Sterling 05/R User's Manual
Contents
1. DUKE REM EE 6 1 1 Warnings and Symbols us uc aco Ca t EC 8 Cn e wh a a RC C 7 1 2 Explanations and 8 1 3 For YOUN safety uu uou CR aa a CR CER 9 1 4 For the safety of the 12 2 Installation 13 2 1 General information 14 2 2 Installing the conveyor 15 2 3 Installing the control and maintenance unit 16 2 4 Connecting the compressed air supply 17 2 5 Electrical 18 3 Functional G6SCriptiOn sera O8 cR oe 19 3 1 Method OF functioning s lt 20 3 2 Control and maintenance unit 20 2 i P 21 21 Preparati nS uiu cartons deae V het dw le ee 22 4 2 Basic setting of the filling level in the conveyor hopper 22 4 2 1 Fine adjustment of the filling level in the conveyor 23 5 nnn 24 5 1 Maintenance 262. and or incomplete and shouldn t be relied upon Please contact the ACS Group for more current information about these manuals and their warnings and precautions Parts and Service Department 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 For immediate assistance please contact e North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 21 35329112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Con
3. as well as spare parts are disposed of properly and in an en vironmentally sound manner Use only original Sterling spare parts Keep record of all maintenance and repair procedures Maintenance 25 SM4 605 SSV 05 R 5 1 Maintenance intervals daily Check the setting of the pressure reducer Empty the water separator Check the danger signs on the unit for legibility and completeness monthly Clean the filter and sieve depending on accumulation of dust Blow out the filter from the inside out by means of compressed air Check the unit plugs for proper functioning every six months Check all electrical and mechanical connections for proper fit Replace the filter and the sieve depending on accumulation of dust The given maintenance intervals are average values Check whether in your individual case the maintenance in tervals must be shortened Maintenance 26 SM4 605 5 2 Cleaning replacing the filter cartridge Switch off the unit Disconnect the mains plug SSV 05 R Disassembly Remove the filter cartridge A Blow out the filter cartridge A from the inside out by means of com pressed air or replace the filter Open the toggle type fastener B Fold the hopper lid C upwards Check the sieve D within the lid for material residue Disassembling the sieve for cleaning draw the sieve out of the fit of the sealing ring Clean the sieve D by means of compres
4. all types of work on electrical components Danger to life due to electrical shock Safety instructions 9 SM4 605 SSV 05 R e Do not carry through modifications attachments or alterations of the unit without the manufacturer s permission Danger of accidents By means of this operating manual prepare precise instructions for use of this unit Faulty operation may lead to accidents Designate a unit leader responsible for the unit In any case the operators of this unit must be thoroughly instructed Faulty operation may lead to accidents If the unit has been switched off for reasons of safety it must be protected from unathorised activation Danger of accidents Before beginning maintenance work designate a supervisor Before beginning maintenance work inform the responsible operating personnel Danger of accidents Before beginning maintenance work interrupt the mains supply so that the unit is not switched on unintentionally Danger of accidents Repair work may only be carried through by trained personnel Danger of accidents The unit may never be operated when it is partially disassembled Limbs may be drawn in Electrical shock In case of functional disturbances switch off the unit immediately Errors must be eliminated immediately Danger of accidents e The unit is exclusively intended for conveying plastic granules and regrind Any other usage is not permitted e his unit is not suitable for pr
5. n PS 3 E o Ee ET m o D 4 yY Es Dimensions and data are not binding All dimensions are in mm in All data are subject to change Technical data 31 SM4 605 6 2 Spare parts list CN J 4 d SSV 05 R Technical data 32 SM4 605 Pos Designation A filter sieve 29252 sealing ring 28628 B conveyor hose level probe D compressed air hose Maintenance and control unit Designation ID No Maintenance and control unit 29370 filter insert 84415 coil 84414 repair set fittings 84413 cable plug housing 84412 ID No 98171 84426 85480 88351 SSV 05 R Technical data 33
6. 5 2 Cleaning replacing the filter cartridge 27 5 3 Adjusting the level probe 28 5 4 Trouble shooting zie ede ect co fec Sg lacs els estas 29 SM4 605 SSV 05 R 6 Technical data ereeeeeeer rnt 30 6 1 Dimension 1 31 6 2 Spare parts list s eure tun tI Rei 32 SM4 605 SSV 05 R 1 Safety instructions These safety instructions apply to all persons within the range of action of the equipment Please inform all persons within the range of action of the equip ment of the direct and indirect hazards connected with the equipment These operating instructions are to be used by all persons as signed activities connected with the equipment Knowledge of the English language is prerequisite Ensure in each case that the operating personnel are familiar with the operating instructions and the function of the equipment Safety instructions 6 SM4 605 SSV 05 R 1 1 Warnings and symbols The following warnings and symbols are used in these operating instructions This symbol indicates danger to life Fatal or serious injury is possible if the corresponding instructions regulations or warn ings are not observed This symbol indicates that serious injury is possible if the cor responding instructions regulations or warnings are not observed This symbol ind
7. SM4 605 Operating Instructions Single Conveyor Unit SSV 05 R Sterling Material Processing Sterling Sterling SM4 605 Sterling Material Processing 5200 West Clinton Ave Milwaukee 53223 Telephone 414 354 0970 Fax 414 354 6421 www sterlco com Technical service Service department Telephone 800 423 3183 Edition 08 99 SSV 05 R Please fill in personally Serial number This operation manual is Built in Date of delivery Number of delivery Date of commissioning Location Group of machines SM4 605 SSV 05 R Sterling Material Processing retains all rights to change the information in these operating instructions at any time without notice We assume no liability for any errors or direct or indirect damage resulting in con text with these operating instructions Copying translation or publication in any form except for personal use of purcha ser requires approval from Sterling Material Processing All rights reserved Please note that our address and phone information has changed Please reference this page for updated contact information These manuals are obsolete and are provided only for their technical information data and capacities AXCAUTION Portions of these manuals detailing procedures or precautions in the operation inspection maintenance and repair of the products may be inadequate inaccurate
8. ed fill ing level in the conveyor hopper is Filling level too high A By means of a screwdriver turn the ad justment screw A of the level probe rotation clockwise Observe the filling level during the next conveying procedure Repeat the process until the desired filling level in the conveyor hopper is reached Set up 22 SM4 605 SSV 05 R 4 2 1 Fine adjustment of the filling level in the conveyor hopper Before the fine adjustment carry through a basic adjust ment During operation carefully turn the ad justment screw A of the level probe by means of a screwdriver until the desired filling level is reached few N ge N _ Pa J A Clockwise rotation makes the filling level fall Counterclockwise rotation makes the filling level rise If the filling level in the conveyor hopper cannot be lowered far enough by means of the level probe the pressure on the control and maintenance unit can be re duced step by step Set up 23 SM4 605 SSV 05 R 5 Maintenance This chapter is intended for persons with skills in electrical and mechanical areas due to their training experience and received instructions Personnel using the instructions in this chapter must be in structed of the regulations for the prevention of accidents the operating conditions and safety regulations and their implemen ta
9. icates that extensive damage to equipment CE is possible if the corresponding instructions regulations or warnings are not observed This symbol indicates information important for becoming fa miliar with the equipment i e technical correlations GY This symbol indicates that a technical term is explained at this point Safety instructions 7 SM4 605 SSV 05 R 1 2 Explanations and information Various terms and designations are used frequently in these operating instruc tions to ensure clarity Therefore please note that the terms used in the text stand for the corresponding explanations listed below e Equipment Equipment can mean an individual unit a machine or an installation e Operating personnel The operating personnel are persons operating the equipment on their own re sponsibility or according to instructions minimum age 16 e Operator The operator of the equipment production manager foreman etc is the per son responsible for all production sequences The operator instructs the operat ing personnel of what is to be done e Operating instructions The plant operating instructions describe the interaction of the equipment pro duction sequences or methods The plant operating instructions must be com piled by the operator of the equipment e Equipment foreman When several operating personnel work on one machine the equipment fore man coordinates the sequences The equipment forema
10. n Observe the regulations of the local electricity board The operating voltage is 230 V AC PE 50 60 Hz Special voltages available on request The connected load is approx 15 W 0 02 hp The connection takes place by means of a mains connector A separate protection of the socket is not necessary Connect the plug of the probe cable to the control unit Plug the mains connector into a corresponding socket Installation instructions 18 SM4 605 SSV 05 R 3 Functional description This functional description is intended for the operating person nel of the equipment General knowledge of operating conveyor units is prerequisite Ensure in each case that the operating personnel are sufficiently informed The single conveyor unit SSV 05 R is designed for conveying dust free plastic granules and regrind directly on the injec tion moulding machine Functional description 19 SM4 605 3 1 Method of functioning The single conveyor unit works according to the venturi principle An external compressed air supply is needed A venturi meter A is integrated in the injector tube The venturi meter aspirates the material in the lower part of the tube C and then conveys the material into the conveyor hopper by means of compressed air in the upper part B In the hopper loader the material is separated from the air The filling level in the conveyor hopper is moni tored and controlled by means of a le
11. n must be appointed by the operator e Trained personnel Trained personnel are persons who due to their training are authorized to carry out the required work in good practice Safety instructions 8 SM4 605 SSV 05 R 1 3 For your safety e operators of this unit must be at least 16 years old e Before initial operation read this operating manual carefully Observe all points Inquire in case of uncertainties This will avoid danger to persons and damage of material e Store this operating manual in such a way that it is always available on the site of operation for the unit Faulty operation may lead to accidents e Note that for reasons of clarity not every possible case of operation or mainte nance can be mentioned e Note the instructions for safety and the danger signs on the unit This will avoid danger to persons and damage of material e All work on the unit may only be carried out by persons whose qualification corre sponds with the individual chapters of the operating manual Faulty operation may lead to accidents For all types of work on the unit proper working clothes must be worn This will avoid danger to persons e Compare the connected loads to those of the mains supply Danger of electrical shock e When using lifting gear observe the specific instructions Danger of accidents Observe the local regulations and requirements concerning the plant e Interrupt the mains supply for
12. ntenance unit SSV 05 R Install the control and maintenance unit at a freely accessible site Observe the length of the connection cable and of the supplied hoses to the injector tube During installation observe the length of the supply lines Installation instructions 16 SM4 605 2 4 Connecting the compressed air supply Check compressed air piping for correct installa tion and assembly Check fittings length and quality of the hose con nections for agreement with requirements Check all compressed air lines for leakages You need a compressed air supply with 5 6 bar system 72 52 87 02 PSI overpressure The air should be free from oil and water if possible Connect the compressed air hose which is part of the supply to the injector tube and to the con trol and maintenance unit To this end the com pressed air hose is firmly pressed into the con necting sockets Connect the control and maintenance unit to the compressed air supply max input pressure 10 bar 145 03 PSI system overpressure SSV 05 R Set the pressure on the pressure reducer at 5 6 bar 72 52 87 02 PSI Maximum input pressure 10 bar 145 03 PSI system Ee overpressure Maximum output pressure 6 bar 87 02 PSI Installation instructions 17 SM4 605 SOIR 2 5 Electrical connectio
13. ocessing foods Safety instructions 10 SM4 605 SSV 05 R e Attachments which are not delivered by Sterling must be constructed according to the safety standard EN 294 Danger of accidents e Check all lines hoses and coupling pieces in regular intervals for leakages and damage Any errors must be eliminated immediately Danger of accidents e Before beginning maintenance work set all compressed air lines on the unit at zero pressure Danger of accidents e The unit may only be operated if all corresponding components have been prop erly connected and are in accordance with the relevant regulations Observe the safety instructions for the connected units Safety instructions 11 SM4 605 SSV 05 R 1 4 For the safety of the units e The unit may only be used for conveying cylindrical plastic granules and regrind on injection moulding machines e Never change settings unless you are able to precisely foresee the conse quences e Use only original Sterling spare parts Observe the maintenance intervals e Keep a book on all maintenance and repair work e Note that electronic subassemblies may be damaged by static discharge e Before initial operation and in regular intervals check all electrical connections for proper fit Never modify sensors without knowing their precise functions e Make sure that all plugs are connected properly Observe the carrying capacity of the machine flange Obser
14. ompressed air hose is properly connected to the injector tube f Check whether the compressed air hose is properly connected to the mainte nance unit g Check whether the level probe is properly adjusted h Check whether the cable of the level probe is properly connected i Check whether the filter is clogged j Check whether the sieve is clogged k Check whether the conveyor hose is properly connected 1 Check whether the compressed air supply is properly adjusted Maintenance 29 SM4 605 SSV 05 R 6 Technical data Max permissible shot weight of the injection moulding machine 100 kg h with 0 6 220 56lbs h with 1 321bs l Weight HTTP approx 3 kg 6 61165 Operating 230 V AC PE 50 60 Hz Special voltage on request connected 22222 ardua wed ea d approx 15 W 0 02hp Total noise IEVEl 2 vce ewe ee eee ELE EERE ERE ERLE CELE EER ES lt 75 dB A Compressed air supply 5 6 bar system overpressure 72 52 87 02PSI 176 Technical data 30 SM4 605 SSV 05 R 6 1 Dimension sheet A _ A I 8 Els 38 a
15. ructions 13 SM4 605 SSV 05 R 2 1 General information Unpack all parts of the single conveyor unit and make sure that everything is available conveyor hopper with level probe A e control and maintenance unit B injector tube C supply hose D with 2 hose clamps e compressed air hose E e operating instructions Installation instructions 14 SM4 605 SSV 05 R 2 2 Installing the conveyor hopper The single conveyor unit is not sensitive to shocks and can be installed directly on the processing machine Make sure that all connections are tight so that the conveying performance is not impaired The conveyor hopper is equipped with a universal flange Depending on the position drill the holes for fastening the conveyor hopper to the processing machine Mount the conveyor hopper on the processing machine Install the supply hose on the conveyor hopper and on the injector tube by means of the hose clamps which are part of the supply Note that the hopper may not touch any other component 50 4 gt 2 07 150 6 01 gt Installation instructions 15 SM4 605 2 3 Installing the control and mai
16. sed air Replace the sieve and sealing ring in case of damage 88 SSV 05 R Maintenance 27 SM4 605 SSV 05 R Assembly Assemble the sieve and the sealing ring Check the sieve for proper fit Clean the hopper loader by means of a vacuum cleaner Close the hopper lid Close the toggle type fastener Assemble the filter cartridge Order number filter cartridge ID 98171 E Sieve ID 29252 Sealing ring ID 28628 5 3 Adjusting the level probe See chapter set up Order number level probe ID 85480 Maintenance 28 SM4 605 SSV 05 R 5 4 Trouble shooting Problem Remedy The unit is not conveying and is not active a b g h The unit is not conveying the compressed air valve is switched when the device is switched on c T The unit is not conveying the compressed air is flowing audibly c f i j The unit is overfilled 9 l m The unit is not filled properly f i j Test steps a Check whether the unit is switched on b Check whether the mains connector is connected and mains voltage is pres ent c Check whether sufficient compressed air is available d Check whether the injector tube is inserted in the material e Check whether the c
17. tact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract 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 For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information please visit us at www acscorporate com United States Asia Australia India ACS India ACS Schaumburg Corporate Offices ACS Suzhou Gat No 191 1 Sandbhor Complex 1100 E Woodfield Road 109 Xingpu Road SIP Mhalunge Chakan Tal Khed Suite 588 Suzhou China 215126 Dist Pune 410501 India Schaumburg IL 60173 Phone 86 8717 1919 Phone 91 21 35329112 Phone 1 847 273 7700 Fax 86 512 8717 1916 Fax 91 20 40147576 Fax 1 847 273 7804 Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 Ul Dzialkowa 115 Phone 1 262 641 8600 Rud Phone 48 22 390 9720 Fax 48 22 390 9724 SM4 605 SSV 05 R Table of contents 1 Safety instructions
18. tion Ensure in each case that the personnel are informed accord ingly For maintenance work taking place at heights of over approx 6 feet 1829 mm use only ladders or similar equipment and working platforms intended for this purpose At greater heights the proper equipment for protection against falling must be worn Use only suitable lifting gear which is in proper working order and load suspension devices with sufficient carrying capacity Do not stand or work under suspended loads Ensure that the electric motors switch cabinets are sufficiently protected against moisture Use only suitable workshop equipment Before starting maintenance work appoint a supervisor Inform the responsible personnel before maintenance work on the system is started Never operate the equipment when partially dismantled All maintenance and repair work not described in this chapter may only be carried out by Sterling service personnel or authorized personnel appointed by Sterling Maintenance 24 SM4 605 SSV 05 R Disconnect the equipment from mains supply before starting maintenance procedures to ensure that it cannot be switched on unintentionally Depressurize all compressed air piping of the equipment be fore starting maintenance work Please observe the maintenance intervals Before starting maintenance work clean the equipment of oil fuel or lubricants Ensure that materials and incidentals required for operation
19. ve the operating manuals of the connected units Safety instructions 12 SM4 605 SSV 05 R 2 Installation instructions These installation instructions are intended for persons with skills in electrical and mechanical areas due to their training ex perience and received instructions Personnel using these installation instructions must be in structed in the regulations for the prevention of accidents the operating conditions and safety regulations and their implemen tation Ensure in each case that the personnel are informed The installation instructions provided in the corresponding oper ating instructions apply for all connected equipment Observe safety regulations with regard to lifting gear handling All installation work must be carried out with the equipment disconnected from electrical power and compressed air supply A For installation work taking place at heights of over approx 6 feet 1829mm use only ladders or similar equipment and working platforms intended for this purpose At greater heights the proper equipment for protection against falling must be worn Use only suitable lifting gear which is in proper working order and load suspension devices with sufficient carrying capac ity Do not stand or work under suspended loads Use suitable workshop equipment Install the equipment such that all parts are easily accessi LIS ble this facilitates maintenance and repair work Installation inst
20. vel probe 3 2 Control and maintenance unit SSV 05 R The unit is switched on and off at the control and maintenance unit On the pressure reducer the operating pres sure is adjusted A water separator is inte grated Functional description 20 SM4 605 4 Set up SSV 05 R This chapter is intended for the operating personnel of the equipment General knowledge of operating conveyor units is prerequisite The functional description must have been read and under stood Ensure in each case that the operating personnel are sufficiently informed Set up 21 SM4 605 SSV 05 R 4 1 Preparations Check whether the injector tube is inserted in the material to be conveyed Switch on the compressed air supply Switch on the conveyor unit at the control and maintenance unit The conveyor unit should now convey until the conveyor hopperis filled up to the level probe 4 2 Basic setting of the filling level in the conveyor hopper The filling level in the conveyor hopper is mainly determined by the level probe Filling level too low By means of a screwdriver turn the adjustment screw of the level probe A rotation counterclockwise Observe the filling level during the next conveying procedure Fall lt Repeat the process until the desir
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