Sterling sse Compact Loader User Manual
Contents
1. i A 7 qo max I EE SAT I J PA GE uszOYequod Sun8p1 ujq 187snysyonnigeg Japo Bunjjeju8que3n Jap Uap lan 24423 a y Z nsiasuappyog nz ueiuz2ildiea uaBunjpunyuspimnz UspubyseBnz 3yoju jamos 383304888 qyoju seqjoyuy sey Bunei pun Bunquamia efpiieun 1859 Dunfpllsia amos aqpBua7yamMm q uBjsop 40 AIN D jo 1438159 yy SO que 3pd D jo 7046 943 O quens ay Ul pa r49S9J ei sqy6u IV seBowpp 490 quew bd SY oF 8 901 919 0 A3 40y no sseldxe USpPIqso y 94D 409 943 susyuos oY 4 UO POOIUNWWOS JO sn yy pub s oyyo o y Buinib pub queunsop 514 LODO pOL AS AAA AAA EA es LL ES EES Se J T IAdog 3 ve NIG e A IS 6 AS E a cm dup ui ve A PE IT Towns aun ap z yop ams E Op pese a p eu sive o SO SE E g Sabod ou 10404 G zt LODO pOL EU ES EES Se suso 6008 sj Ly 9 gei aud ZH 09 0S 3d N A 066 04 IV Jayos Jamod ym Jamod UU ZX UDJIMS IH IL doy IX bk 5 e A NH E ERE I I J EE EE Ee ML Rio ne pe KW dp2. Quick Start Guide Turning on the loader Locate the power switch on the left side of the control box and move to the ON position Setting the loader convey time e Itis only possible to set the convey time when the unit is not conveying material 1 Disconnect the flapper valve switch from the control box by unscrewing the plastic retainer ring and pulling the plug straight down 2 Adjust the conveying time by pressing the up arrow button the center LED on the display lights up Convey time can be adjusted from 1 to 99 seconds incrementally 3 Make note of the conveying level and adjust time accordingly e Please Note The material level inside the loader should never exceed the material inlet Setting the line clearing time or purge time e Itis only possible to set the purge time when the unit is not conveying material 1 Press and hold the change over key bottom LED on the display lights up 2 While holding the change over key adjust the purge time by pressing the up arrow Purge time can be adjusted from 0 to 99 seconds e If no line clearing valve has been installed be sure to set purging time to 0 e Make note of the purge time and adjust for optimum efficiency Machine Side Loaders Connecting the proportioning valve Control and power of the proportioning valve is supplied through a 4 wire control connection Brown Pos Power X7 L Blue Neg power X7 N Black Li
3. equipment production sequences or methods The operating instructions must be compiled by the operator of the equipment Equipment foreman When several operating personnel work on one machine the equipment foreman coordinates the sequences The equipment foreman 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 1 3 Legal basis See Manufacturer s Certificate resp Certificate of Conformity 1 4 Fields of applications These machine side hopper loaders are designed for use in facilities that require independent machine conveying systems The loaders have been developed for conveying thermoplastic granules A typical area of application is for processing machines and drying hoppers with throughputs of up to 400 Ibs hr 180 kg h 1 5 Notes on usage e Experienced operators can begin directly with the chapter on Start up if the unit has been properly installed e Ifthe unit has not been installed yet observe the instructions in the chapters Transport Assembly and Storage and Assembly Instructions General instructions 1 3 Machine Side Hopper Loaders 2 Safety instructions d These safety instructions apply to all persons within the range of action of the equipment and should be used by all persons assigned activities connected with the equipment Please inform
4. 2 LL Z SK gt Z L LEX 2 L 06 Z GEX UDJIMS doy iai T Lp pp yz zz I i l si alen l i A OEZ XDU l WIJD D A ral Em ad as SE EINES a pop LL J o A GE ua jppyaqguoa Sun8p1 ujg 187snyusyonnigeg Japo Bun ja 7187 Ua7ng Jap Uap len 24423 8 y z psiasuappyog nz us3yo pdiea uaBunjpunyuspimnz UspubyseBnz yo pyonipsno 3yoju amos 1911018886 Sa qpyu seny Buneary pun Bunquamia eBojuequg dessip Dun ie amos 806 5 29 d 1 NIG uBjsep Ain D 40 4 5 Ba eyy 240 juazodo jo yUD4B y o quene ul parsesel ein s3yBu IN sefpupp jo quew bd y 0 ejgoij suepue 440 A 140 yYznND sseldxe 3noy3m USPPIquos 940 10910 yY SUS UO Y o JO een BY PUD s9470 0 SUMIS pub queunsop siy o BujAdo 6 NIG e A TS _rT _ ELENA cm teuer WZ A PE CI O EE boa oe Ga E Op pese Pp SO SE E g Sabod ou 10 01 Q zt npo LODO pOL ES EES Se suso 6008 sj Ly 9 gei aud ZH 09 0S 3d N A 066 04 IV Jayos Jamod ym Jamod UU dA IVA ds SVIS uu W
5. 34179 8 6 Maintenance Cleaning the filter cloth 1 LUI Open the toggle fasteners A and the access door B of the hopper loader Check the filter cloth C and the wire cloth D for material residue Clean the filter by means of compressed air Close the access door B and the toggle fasteners A on the access door of the hopper loader Order numbers Filter cloth ID 28626 Wire cloth ID 23091 Machine Side Hopper Loaders Figure 14 Filter Cloth Maintenance 8 7 Machine Side Hopper Loaders 8 2 4 Replacing carbon brushes at the motor The carbon brushes in the motor must be replaced after approximately 1000 hours of operation The brushes can be replaced twice before the entire motor has to be replaced BL model loaders feature brushless motors and do not require this procedure ke This work must be carried out by qualified personnel only Disconnect the unit from main power supply before working on the controller Remove compressed air and depressurize unit prior to disassembly Disassemble the unit 1 Remove the screws A at the lid 2 Remove the lid B 3 Remove the latch carefully from the brush holder C 4 Remove the cover D 5 Loosen the brush holder lock 6 Pull out the brush holder Installation 1 Push the latch with the connecting line onto the new brush holder 2 Mount the brush holder Ge Please be careful with the latch
6. OEZ Du E i 4000 PA GE EA uszOYequod Sun8p1 ujq 187snusyonnigeg Japo Bunjjequ8queqn Jap Uap Jen 24423 8 y Zjpsiasuappyog nz us3yo pdiea usBunjpunyispimnz UspubyseBnz Y9jppPonipsnpo 3yoju jamos 1911018856 7Y9 U seqjoyuy sey Sunyie3 ip pun Bunquamia efpiieiun dessip BunBjypj ajAuaX amos 806 91 9 T uBjsep Ain D 40 4 5 Ba eyy 240 juazodo jo y o quene sy ul parsosel ein SqUSU IN 595 yo quew bd ey oi e qpi suepue 440 Ailuoy3np sseldxe 3noy3m USppliqg404 910 10918 SUS UOS Y o JO een BY PUD 0 5290 oi y SUMIS pub queunsop sjy ment LS DS suso 6008 sj ZH 09 05 dd N A 056 00 IV joy0s Jamod ym Jamod upu Jl To AN Y d 34 Mn da a PEA 3 y bua 4 Ajddns UJJIMS doy LE Ni N eee O 4 gt d 4 Z L SX 2 9X Ze 19508 a x se x 0 UOD pOL AS A AAA A A es LL Lo 50 4002 y ES EES Se ve NIG ET SS SS TS SS E ooa IS 0 Dousen A A Wo O REE Tepa y ap u Gym peg WE acte HA SES ER EE ES 0 Aopo am 42 0 ova gt g Sabod ou 10404 8 apod a LV QL asn
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8. connecting line Mount the cover Mount the lid Mount the screws at the lid ch A a Install the unit 8 8 Maintenance n E 1 1 Il 3 E I a Figure 15 Replacing the carbon brushes LUI Verify that no cables are pinched or cut Carbon brushes can be replaced twice After that the turbine has to be completely replaced Order numbers Turbine 230 V 1200 W Carbon brushes switching off Turbine 230 V 800 W Carbon brushes switching off Turbine 110 V 800 W Carbon brushes switching off ID 83380 ID 85628 ID 85629 ID 85628 ID 85844 ID 84716 Machine Side Hopper Loaders Maintenance 8 9 Machine Side Hopper Loaders 8 3 Taking out of service dismantling disposal 6 Only skilled personnel qualified for this work may dismantle the individual product modules Parts that are under mechanical stress should be dissembled with utmost care to avoid the energy trapped in these parts from unleashing and causing injury 8 3 1 General To dispose of the products you should take the following action Remove and destroy the nameplate with the CE sign Completely disassemble the product and dispose of the various components or recycle them 8 3 2 Disposal Instructions All components must be pressureless prior to disassembly Oil grease and other fluids have to be disposed of separately in accordance with local regula
9. cord and plug Check all electrical and mechanical connections for tight fit Check setting of the level sensor if present optional Replace the sieve or filter according to the accumulation of dust Replace outlet valve sealing Adjust valve switch Replace carbon brushes n a on BL models The given maintenance intervals are average values Check whether in your individual case the maintenance intervals must be shortened Maintenance 8 3 Machine Side Hopper Loaders 8 2 Servicing the loader 2 Disconnect the unit from main power supply by unplugging it Depressurize all system sections of the equipment only units with active cleaning 8 2 1 Changing the sealing ring of the outlet flap 1 Open the toggle fasteners A and the access door B of the hopper loader 2 Draw the old sealing ring C off the nozzle of the material outlet p 3 Install the new sealing ring C L Li GU Make sure the new sealing ring C K in installed properly Do not install Figure 12 Installation sealing ring the sealing ring upside down 4 Close the access door B and the toggle fasteners A LL Order number sealing ring material outlet 2 liter model ID 29258 5 liter model ID 23098 8 4 Maintenance Machine Side Hopper Loaders 8 2 2 Adjusting the dump valve sensor la Stop the conveying cycle by ee disconnecting the dump valve ss sensor from the controller With the dump
10. hose with your hand 3 Connect the unit to the main power supply and turn the machine on a Ifthe motor is operating your hand will feel the suction within few seconds b If you dont feel the vacuum the flexible hose is not tight 4 Check the hose and seal any loose points you may have identified 5 Reconnect the pickup wand 6 2 Operation Machine Side Hopper Loaders 6 3 Setting the conveying time E LU Do not overfill the hopper loader The conveying time cannot be set while the unit is in the process of conveying material By correctly setting the conveying time you can reduce vacuum motor wear save energy and reduce your need to maintain filters 1 2 NOTE LUI Turn on the hopper loader Observe the flex hose and the material in which you buried the pickup probe Listen to the vacuum motor and the sound that the material makes as it enters the hopper loader When the hopper loader is full the conveying rate drops off sharply You can observe this condition in the clear flex hose and the material container in which you buried the pickup probe When the hopper loader is full the vacuum motor and material sounds also change Make a note of the elapsed time from the start of conveying to the time the hopper loader is full Turn the hopper loader off Disable the conveying cycle by disconnecting the dump valve sensor from the controller With the dump valve sensor disabled no demand will be indic
11. only by trained personnel Other persons are not permitted to modify or repair the equipment LL Wear Code A Wearing part wears quickly B Wearing part C Spare part reorder every year D Spare part reorder every 2 years E Spare part rarely reordered Spare parts list 10 1 Machine Side Hopper Loaders 10 1 Parts breakdown brush type motor 1 10 2 Spare parts list Machine Side Hopper Loaders 10 2 Parts lists 2 liter model 10 2 1 230 V 50 Hz Pos Order no Designation Wear Code 1 37767 Turbine head complete with turbine and controller 2 37765 Covering cap 3 18491 Sieve 4 34197 Isolation 5 37768 Support 6 85629 Turbine 800 W D 85628 Carbon brushes switching off B 7 24679 Isolation 8 26384 Filter round 9 37764 Turbine lower part 98194 Cable bushing 10 82277 Controller ECO 83098 High comfort control 11 35014 Sieve with sealing ring A 12 28626 Filter cloth C 13 23091 Wire cloth C 14 28625 Sealing C 15 29258 Sealing ring A 16 28647 Outlet flap with magnet 17 28839 Flap switch with plug C 26462 Covering C 18 37761 Separator 19 82566 Tension ring vvith sealing ring B Spare parts list 10 3 Machine Side Hopper Loaders 10 2 2 Pos 1 On B W WN 10 4 Spare parts list 110 V 60 Hz Order no Designation 377711 Turbine head complete with turbine and controller 37765 Covering cap 18491 Sieve 34197 Isolation 37768 Support 85844 Turbine 00 W 84716 Carbon brushes sw
12. valve sensor insert the appliance plug of the dump valve sensor into the connector Figure 3 on the lower side of the controller gt Figure 3 Lower side of the controller Assembly instructions 4 3 Machine Side Hopper Loaders 4 3 Attaching the pickup wand Use the following procedure to attach the pickup wand 1 The pickup wand must be connected to flexible hose to allow sufficient movement The length of the hose should not exceed 10 feet 3 meters Push the free pipe end approximately 1 5 to 2 4 5 cm into the hose Use a hose clamp to secure the connection The flex hose should not cover the aeration holes on the pickup wand 2 Slide the flexible hose onto the material inlet Use the hose clamps supplied to secure the flex hose The pickup wand needs no adjustment for most applications Insert it into the material to be conveyed and turn the loader on Some applications require a more defined air to material ratio The pickup wand can be angled up to approximately 45 degrees in either direction to the vertical Additional fastening is not required When conveying from the bottom of storage containers silos surge bins blender bins etc a suction box is required 4 4 Assembly instructions Machine Side Hopper Loaders 4 4 Mounting Please check during assembly that the admissible bearing loads are not exceeded Mount the loader in such a way that the outlet flap swings in a right angle to the directi
13. 6 up Adr UIJIMS dDy E WIS cc Z Cex Z V 9X UJJIMS i Jasay doy i ai o n DE A Ze 0 3 VA 00 A OEZ XDW WDO ee acts ape tota nio 4006 Jamo pJD04 2ID07 LL A EE PA GE EA UeilpuegioA Sun8p1 ujq 187snyusyonnigeg Japo Bun ja 187 Ua7ng Jap jjoj Uap lan 24423 8 y z nsiasuappyog nz usqyojjpduea usBunjpunyispimn7z UspubyseBnz yo pyonipsno 3yoju jamos 1911018856 SeqjOYUT seul Buneary pun Bunquamia eBojuequg dessip BunBjypj ajAuaX amos 806 6 1 5 29 NIG uBjsep Ain D 40 1351694 eyy 240 juazodo jo yUD4B y o quene ul parsesel ein SqUSu IN 595 jo quew bd y 0 e qpi suepue 440 41 sseldxe 3noy3m USppIquo 940 jo9 ey3 suejuos Y o een BY PUD s19U o 0 SUMIS pub queunsop sy o BujAdo 6 NIG EES VOI L ajop Suyud 9IHLV g Sabod ou 10404 L apod Ly 9 gei aud xow 6 391 a A A E n rt TE r eeneg AL SE E Ju BUIMDJP MDP ou AJ0JDj Jagunu JapJo o esa AA F 4 W 2 u 6X 2 DS Z ox i 2 licei 7b 1 bt L 0 0 om A
14. CE ets cd ele SA Pen AP 8 1 8 3 SL NIC EN E 8 4 Changing the sealing ring of the Outlet Aan 8 4 8 2 2 Adjusting the dump valve SENS OF inci 8 5 23s CANNE 1E UNU tos tema mt cat ei 8 6 6 24 Replacing carbon brushes dt the MOOT emma ia 8 6 8 9 Taking out Of service dismantling disposal allea 8 10 Ci G iii 8 10 AE SOSA ANS AUN RP RATE NERE SEO E RIEN IO E II PRONTI 8 10 Technical datan a A Es 9 1 10 Spare parts 10 1 10 1 Parts breakdown Brush pe 0 0 08 10 2 102 Parts E E El EE 10 3 MO DOO AAA A A alain 10 3 10 2 2 CIPRESSI III AIA 10 4 10 2 3 230 V IAE with acuve cleanin o SS fay Seana lait 10 5 10 2 4 FOV Ee tando e 10 5 LOSS SP arts Hst di iaa 10 6 TOS 10 6 10 3 2 LIOV O0 AMM 8 10 7 10 3 3 7 0 HZ Wilt active cleanin cilea 10 8 10 3 4 LO OO TI wuha iVE Mia 10 8 10 4 Parts breakdown and list 5 liter model with brushless Motor ooocccccnnnnnncnnnncncncnonononininicicnnos 10 9 AA a o O 10 10 11 1 125 Electrical 12 1 VI Machine Side Hopper Loaders 1 General instructions NIZ These instructions apply to all persons within the range of action of the equipment These operating instructions are to be used by all persons assigned activities connected with the equipment General instructions 1 1 Machine Side Hopper Loaders 1 1 Warnings and symbols The following warnings and symbols are used in these operating instru
15. EOE eccetto PA GE EA UeilpuegioA Sun8p1 ujq 187snyusyonnigeg Japo Bun ja 187 Ua7ng Jap jjoj Uap lan 24423 8 y z nsiasuappyog nz usqyojjpduea usBunjpunyispimn7z UspubyseBnz yo pyonipsno 3yoju jamos 1911018856 SeqjOYUT seul Buneary pun Bunquamia eBojuequg dessip BunBjypj ajAuaX amos 806 6 1 5 29 NIG uBjsep Ain D 40 1351694 eyy 240 juazodo jo yUD4B y o quene ul parsesel ein SqUSu IN 595 jo quew bd y 0 e qpi suepue 440 41 sseldxe 3noy3m USppIquo 940 jo9 ey3 suejuos Y o een BY PUD s19U o 0 SUMIS pub queunsop sy o BujAdo 6 NIG o 002 L60 8 860 8 Joo L 3000 ajop Buyulsd Ju BUIMDIP MDP DU AJOPDI Jagunu JapJo g Sabod ou 10404 y apod LV OL aen ad xow ZH 09 05 dd N A 066 06 IV Jayos Jamod ym Jamod UU ype 1 3df md ds 6 AVIS yu 4 6 unu Ajddns SVIS 4000 Jamog ee A ZZZ cen rt aal JOIJuajod WOD q DUDUIX Jo GDUDUJXC ment LS DS suso 6008 sj UJJIMS doy L y AZ N i i XHAQVOI El LS I keete miel eg WE REESEN pe I A A eee EE E Z L ZX 2 L SX 2 9X I UDJIMS doy I 8 ir A O 3dx i
16. General imstrucnons assediati 1 1 Silone a anni 1 2 1 22 Explanatons and M orma ON 0700700 1 3 li Eesalbastall ccm len 1 3 LA Lilli 1 3 ee 1 3 Zi ES E IS CIC LION sgabelli aaa ni 2 1 AR E 2 2 E E EE 2 2 Didi dl SOM DE noi sir i iii a 2 3 CEE ET ACE NE RT 2 4 Dl Le US AAA A a es 2 4 22 Por Opetabine Sa CI OF ING E 2 5 di Pransportassemblvand storage Lcd lla 3 1 A E 3 2 DANS CM OI O RCP RO ses iaatis sans 3 2 e Pa 1197 104 ER O O oOo OOOO 3 2 4 Assembly 4 1 EENEG 4 2 4 2 Installing the Gump valve Sensor RR 4 3 ACS NS PICO Wand ea ct cc Gats eco 4 4 MO 4 5 4 4 1 Mounting on the processing machine A dad 4 6 4 4 2 Mounting onto a machine hopper 4 6 4 4 3 Mounting onto mixing hoppers with lateral niet 4 7 4 4 4 Mounting onto DT 30 dosing station io iaia 4 7 4A S5gElecticalconneciotni illude 4 8 AO COMPIESSEA A lol dll 4 8 4 7 Installation of the optional proportioning valve 4 9 Si e RA ea 5 1 Sle SEQUCHICE Ol Operi Onani 5 2 o A SO EU READ 5 2 6 EISEN IU O 6 1 oye Switching d EE 6 2 02 Checkin 6 2 AS Geh dE E AAA ada de See 6 3 6 45 setting th purre time WEE 6 4 6 6 5 RR nn 6 5 Ze slice 7 1 TA E a AEAEE PE EAA ASEPE E EE 7 2 Machine Side Hopper Loaders IM CN A
17. Operating Instructions Machine Side Hopper Loader SSE Series Machine Side Hopper Loaders Machine Side Hopper Loaders Sterling Material Processing 5200 West Clinton Ave Milwaukee WI 53223 Telephone 414 354 0970 Fax 414 354 6421 www sterlco com Technical service Service department Telephone 800 423 3183 Edition 03 04 Bulletin SM4 615 2 These operating instructions are for please fill in personally Serial number Year of manufature Date of Delivery Number of delivery Date of commissioning Location Group of machines Machine Side Hopper Loaders 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 context with these operating instructions Copying translation or publication in any form except for personal use of purchaser requires approval from Sterling Material Processing All rights reserved 111 Machine Side Hopper Loaders 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 Portions of these manuals detailing procedures or precautions in the operation inspection maintenance and repair of the products may be inadequate inaccurate and o
18. 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 8 17 1916 Fax 91 20 40147576 Fax 1847 273 7804 l l Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 UI Dzia kowa 115 Phone 1 262 641 8600 02 234 Warszawa Fax 1 262 641 8653 Phone 48 22 390 9720 Fax 48 22 390 9724 Machine Side Hopper Loaders Table of Contents
19. ack Line signal XI ZKW Green w Yellow Ground X3 1 Remove the control box face and locate the removable plug in the bottom of the Dox Remove the plug and feed the wire of the proportioning valve through the empty hole Tighten the lock nut inside position the wire length for optimum use and tighten the lock nut on the outside Strip the wires so that 1 4 of wire is showing for connection to terminal blocks Upon removal of the loader control face you will see two printed circuit boards One board on the reverse of the control face and the other mounted inside the control box The ground wire will connect to the terminal block X3 on the back of the control face The other three wires connect to terminal block X7 inside the control box in order from left to right Brown Blue then Black Please refer to the schematic in the back of the manual Assembly instructions 4 9 Machine Side Hopper Loaders Connecting Material Lines Component 1 connected to the intake port furthest from the air cylinder regrind Component 2 connected to the intake port closest to the air cylinder virgin 21 Bay a 7 7 LA WA m 4 S 9 A_N Ch Y LASA La 22 WW LEET 450 17 72 T gt 105 4 13 Setting the ratio When the loader motor is not running pressing the arrow key on the valve s controller will change the percentage of component 1 This can be set fro
20. all persons within the range of action of the equipment of the direct and indirect hazards connected with the equipment Knowledge of the English language is prerequisite Ensure that all operating personnel are familiar with the operating instructions and the function of the equipment Safety instructions 2 1 Machine Side Hopper Loaders 2 1 For your safety 2 1 1 General To prevent injury and or damage to equipment observe the following safety rules Read these operating instructions carefully before operating for the first time Contact us should questions arise These operating instructions must be kept available at all times at the place of operation of the equipment Please note that for reasons of clarity not all conceivable cases regarding operation or maintenance of the equipment can be covered in these operating instructions Observe all safety instructions and warnings on the equipment All work on the equipment is to be carried out by persons whose qualifications are specified in the pertaining chapters of the operating instructions Wear proper working clothes while performing any work on the equipment The local regulations and requirements pertaining to this equipment must be observed Disconnect electrical components from the main power supply before work is carried out on these components Compile detailed operating instructions based on these operating instructions for the sequence of procedures to
21. ated and the conveying cycle will not start Turn the hopper loader on Use the arrow key to adjust the conveying time to slightly shorter than it takes to fill the hopper loader For example if the hopper is 1 full by the 30 second point of the conveying sequence set the conveying time to 28 seconds To decrease the load time setting it is necessary to cycle the time setting past 99 and then to the desired setting There is no down button With the new time setting entered reconnect the dump valve sensor Conveying should start again The conveying time that was last selected appears in the display The conveying time can be set at 1 to 99 seconds If the hopper loader is overfilling reduce the conveying time If the hopper loader is not filling to capacity increase the conveying time 10 Check operation to ensure proper settings If settings are not right repeat steps 1 9 Operation 6 3 Machine Side Hopper Loaders 6 4 Setting the purge time optional To set the purge time press and hold the change over key while using the arrow Rey to adjust the time Ze LUI The purge time that was last selected appears in the display The purge time can be set at 1 to 99 seconds If no line clearing valve has been installed enter 0 1 Turn the hopper loader off 2 Disable the conveying cycle by disconnecting the dump valve sensor from the controller With the dump valve sensor disabled no dema
22. atic charging 3 3 Storage The control system may only be stored at temperatures from 13 to 131 F 25 to 55 C Between delivery and machine commissioning the equipment should be stored in a dry dust free and vibration free room 3 2 Transport assembly and storage Machine Side Hopper Loaders 4 Assembly instructions SiZ 6 These installation instructions are intended for persons with skills in electrical and mechanical areas due to their training experience and received instructions Personnel using these installation instructions must be instructed in the regulations for the prevention of accidents the operating conditions and safety regulations and their implementation Ensure in each case that the personnel are sufficiently knowledgeable about the equipment The installation instructions provided in the corresponding operating instructions apply for all connected equipment Please observe all safety regulations for the operation of lifting gear All installation work must be carried out with the equipment disconnected from electrical power and compressed air supply For installation work taking place at heights of over approx 6 feet 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 used Use only suitable lifting gear that is in proper working order and load suspension devices with s
23. aud Xow ci dl ZH 09 0S dd N A OEC O IV joy0s Jamod ym Jamod upu a ew 1 dua Di Bulyshpap Y 3 di MN End El LA AAA E 1 y bua 4 Addns STE doy L E C Nal ANZ oi il 7 cl El iene a i 0 a on d 4 F RI eee O 4 gt d 4 Al i 2 6 Z LA Z EX Z SX Z L A UDJIMS 2 7 Wo O i oi 3 E Lin da sE AM A a a A i A A gelies YA 00 A OEZ XD i l WYO NA O A AA Se a pupog 3Ib07 GG LL A EE PA GE EA UeilpuegioA Sun8p1 ujq 187snyusyonnigeg Japo Bun ja 187 Ua7ng Jap jjoj Uap lan 24423 8 y z nsiasuappyog nz usqyojjpduea usBunjpunyispimn7z UspubyseBnz yo pyonipsno 3yoju jamos 1911018856 SeqjOYUT seul Buneary pun Bunquamia eBojuequg dessip BunBjypj ajAuaX amos 806 6 1 5 29 NIG uBjsep Ain D 40 1351694 eyy 240 juazodo jo yUD4B y o quene ul parsesel ein SqUSu IN 595 jo quew bd y 0 e qpi suepue 440 41 sseldxe 3noy3m USppIquo 940 jo9 ey3 suejuos Y o een BY PUD s19U o 0 SUMIS pub queunsop sy o BujAdo 6 NIG 2
24. avings may be inside the pipe from cutting down pipes into lengths These are pulled during the first conveying process and collected in the separator This material should not be used again 6 6 Switching off the unit Locate the power switch on the left side of the control box and switch it to the off position Operation 6 5 Machine Side Hopper Loaders 7 Troubleshooting 6 This chapter is intended for the operating personnel of the equipment General knowledge of the operation of conveying systems is required to perform these tasks Make sure you have read and understood the Start up section of this manual before proceeding Ensure that the operating personnel are sufficiently knowledgeable about the equipment Troubleshooting 7 1 Machine Side Hopper Loaders 7 1 Alarms An alarm will be triggered if there is no material to convey or if the loader overheats LUI An E appears in the display and an error number And alarm will sound L The following error messages can be displayed Eq D The alarm message E1 is displayed when no material has been conveyed during 3 consecutive conveying cycles e Check that sufficient material is being conveyed Do not restart operation until the malfunction has been corrected e Check that the flap switch is set correctly As supplied this feature is disabled To enable it 1 Turn the loader off and remove power 2 Remove
25. be carried out on this equipment Please note that sound levels exceeding 85 db A may in the long term damage your health Use appropriate ear protection to prevent hearing impairment 2 2 Safety instructions Machine Side Hopper Loaders 2 1 2 Assembly To prevent injury and or damage to equipment observe the following safety rules Compare the connected loads with those of the main supply Use care when using lifting gear and observe any pertaining regulations Do not modify add other equipment or change the design of the equipment without the approval of the manufacturer Attachments not supplied by the manufacturer must be manufactured in accordance with safety regulation EN 294 Make sure all the accessories and components are properly connected in accordance with any relevant regulations To prevent electrical shock operate the device only if all its components are grounded Do not allow solid particles and dust to enter to the vacuum generator Safety instructions 2 3 Machine Side Hopper Loaders 2 1 3 Operation To prevent injury and or damage to equipment observe the following safety rules Appoint an equipment foreman to be responsible for the equipment Ensure that the operating personnel are provided detailed instruction in the operation of the equipment When the main switch is switched off for reasons pertaining to safety it must be secured against unauthorized activation Repair work may be ca
26. bly Flange 4 6 Assembly instructions Machine Side Hopper Loaders 4 4 3 Mounting onto mixing hoppers with lateral inlet A VT Series adapter is required to mount the loader on a mixing hopper with a laterial inlet Two liter models require a VT 1 0 adapter Five liter models require a VT 2 3 70 or VT 2 8 70 adapter Use the follovving procedure to mount the loader to the mixing hopper 1 Mount the adapter onto the swan neck of the mixing hopper Figure 8 VT Adapter 2 Mount the loader onto the adapter Observe the bearing capacity of the machine flange 4 4 4 Mounting onto DT 30 dosing station Two liter loaders mount directly onto the DT 30 Dosing Station Five liter models require an AD 1 5 adapter Two Liter Models 1 Mountthe dosing hopper directly onto the dosing container of the dosing station DT 30 2 Mountthe loader onto the dosing hopper Figure 9 DT 30 Observe the bearing capacity of the machine flange Five Liter Models 1 Mountthe adapter piece directly onto the dosing container of the dosing station DT 30 2 Mountthe loader onto the adapter piece Figure 10 AD 1 5 Observe the bearing capacity of the machine flange Assembly instructions 4 7 Machine Side Hopper Loaders 4 5 Electrical connection NI The regulations of the local electrical codes must be observed Before connection to the electricity supply ensure that the supply voltage and the powe
27. conds Therefore if the convey time is 60 seconds and you select a cycle time period of 10 seconds the valve will switch a total of 6 times Quick Start Guide
28. ctions SILA This symbol indicates danger to life Fatal or serious injury is possible if the corresponding instructions regulations or warnings are not observed D This symbol indicates that serious injury is possible if the corresponding instructions regulations or vvarnings are not observed S This symbol indicates that extensive damage to equipment is possible if the corresponding instructions regulations or warnings are not observed This symbol indicates information important for becoming familiar vvith the equipment i e technical correlations Ed This symbol indicates that a technical term is explained at this point 1 2 General instructions Machine Side Hopper Loaders 1 2 Explanations and information Various terms are used in these operating instructions 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 Operating personnel The operating personnel are persons operating the equipment on their own responsibility or according to instructions e Operator The operator of the equipment production manager foreman etc is the person responsible for all production sequences The operator instructs the operating personnel of what is to be done e Operating instructions The operating instructions describe the interaction of the
29. itching off 24679 Isolation 26384 Filter round 37764 Turbine lower part 98194 Cable bushing 83097 High comfort control 35014 Sieve vvith sealing ring 28626 Filter cloth 23091 VVire cloth 28625 Sealing 29258 Sealing ring 28647 Outlet flap with magnet 28839 Flap switch with plug 26462 Covering 37761 Separator 85481 Tension ring with sealing ring Wear Code PRO Machine Side Hopper Loaders 10 2 3 230 V 50 Hz vvith active cleaning Pos Order no Designation Wear Code 1 37755 Filter with sealing A 2 37222 Basket 3 82593 Solenoid valve B 4 97745 Bush D 5 37800 Breather tube D 10 2 4 110 V 60 Hz with active cleaning Pos Order no Designation Wear Code 1 37755 Filter with sealing A 2 37222 BasRet 3 82592 Solenoid valve B 4 97745 Bush D 5 37800 Breather tube D Spare parts list 10 5 Machine Side Hopper Loaders 10 3 Parts list 5 liter model 10 3 1 Pos 1 DD Vi DB W WN 10 6 Spare parts list 38242 37765 18491 34197 37768 83380 85628 24679 26384 37783 98194 83098 82277 34193 28626 23091 28625 23098 23093 28839 26462 26455 82588 38243 230 V 50 Hz V66372 V66363 Order no Designation Turbine head complete with turbine and controller Covering cap Sieve Isolation Support Turbine 1200 W Carbon brushes switching off Isolation Filter round Turbine lower part Cable bushing High Comfort Controller Controller ECO Sieve with sealing
30. l piDogq aw pJ00q 21D07 LL A EE PA GE EA UeilpuegioA Sun8p1 ujq 187snyusyonnigeg Japo Bun ja 187 Ua7ng Jap jjoj Uap lan 24423 8 y z nsiasuappyog nz usqyojjpduea usBunjpunyispimn7z UspubyseBnz yo pyonipsno 3yoju jamos 1911018856 SeqjOYUT seul Buneary pun Bunquamia eBojuequg dessip BunBjypj ajAuaX amos 806 6 1 5 29 NIG uBjsep Ain D 40 1351694 eyy 240 juazodo jo yUD4B y o quene ul parsesel ein SqUSu IN 595 jo quew bd y 0 e qpi suepue 440 41 sseldxe 3noy3m USppIquo 940 jo9 ey3 suejuos Y o een BY PUD s19U o 0 SUMIS pub queunsop sy o BujAdo 6 NIG AAA A n Tm E 70107 ne A oo O EE p a oe Ga E Op pese Pp E 04 LECH SO SE E g Sabod ou 10404 6 apod UOD pOL ES EES Se suso 6008 sj Ly 9 asn aud ZH 09 05 3d N A 066 04 IV Jayos Jamod ym Jamod UU 1 i Smd JOSUSSIAIT i E SEENEN pee SCENE WER UU 4 6 um Ajddns L 6 WS WE A Z y GX Z i 9X STE doy 19S9Y lo A 7 ad NPT uv VA 00 A OEZ XDU LUIJD D ll Ln cnc dll piDogq aw pJ00q 21D07 LL A
31. m 0 to 99 Set the cycle switching Press and hold the percentage key on the valve s controller Then by pressing the up arrow you will be selecting the cycle time period in increments of 5 sec For example if the convey time is 60 seconds and you select a cycle time period of 10 sec the valve will switch a total of 6 times 4 10 Assembly instructions Machine Side Hopper Loaders 5 Functional description 6 This functional description is intended for all operating personnel of the equipment General knowledge of conveying systems is required to operate the equipment Ensure in each case that the operating personnel are sufficiently knowledgeable about the equipment Functional description 5 1 Machine Side Hopper Loaders 5 1 Sequence of operation The sequence of operation is as follows 1 Plug in the machine and move the on off switch to the on position 2 All LEDs on the controller blink and the software version is displayed on the screen 3 A 2 second blowback pulse cleans the filter During blowback the screen displays A2 4 The motor starts and conveying begins The screen displays a countdown of the conveying time Conveying time can be set for 1 99 seconds 5 Ifthe optional purge valve is installed line purging begins and the screen displays a countdown of purge time Purge time can be set for 0 99 seconds 6 The motor shuts off for 8 seconds while material dumps The screen di
32. nd will be indicated and the conveying cycle will not start 3 Turn the hopper loader on 4 Enter a conveying time setting See Section 6 3 on page 6 3 5 Entera purge time This is done by pressing and holding the change over key the bottom and center LED should be lit Then pressing the arrow key The purge time on the display will increase 6 Reconnect the dump valve sensor Conveying should start 7 Verify both the load time and purge time settings This can be done by observing the conveying cycle When the loader motor starts it will convey material for the time entered After this time expires the motor stays on and the line clearing valve is activated At this time the conveying line will be purged clean of material When the settings are correct the load time is just long enough to pull the desired amount of material into the conveying line and the purge time is just long enough to clean out the line Once both of these functions are complete the material level in the hopper should be at the material inlet level but not above If this is not the case readjust the settings by repeating steps 1 7 NOTE To decrease the load time and purge settings it is necessary to cycle the time setting past 99 and then to the desired setting There is no down button 8 Once the settings are optimized the loader is ready for operation 6 4 Operation Machine Side Hopper Loaders 6 5 Initial operation Metal sh
33. ne signal X7 ZKW Green Yellow Ground X3 3 Remove the control box face and locate the removable plug in the bottom of the box 4 Remove the plug and feed the wire of the proportioning valve through the empty hole 5 Tighten the lock nut inside position the wire length for optimum use and tighten the lock nut on the outside 6 Strip the wires so that 1 4 of wire is showing for connection to terminal blocks 7 Remove the loader control face Upon removal of the loader control face you will see two printed circuit boards One board on the reverse of the control face and the other mounted inside the control box The ground wire will connect to the terminal block X3 on the back of the control face The other three wires connect to terminal block X7 inside the control box in order from left to right Brown Blue then Black Please refer to the schematic in the back of the manual Connecting Material Lines Component 1 connected to the intake port furthest from the air cylinder regrind Component 2 connected to the intake port closest to the air cylinder virgin 105 4 13 450 17 72 Setting the ratio When the loader motor is not running pressing the up arrow key will change the percentage of component 1 This can be set from 0 to 99 Set the cycle switching Press and hold the percentage key Then by pressing the up arrow you will be selecting the cycle time period in increments of 5 se
34. on of machine movement Please check that all connecting points are tight to ensure that the conveying performance is not impaired Figure 4 Mounting Assembly instructions 4 5 Machine Side Hopper Loaders 4 4 1 Mounting on the processing machine A VT Series adapter is required to mount the loader on the processing machine Two liter models require a VT 1 0 adapter Five liter models require a VT 2 3 70 or VT 2 8 70 adapter Use the following procedure to mount the loader to the processing machine 1 Mountthe VT Series adapter onto the flange of the processing machine Figure 5 VT Adapter 2 Mountthe loader onto the adapter Observe the bearing capacity of the machine flange 4 4 2 Mounting onto a machine hopper Two liter models require an EF 190 welding flange for mounting onto a machine hopper Five liter models can be mounted to a machine hopper using either the EF 253 welding flange or the MF 253 assembly flange Using the EF Series Welding Flange D Please observe all safety regulations for the Lo operation of vvelding equipments Fi 6 EF Welding FI Alvvays vvear safety goggles ISOLE elding Flange 1 Weld the welding flange into the machine hopper lid 2 Mount the loader onto the welding flange Using the MF Series Assembly Flange Five liter models only 1 Mountthe assembly flange into the machine hopper lid 2 Mount the loader onto the assembly flange Figure 7 MF Assem
35. perating conditions and safety regulations and their implementation Ensure in each case that the operating personnel are sufficiently informed Please inform all persons within the range of action of the equipment of the direct and indirect hazards connected with the equipment Please observe all safety regulations for the operation of lifting equipment Transport assembly and storage 3 1 Machine Side Hopper Loaders 3 1 Transport and packing NI Please ensure adequate carrying capacity of the lifting equipment The equipment passes rigorous testing in the factory and is packed carefully to avoid transport damage Please check packing on delivery for transport damage The inlet and discharge flanges are sealed with plugs so that no dirt can enter during transport Plugs must be removed before assembly Packing materials should be disposed of according to environmental laws or reused Only use for transport of the equipment a suitable lifting device e g a fork lift truck or a workshop crane Transport must be shock proofed and free from vibrations 3 2 Assembly NIZ Please ensure adequate carrying capacity of the lifting equipment Check the carrying capacity of the point of installation particularly if installed on a platform The place selected for installation should be as free of vibrations as possible The main power switch must be freely accessible Ground the equipment against electrost
36. r frequency are in accordance with the data on the nameplate of the machine The electrical connection may only be carried out by the manufacturer s service staff or trained personnel authorized by the manufacturer It is not permitted for other persons to undertake the electrical connection The main switch must be freely accessible Ground the equipment against electrostatic charging The equipment is connected to main power supply by a standard plug Separate fuse protection of the wall socket is required max 16 A 4 6 Compressed air connection The hopper loader requires a clean dry 72 87 psi compressed air supply A filter regulator and shut off valve are recommended components of your in plant air supply You may need to install an accumulator in your air supply system to enhance blowback effectiveness if your system cannot consistently meet these requirements Make sure you use full sized 3 8 diameter pipe or tubing when making the connection 4 8 Assembly instructions Machine Side Hopper Loaders 4 7 Installation of the optional proportioning valve LUI Before proceeding review the connecting diagram included with the unit For more information refer to the manual that shipped with the proportioning valve Connecting the proportioning valve Control and power of the proportioning valve is supplied through a 4 wire control connection Brown Positive Povver XI L Blue Negative povver XI N Bl
37. r 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 e 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 Contact our
38. re parts list 10 9 Machine Side Hopper Loaders 10 5 230 V 50 Hz Pos Order no Designation Wear Code 1 S38217 Turbine lid with turbine complete 82995 Turbine 119 154 01 83375 Solenoid valve 84914 Pneumatic hose 2 83098 Controller 3 34179 Filter B 4 28420 Sealing ring C 8 5533 Tension ring 26451 Lock 5 28839 Flap switch with plug 6 23093 Outlet flap with magnet 85477 Nut 85471 Screw 93358 Disc 7 23098 Sealing ring B 8 28626 Filter cloth D 9 23091 Wire cloth E 10 28625 Sealing D 10 10 Spare parts list Machine Side Hopper Loaders 11 Accessories Accessories 11 1 Machine Side Hopper Loaders 12 Electrical manual This electrical manual is intended to be used only by the manufacturer s service personnel and trained personnel authorized by the manufacturer Other persons are not permitted to modify or repair the equipment Terminals X2 Power supply X4 Blower X5 Cleaning X6 Clearing X9 Alarm X3 PE X5 Flap switch X6 acknowledgement key Electrical manual 12 1 e AA AY AE ooa IP een es KEE LE ES REL INE op Duna MLT 4 Aopo au ATTE g Sabod DU 70404 L apod opp UONDIJIPOLIT zept suso 6008 sj 3A DA 3A DA VA Id UDJIMS dO JASON uva Buljsnpap ONINOILJIOJO YA 7X EX JIMOQ Jamod D 6X UNA A X O j a UN EE EC x EN I J L WJDID Lu WHOS PIO
39. ring Filter cloth Wire cloth Sealing Sealing ring Outlet flap with magnet Flap switch with plug Covering Separator lower part Tension ring with sealing ring Separator upper part Wear Code gt AANS LO Machine Side Hopper Loaders 10 3 2 110 V 60 Hz V66378US Pos Order no Designation Wear Code 1 S39361 Turbine head complete with turbine and controller 2 37765 Covering cap 3 18491 Sieve 4 34197 Isolation 5 37768 Support 6 82359 Turbine 1200 W D 82352 Carbon brushes switching off B 7 24679 Isolation 8 26384 Filter round 9 37783 Turbine lower part 98194 Cable bushing 10 83097 Controller 11 34193 Sieve with sealing ring A 12 28626 Filter cloth C 13 23091 Wire cloth C 14 28625 Sealing C 15 23098 Sealing ring A 16 23093 Outlet flap with magnet 17 28839 Flap switch with plug C 26462 Covering C 18 26455 Separator lower part 19 85481 Tension ring with sealing ring B 20 38243 Separator upper part Spare parts list 10 7 Machine Side Hopper Loaders 10 3 3 230 V 50 Hz with active cleaning V66364 Pos Order no Designation Wear Code 1 34179 Filter with sealing A 2 31222 Basket 3 82593 Solenoid valve B 10 3 4 110 V 60 Hz with active cleaning Pos Order no Designation Wear Code 1 34179 Filter with sealing A 2 37222 Basket 3 82592 Solenoid valve B 10 8 Spare parts list Machine Side Hopper Loaders 10 4 Parts breakdown and list 5 liter model with brushless motor 10 Spa
40. ronic components may be damaged by static discharge Check all electrical connections for proper fit before the equipment operated for the first time and at regular intervals The operating temperature range is 32 to 113 F 0 C to 45 C The recommended storage temperature range is 13 to 131 F 25 C and 55 C Write down all data that you have entered into the control system Please ensure that all plugs are correctly plugged in The operating instructions of the connected machines must be followed Operate the device only if all its components are grounded Never adjust sensors without exact knowledge of their function Please note that a compressed air supply is required for the operation of the active cleaning option Compressed air supply for the active cleaning option should not exceed 87 PSI 6 bar active cleaning option only Align the suction tubes correctly The unit should be installed in such a way that the outlet flap swings at right angles to the moving direction of the equipment The load bearing capacity of the machine flange should be adhered to A level indicator is required when conveying from granulators Safety instructions 2 5 Machine Side Hopper Loaders 3 Transport assembly and storage Gel 6 This chapter is intended for all operating personnel of the equipment Personnel using these instructions must be instructed in the regulations for the prevention of accidents the o
41. rried out by trained personnel only Never operate the equipment when partially dismantled In case of malfunction shut down the equipment immediately Have malfunctions corrected immediately The equipment is intended only for conveying granulated plastics and regrinds Any other or additional use is contrary to specifications This equipment is not suitable for food processing The safety instructions of the connected machines must be followed Explosive gases and mixtures of gas and air must not be conveyed 2 1 4 Maintenance To prevent injury and or damage to equipment observe the following safety rules Before starting maintenance work appoint a supervisor Inform the responsible personnel before maintenance work on the system is started Disconnect the equipment from main supply before starting maintenance procedures to ensure that it cannot be switched on unintentionally All pipes hoses and screwed connections should be checked regularly for leaks and damage Any faults that arise should be corrected immediately Depressurize all compressed air piping before starting maintenance work 2 4 Safety instructions Machine Side Hopper Loaders 2 2 For the operating safety of the equipment Never change settings if the consequences are not precisely known Use only original manufacturer approved spare parts Please observe the maintenance schedule Keep record of all maintenance and repair work Please note that elect
42. splays L8 The 8 second dump time is a fixed setting and is not adjustable 7 The controller checks for demand and if material is needed the cycle starts over from step 3 5 2 Controller 3 LEDs indicate the respective modes of operation blowback conveying purging and dumping iui rei cr aE ie TAI P ne Se 188 ET eden Dumping Blowback Conveyin Blowback Icon Conveying Icon Purging Icon 1 Sa Change over Rey Arrow Key Figure 11 Controller 5 2 Functional description Machine Side Hopper Loaders 6 Operation NIZ This chapter is intended for operating personnel General knowledge of the operation of conveying systems is required to perform these tasks Make sure you have read and understood the Functional Description chapter in this manual before operating the equipment Ensure that all operating personnel are sufficiently knowledgeable about the equipment Make sure the plastic stopper has been removed from the material inlet nozzle Make sure the adhesive tape has been removed from the exit flap Operation 6 1 Machine Side Hopper Loaders 6 1 Switching on the unit Locate the power switch on the left side of the control box and switch it to the on position 6 2 Checking the flexible hose Before operating the equipment check to make sure the suction is working 1 Remove the pickup wand from the flexible hose 2 Cover the open end of the
43. the cover from the control 3 Remove the two wires that are connected to terminals X9 and X6 4 Replace the cover and turn the loader on GG E2 If the control system becomes too hot during operation gt 158 F 70 C the E2 alarm message is displayed and the unit is switched off e Allow the system to cool before restarting LU When the malfunction has been corrected turn the power off and then on again to restart 7 2 Troubleshooting Machine Side Hopper Loaders 8 Maintenance 6 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 instructed of the regulations for the prevention of accidents the operating conditions and safety regulations and their implementation Ensure in each case that the personnel are sufficiently knowledgeable about the equipment For maintenance work taking place at heights of over approx 6 feet 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 that 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 onl
44. tions Bright steel parts are to be treated as steel scrap Depending on local disposal regulations painted steel parts may have to be shotblasted before they can be disposed of as steel scrap Shotblast shall be disposed of separately Galvanized steel parts must be disposed of separately according to local regulations Stainless steel parts are to be disposed of as stainless steel scrap Aluminum parts such as manhole components come under aluminum scrap Sealing materials have to be separately disposed of Electronic components must be disposed of separately according to local regulations 8 10 Maintenance Machine Side Hopper Loaders 9 Technical data NIZ These instructions apply to all persons within the range of action of the equipment These operating instructions are to be used by all persons assigned activities connected with the equipment Technical data 9 1 Machine Side Hopper Loaders Standard Features Integrated control with LED display indication of the respective modes of operation adjustable conveying time adjustable line clearing time Integrated vacuum pump Integrated filter with automatic cleaning Parts coming in contact with material are made of stainless steel Simple mounting to dosing and blending units due to compact and weight saving design Alarm output Automatic shut down with lack of material Display of error codes Optional Features Material purge valve ou
45. tput with adjustable line purging time Two component valve output Granulator level sensor input Extension modules Specifications 2 liter model 5 liter model 5 liter model brushless motor Loader Capacity 0 088 cu ft 2 51 0 17 cu ft 5 I 0 17 cu ft 5 I Conveying Capacity 440 Ibs hr 200 770 Ibs hr 350 1090 Ibs hr 500 kg hr kg hr kg hr Connected load 230 V AC N PE 230 V AC N PE 230 V AC N PE 50 60 Hz 0 8 kW 50 60 Hz 1 2 kW 50 60 Hz 01 2 kW 110V AC N 60 Hz Noise Level max 80 dbA 78 dbA 82 dbA Weight 22 los 20 kg 33 lbs 15 kg 35 Ibs 16 35 lbs 16 kg Air bici FI 0 35 cfm at 87 PSI 0 35 cfm at 87 PSI 0 35 lette at 87 PSI 10 lpm at 6 bar 10 lpm at 6 bar 10 lpm at 6 bar 9 2 Technical data Machine Side Hopper Loaders Dimension Sheet Two liter model 11 5 292 mm 9 8 248 5 mm Pm E CH 00 N di 7 48 190 mm Technical data 9 3 Machine Side Hopper Loaders 5 liter model 13 39 340 mm 13 98 355 mm E E O J D co E E mM CH N t Y vi CO 9 96 253 mm 5 liter brushless model 12 87 327 mm E E PLA CH E 1 o 5 38 98 990 mm 9 96 253 mm 9 4 Technical data Machine Side Hopper Loaders 10 Spare parts list NIZ This spare parts list is intended to be used
46. ufficient carrying capacity Do not stand or work under suspended loads Use only suitable workshop equipment Install the equipment so that all parts are easily accessible this facilitates maintenance and repair work Assembly instructions 4 1 Machine Side Hopper Loaders 4 1 Unpacking The loader is insensitive to shocks and can be mounted directly onto the processing machine on a machine hopper a drying hopper or a dosing and blending unit The equipment is delivered as a complete assembly Use the following procedure to prepare the machine for assembly 1 Unpack the equipment 2 Remove the plastic stopper A from the material inlet nozzle 3 Open the access door B and remove the adhesive tape from the dump valve The controller must be freely accessible Figure 1 2 liter model 4 2 Assembly instructions Machine Side Hopper Loaders 4 2 Installing the dump valve sensor The controller uses a dump valve sensor A with a magnet B to determine demand When the dump valve is closed indicating demand the magnet is pushed towards the sensor The presence of the magnet near the sensor indicates demand and triggers a new conveying cycle When the dump valve is open indicating that no material is needed the magnet is pushed up and away from the sensor If the sensor does not detect the magnet it does not trigger a new Figure 2 Dump valve and sensor conveying cycle To install the dump
47. valve sensor disabled no 6 demand will be indicated and PA conveying will stop The Connect an ohmmeter to PINS 2 x Y and 3 of the dump valve sensor Q Release the nuts A of the dump 1 valve sensor B until the support I can be displaced C B A Open the dump valve C so far that Figure 13 Dump Valve the front tip of the outlet flap is approx 1 2 30 mm away from the sealing surface Displace the dump valve sensor B until the contact of the magnet switch is closed Tighten the nuts A of the dump valve sensor Check the adjustment In case of free hanging dump valve empty hopper loader the contact of the magnet switch must be closed If the dump valve sensor cannot be properly adjusted replace the dump valve and magnet or the sensor Order numbers Sensor with plug 2 liter model ID 29570 5 liter model ID 28839 Dump valve with magnet 2 liter model ID 28647 5 liter model ID 23093 Maintenance 8 5 Machine Side Hopper Loaders 8 2 3 Cleaning the unit 1 Openthe toggle fasterner on the tension ring Tilt the turbine head upwards Remove the filter Clean the filter by means of compressed air Clean the hopper loader by means of a vacuum cleaner Mount the filter Pay attention for proper fit Mount the turbine head eo PS oS N Mount the tension ring and close the toggle fastener MA Order number filter with sealing 2 liter model ID 37755 5 liter model ID
48. y 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 the manufacturer s service personnel or authorized personnel appointed by the manufacturer Disconnect the equipment from main power supply before starting maintenance procedures to ensure that it cannot be switched on unintentionally Depressurize all system sections of the equipment before carrying out any repair work Maintenance 8 1 Machine Side Hopper Loaders L 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 as vvell as spare parts are disposed of properly and in an environmentally sound manner Use only original Sterling spare parts Keep record of all maintenance and repair procedures 8 2 Maintenance Machine Side Hopper Loaders 8 1 Maintenance intervals Daily Monthly Every 6 months Annually After 1000 operating hours Check that warning labels on the equipment are clear and readable Clean the sieve or filter Use compressed air to blow through the sieve or filter according to the accumulation of dust Check function of the power
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