fre quen cy are in ac cor dan ce with the data on the name pla te of the de vi ce.
9. Tech ni cal Data Ba sic Equip ment · Cen tral ly mo ni to red PLC S7 dry ing con trol sys tem with ope ra tor pa nel OP 7 · Cen tral tem pe ra tu re con trols for all hea ting ele ments to en su .
Di men si on sheet 0 3 6 - 2 M S STT 1600 Tech ni cal Data 9 - 2 All di men sions are in mm (in). Sub ject to al te ra ti on..
10. Spare parts list Version: 64.10-0233GB05 11/02 » This spare parts list is intended to be used only by trained personnel. Other persons are not permitted to modify or repair the equipment. & ID-num bers for units with spe cial volt age, for ex.
12 99716 Ball bearing 16 05190 Valve stem 86363 Spin dle mo tor 24 V 0 3 6 - 2 M S STT 1600 Spare parts list 10 - 2 12, 16.
39 31536 Sealing 72 16517 Mo tor flap (op tional) 86379 Mo tor 88952 Sealing 100 83986 Mois ture sen sor 86387 Sen sor PT 100 (12 m) (39.37 ft.) 0 3 6 - 2 M S STT 1600 Spare parts list 10 - 3 39 100 7.
4 S89532 Blower HRD 1/5 94211 V-belt 5 83970 Blower HRD 7/12 31924 Acous tic cover 83963 V-belt 33 31516 Drying cell 96196 Drying agent 96143 Ten sion ring 28420 Sealing ring 85533 Ten sion ring 36 86.
Control 27892 Front panel with flow chart 83468 CPU 315 (S7) 83809 Battery 83811 OP 7 84156 Fan 84157 Fil ter Hop per heat ers Ca ble set heat ing 95828 Tu bu lar heat ing el e ment 230 V, 3 kW 85652 .
11. E lec tri cal ma nu al Ver si on: 64.10-0133GB01 10/97 » This electrical manual is intended to be used only by Ster ling service personnel and trained personnel authorized by Ster ling. Other persons are not permitted to modify or repair the equipment.
12. Ac ces so ries Ver si on: 64.10-0134GB01 10/97 ¨ En te ring va lu es on the OP 7 / 17 ¨ Flap con trol with Fuz zy-Lo gic ¨ Elek tror High-pres su re blo wer with fre quen cy con ver ter ope ra .
Ac ces so ries En te ring va lu es on the OP 7 / 17 Ster ling Ma te rial Pro cess ing B G 1 0 / 2 0.
1 OP7, OP17 09/96 3.3 Entering V alues In input fields, values can be entered on the OP and transferred to the PLC. T o do this, proceed as follows: S tep Procedure 1 Branch initially to the screen you require and then to the corresponding screen entry .
2 OP7, OP17 09/96 3.3.1 Entering Nume rical V alues In fields that allow the operator to enter a numerical value, you enter the nu- merical value character by character using the keypad on the system key- board. If there is a value in the field already , it is cleared completely from the field when the first character is entered.
3 OP7, OP17 09/96 3.3.2 Entering Alph an umeric V alues W ith the input of alphanumeric values, digits and letters are mixed. For the numerical components of the input, proceed as described in section 3.3.1. If, however , you wish to enter a letter at the current cursor position, you must enable the corresponding alphanumeric font.
4 OP7, OP17 09/96 If the characters available on the keypad are not sufficient for the alphanu- meric input, you can select additional letters and special characters from the extended character set. The extended character set is available for all KC type fields.
5 OP7, OP17 09/96 3.3.3 Entering Sym bolic V alues When you enter a symbolic value, text is displayed instead of the value. If a field has to be filled by entering symbolic values, take the value from a list of options. T o do so, proceed as follows: S tep Procedure 1 In the input field press Shift LED is on.
Acces so ries Flap con trol with Fuzzy-Lo gic Ster ling Ma te rial Pro cess ing B G 0 0 / 0 1.
F Obser ve that the hop per is not swit ched off af ter the flap has clo sed. Tur ning hop per off: see chap ter “start-up, tur ning the de vi ces on/off ”.
An important point after buying a device Sterling stt 1600 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Sterling stt 1600 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Sterling stt 1600 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Sterling stt 1600 you will learn all the available features of the product, as well as information on its operation. The information that you get Sterling stt 1600 will certainly help you make a decision on the purchase.
If you already are a holder of Sterling stt 1600, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Sterling stt 1600.
However, one of the most important roles played by the user manual is to help in solving problems with Sterling stt 1600. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Sterling stt 1600 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
