SRL, SLC and SRIL Series Sight Glass Hopper Loaders
Contents
1. 19 1 A0541037 COVER BOX SINGLEGANG4X2_________________ 1 A0565925 FILTER SRL I 02 04 POLY GLAZED CORD GRIP 7 0 120 0 470 PLUG BOX GANG 77 NPT WASHER REDUCER 75 X 5 NIPPLE CONDUIT NPT 1 A0555614 COVER WELD 14 ID SSTL SLC02 04 COVER WELD 14 ID SSTL SLC08 16 1 Woo020082 MOTOR VACUUM 230V 1 W00020083 MOTOR SPARE BRUSHES 115V 1 W00020176 MOTOR SPARE BRUSHES 230 V FITTING NIPPLE 3 8 ELBOW SSTL FITTING NIPPLE 3 8 X 6 SSTL SRX 08 16 SCREW BTNHD PHILLIPS 46 32 X 4 LG S S HOSE RUBBER BLK 4 X 1 16 SCREW FLTHD PHILLIPS 46 32 X 72 LG S S CLAMP NOSE 1 5 2 5 SCR 10 32 X 4 SELF TAPPING SCR SHC 4 20 X 5 8 WIPATCH tem Quantity Partno Description GSKT THRT NEOPRENE WHITE 4 STD TEMP FDA SRL SLC amp SRIL Series Sight Glass Hopper Loaders 61 Figure 18 Typical SRIL Series Sight Glass Hopper Loader Exploded Vievv D MN AAA FER A SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 62 Figure 19 SRIL Series Sight Glass Hopper Loader Parts List Refer to Figure 18 on the previous page for parts location Item Model no Quantity Partno ____________ Descriptin__________________ 1 2 CONE WELD 9 ID SSTL SRX02 3 6 SRILO2 04 1 0556504 TUBE IN OUT 1 5 SRX02 04 7 8 50204 32. 0556517 J BOLT 10 32 5251 SRLO216 U O BEAT ECOSSE EMINUS SRILO1 SRILO2 04 __1 A0553726 SIGHT GLASS PYREX 50 0208 S O SRILO1 4 A0553715 SUPPORT ROD BODY ALU SRI ILO1 2 4 SRIL02 04 A0553723 SUPPORT ROD BODY ALU SRI ILO2 08 SRILO1 A0553712 BASE MACH BODY ALU SRI ILO1 MEE 55108 2 0553728 ORNG SIL 2 234 ID X 0 139 THK EME 1 1 SRILO1 1 A0553710 BASE MACHINE MOUNT THRT SRI ILO1 SRIL02 04 A0553720 BASE MACH BOCY ALU SRI IL02 08 1 1 2 N Jo All 8 A0553718 SCREW SHC SS 1 4 20 x 34 14 SRIL02 04 W0002373 FLAT WASHER WI 3 16 100 PCS 15 Al 1 A0541543 GASKET SILC SGLS MVHO1X 5 77 CDNUT NIP 1 2 CN 0 REDUCTION WASHER 75 50 STEEL 5 2 PROXIMITY SWITCH 115 VAC KI 2015 BBOR NI PROXIMITY SWITCH 24 VDC KI 3015 FNKG NI SRL SLC amp SRIL Series Sight Glass Hopper Loaders o 3 Chapter 8 Troubleshooting SRL SLC and SRIL Series Hopper Loaders vvith Standard Series One Controllers Problem Possible cause Solution No power to control box Plug in power cord Check main disconnect Power switch is off Turn ON control box Fuse is blown Replace the MDL 10 fuse Unit resumes operation when Te Al below the hopper the material level drops this is loader is filled to capacity Aa Remove obs
3. SRL SLC 4 SRIL Series Sight Glass Hopper Loaders Clean or replace filter as needed Replace filter as needed Set Menu 1 to an appropriate value Clean proximity sensor Reduce sensitivity of sensor Additional grounding is necessary Contact the Engineering Department Secure connections on circuit board Replace proximity sensor 67 SRL SLC and SRIL Series Hopper Loaders vvith Optional Series One Plus Controllers Cont d Low material supply Replenish material supply The screen displays the Material supply obstructed Clear all obstructions No Convey Er 1 error Proximity sensor misadjusted crease sensitivity of proximity sensor sin Set M 1 to an appropriate Vacuum timer is set too low ms SAS pprop Menu 5 is set to zero Set Menu 5 to 2 or 3 The proximity sensor has Repair or replace proximity Thesecreen doesnot failed sensor as needed display the No Convey Er material supply is empty Department See the last step of Section 5 10 for information on restoring factory settings properly in the material supply Dirty filter Clean or replace filter as needed Proximity sensor is not adjusted properly for material No Convey alarm triggers being conveyed but the material supply bin is full Increase sensitivity of proximity sensor Material line has obstruction Clear material line of all obstructions Convey distance exceeds Menu Z to a longer time vacuum tim
4. www PO NT TTT BLOWBACK ps 1 we Po JIAP MEE 1 4 MATL g 1 gt ONE COMPLETE CYCLE ei NOTE RPC CYCLE RESUMES FROM WHERE IT LEFT OFF SRL SLC amp SRIL Series Sight Glass Hopper Loaders 43 Menu 5 Error After n Cycles 0 to 8 Cycles Default 3 Cycles The Error After n Cycles menu lets you e control the number of unsuccessful loading cycle attempts maximum vacuum timer times out and proximity sensor does not sense a full hopper before the Er 1 error message displays e increase to prevent alarms while you refill the material supply on high throughput processes e decrease to get earlier warning of material supply problems e disable 0 if you are using a short maximum vacuum time for less than full dumps Menu 6 External Activation Enable Disable Default Disable 0 The External Activation menu lets you e enable or disable recognition of the external system control contact e disable for stand alone operation e enable if the hopper loader is in a central system and the external enable contact is in use Menu Auxiliary Proximity Switch Enable Low Bin Op Ignore Default Ignore 0 The Auxiliary Proximity Switch menu lets you e enable a customer supplied auxiliary proximity switch 2 This proximity switch is typically mounted low in the machine bin below the hopper loader and is wired into the hopper loader as shown in Figure 1
5. 3 A0563700 SCREW 7 20X 1 HEX SER FLANGE 22 2 A0563701 SCREW Ya 20 HEX SER FLANGE apo 1 Ao563515 MAGNET REED SWITCH ACTUATOR 24 1 A0563703 RIVET 1 8 CLOSED DOMEHEAD VENT LOUVER 1 DIA 27 3 0556517 BOLT J 10 32 X 5 25L 28 1 Woo020081 MOTOR VACUUM 120 VAC 3 STAGE FITTING NIPPLE 3 8 X 4 pap 1 A0541543 GASKET SILICONE 3 75 OD 188 THICK 33 1 A0556547 VALVE SOLENOID 3 8 115 VAC 35 poo ___ 10FT Wwoo017594 HOSE FLEX 1 5 CLEAR VINYL 3 2 Woo001917 CLAMP HOSE 1525 3 1 0533933 WAND PICKUP 1 5 ALUMINUM SRL SLC amp SRIL Series Sight Glass Hopper Loaders 59 Figure 16 Typical SLC Series Hopper Loader Version 2 Exploded View Figure 17 Typical SLC Series Hopper Loader Parts List Version 2 Item Quantity Partno Description A0563504 CONE WELD 14 DIA SRC SLC02 1 A0563505 CONE WELD 14 DIA SRC SLC04 1 A053506 CONE WELD 14 DIA SRC SLC08 31 A0563507 CONE WELD 14 DIA SRC SLC16 SRL SLC amp SRIL Series Sight Glass Hopper Loaders 60 Figure 17 Typical SLC Series Hopper Loader Parts List Version 2 continued Item Quantity Partno Description TUBE INLET OUTLET 1 72 SRX08 16 16 1 0556546 ORNG SIL 3 234 ID X0 139THK 8 1 0541036 BOX SINGLEGANG 4X2X2
6. To enter the menu system When the screen displays AEC press the se SCROLL key to enter the menu system The screen displays 1 for Menu 1 ED Press and hold the se SCROLL key to scroll through the eight 8 menus If you scroll past a menu you want Co Press and hold both the NI DOWN key and the SCROLL key together simultaneously to scroll backwards through the menus When the menu you want displays Press the S START STOP SELECT SET key to gain access to the menu The screen changes to display the current setting of the menu you selected To adjust the current menu parameter M Press the UP key or the 3 DOWN key until the screen displays the parameter value you want SRL SLC 8 SRIL Series Sight Glass Hopper Loaders 40 Press the S START STOP SELECT SET key The new setting is stored in the battery backed RAM memory If you decide that you don t want to modify the current setting of a parameter co Press the SCROLL key to abort the change The change is aborted and the AEC screen displays again To return all parameters to factory default values Turn off the Series One Plus using the green power switch EM Press and hold both the Taw UP key and DOWN key together simultaneously as you turn on the Series One Plus green power switch All menu parameters are restored to factory default values 5 11 Series One Plus Operating Parameter Menus Menu 1 Maxi
7. and that 1t 1s free of obstructions If the installation has the SRL or SRIL Series hopper loader wired directly to a power main you must install a fused disconnect with lockout to allow safe operation and maintenance Make sure all connections are tight 3 9 Installing the Remote Control Box Optional Series One Plus Controller Only The remote option permits mounting a control up to 9 feet 2 75 m from the primary control box Both controls remain operational WARNING HAZARDOUS ELECTRICAL CURRENT PRESENT To avoid burn or electrocution hazard disconnect electrical power before installing this option l Install the SRL SLC or SRIL Series hopper loader 2 Select a location for the remote box and mount it securely 3 Plug the cable supplied into the 25 pin receptacle on the hopper loader controller Route the cable to the remote box so it doesn t interfere with processing operations Observe all applicable electrical codes 4 Connect the cable to the receptacle on the remote control enclosure Both controls are now fully operational e Main power supervision is available on the hopper mounted control only SRL SLC amp SRIL Series Sight Glass Hopper Loaders 21 3 10 Adjusting the Proximity Svvitch SRIL Series Sight Glass Loaders vvith Series One Plus Controllers Only The proximity switch mounted through the side of the hopper loader tank senses when the hopper loader is full It is factory set to se
8. 560 Kg cu m SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 17 Notes SRL SLC SRIL Series Sight Glass Hopper Loaders 18 Chapter 3 Installation 3 1 Work Rules Install operate and maintain this equipment according to all applicable work and safety codes This includes but 1s not limited to OSHA NEC CSA and any other local national and international regulations Obey these specific work rules M Read and follow these instructions when installing operating and maintaining this equipment If the instructions become lost or unreadable obtain a new copy from the manufacturer M Only qualified persons should work on or with this equipment M Work only with approved tools and devices M Disconnect and lock out electric power before maintaining or servicing a hopper loader If the unit is installed with a power cord that can be unplugged unplug it If the unit is permanently wired to a power main have a fused power disconnect capable of being locked in the OFF position installed 3 2 Safety Considerations Connect the hopper loader to a grounded three prong power receptacle If this is not possible ground the hopper loader motor for electrical isolation and protection from electric shock M Do not use hopper loaders in explosive atmospheres M Do not use outdoors or in wet environments Moisture damages the motor and can create an electric shock hazard M Operate hopper loaders at the rated
9. SCROLL Rey Press the SCROLL key to display e the available menus when the controller is in Standby mode e Operations screens such as batch counter and RPV settings when the controller is operating 1S START STOP SELECT SET Key Press the S START STOP SELECT SET key to e start the hopper loader e stop the hopper loader e select parameters from menu screens e set parameters Series One Plus Controller Indicators LED Screen The red LED screen is a four character alphanumeric display It displays system statuses menus and variable values for operating the hopper loader The MATERIAL A indicator lights when the Material A port is open SRL SLC amp SRIL Series Sight Glass Hopper Loaders 32 The MATERIAL B indicator lights when the Material B port is open 5 4 Starting Up the Hopper Loader for the First Time Using the Series One Plus Controller Non Proportioning Models l 2 3 Note Insert the pickup wand into the material supply Turn on the compressed air to the hopper loader Apply power to the controller AJ IX Press and hold the AM UP key and DOWN key together simultaneously while applying power to restore all factory defaults As the controller powers up the screen displays in succession e PLUS for three seconds e the software version number n nn e the standby mode display Press the S START STOP SELECT SET key to start the hopper loader The vacuum motor conveys mat
10. SRIL Series Sight Glass Hopper Loaders 6 Chapter 1 Safety SRL and SLC Series hopper loaders and SRIL Series sight glass hopper loaders are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personnel injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices M Follow all SAFETY CODES M Wear SAFETY GLASSES and WORK GLOVES M Disconnect and or lock out power before servicing or maintaining the hopper loader M Use care when LOADING UNLOADING RIGGING or MOVING this equipment M Operate this equipment within design specifications M OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you M Make sure the hopper loader and components are properly GROUNDED before you switch on power M Do not jump or bypass any electrical safety control M Do not restore power until you remove all tools test equipment etc and the hopper loader and related equipment are fully reassembled M Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment SRL SLC amp SRIL Series Sight Glass Hopper Loaders 7 Chapter 2 Functional Description 2 1 Introduction SR Series hopper loaders economically and efficiently load free flowing
11. Glass Hopper Loaders 66 SRL SLC and SRIL Series Hopper Loaders vvith Optional Series One Plus Controllers Cont d Problem Possible cause Solution The blowback valve is Plug in the blowback valve unplugged cable Control and vacuum motor The number of blowback are operating normally but pulses on Menu 2 is set to the blowback cycle isn t zero Restore Menu 2 to an appropriate value working The blowback TB1 is loose or disconnected Secure TB1 solenoid makes no sound Solenoid valve or its coil has failed Repair or replace as needed The circuit board has failed Call the Service Department Material supply is low Fix material supply problem Material wand is not properly Adjust material wand at positioned in material supply material pickup point Material wand not adjusted for the flow characteristics of the material conveyed Hopper doesn t Adjust material wand to compensate for flow characteristics See Section 3 6 for more information fill completely Obstructions in supply line mang A OOOO Filter is dirty Filter is clogged holding open the flapper discharge valve Vacuum time is set too low Material residue buildup on proximity sensor Proximity sensor sensitivity is set too high Proximity switch trips before tank is full Material possesses excessive static properties Control wiring connections on circuit board are loose Proximity sensor wire is cut
12. Press and hold both the UP key and DOWN key together simultaneously any time the batch counter is displayed The batch counter resets to zero 0 and the screen reverts to the vacuum timer display 5 8 Operating in Single Shot Mode 1 Disconnect the Bin Full reed switch sensor and in its place wire a normally closed proximity switch 2 Install a proximity switch in the machine bin at the highest level you want the material to reach e The Series One Plus controller fills the machine bin until material covers the proximity switch e The screen displays FULL until the material level drops below the proximity switch The hopper loader then resumes operation automatically 5 9 Customizing Series One Plus Controller Operations The full feature control gives you complete control over the loading process You can gain access to adjustable parameters by using the Series One Plus menu system as shown in Figure 9 You can then fine tune hopper loader operation at this point to fit the exact requirements of your process as required SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 39 5 10 Navigating Series One Plus Controller Menus You ll always enter the menu system when the screen displays AEC on the controller screen This screen displays at startup before you press the IS START STOP SELECT SET key to start the hopper loader and displays again when you press the s START STOP SELECT SET key to stop the hopper loader
13. SPI network e disable the SPI communication function 0 if the SPI option is installed but the hopper loader is not currently on an SPI network 5 12 Shutting Down the Hopper Loader using the Series One Plus Controller Press the S START STOP SELECT SET key to stop the hopper loader For maintenance or for a long term shutdown unplug the unit from the power source and shut off the compressed air supply SRL SLC amp SRIL Series Sight Glass Hopper Loaders 45 Notes SRL SLC SRIL Series Sight Glass Hopper Loaders 46 Chapter 6 Series One Plus SPI Communications 6 1 SPI Network Functions The Series One Plus controller equipped with the SPI communications option lets you operate the controller on a network con forming to Version 3 01 or later of the SPI protocol specification When installed on an SPI network SR Series hopper loaders as well as other auxiliary processing machines can be controlled by an injection molding machine IMM or an operator at the IMM controls Two 2 SPI interchangeable communication ports are provided for easy connection into any daisy chain type SPI network Series One Plus controllers with the SPI option support all required parameters of an SPI network and some of the non required parameters too The supported parameters are e Echo system use only e Version e Status process B Processing flag B Low material alarm with auxiliary proximity switch installe
14. SRIL Series Sight Glass Hopper Loaders 15 Figure 4 Typical SRIL Series Sight Glass Hopper Loader SRIL 02 04 Sight Glass SRIL 01 Sight Glass Hopper Loader Hopper Loader Ji ELE tj SRIL Flange E E HOPSRIL DWG SRL SLC 8 SRIL Series Sight Glass Hopper Loaders 16 Figure 5 SRIL Series Dimensions Specifications and Maximum Machine Side Throughput American Standards cu ft A B C D E sq G sq H sq Isqo J 3514 Metric Standards Dimensions in cm liters A B C D E sg G sq H sq l sq 0 J3 56 895 495 232 76 178 89 70 140 76 113 1048 654 232 76 178 89 70 140 76 0 281 7 1 mm diameter holes four 4 places equally spaced SRIL Series Specifications Full Specifications load Inlet outlet Square mounting Shipping Hopper capacity Sight TS capacity Model amps range flange dimensions weight eu ft fiters lbs Kg cu ft liters lbs no 0 1 28 3 5 1 5 0 02 0 57 o 021951 7015 1 0 09 255 325 pas ra SRILO2 0 4 11 3 114 0 6 3 0 09 2 55 3 25 48 4 Non Proportioning O number Kg hr sor 10 68 Notavailable O Maximum throughput beside the press loading includes 12 foot 3 6 m vertical lift 1 2 OD approx 38 mm flex hose pellets 35 Ibs cu ft
15. e Sensor driven volume fill cycle to assure full load discharge for each cycle e Operator programming of blowback pulses to optimize efficiency e Accurate fill cycle counts up to 9 999 on the batch counter to assist in estimating material usage e No Fill alarm with automatic shutdown notifies the operator of an empty material source or lack of material flow saves motor brushes and reduces maintenance e Proportioning capability 5 1 Pre Startup Checklist M Are all electrical connections correct secure and to code Is the compressed air connection secure and safe Is the hopper level and mounted securely Are the flex hose and pick up wand secure NA RI Can the material discharge valve swing without obstruction SRL SLC amp SRIL Series Sight Glass Hopper Loaders 29 Figure 9 Series One Plus Graphic Panel AUTOLOADER SERIES ONE PLUS 3 A Y e SI L CLEAR SCROLL START STOP C VACUUM MATERIAL A C dI 4 Zo a C BLOWBACK MATERIAL B C gt K ADJUSTMENTS MADE WHILE RUNNING PROPORTIONING ADJUSTMENTS UNTIL OF MAT L B DISPLAYED ADJUST OF MAT L B SAVE NEW SETTING BATCH COUNTER RESET UNTIL 4 DIGIT BATCH CNTR IS DISPLAYED RESETS BATCH COUNTER TO 0000 CLEAR ERROR CLEARAN Er 4 MENU ADJUSTMENTS AND INSTRUCTIONS MENU TITLE FACTORY SETTING MENU UPDATING WHILE STOPPED MAXIMUM LOAD TIME 0 360 60 SEC RO EI OF BLOWBACK PULSES 0 1
16. material sounds also change 5 Make a note of the elapsed time from the start of conveying to the time the hopper loader is full 6 See Figures 7 and 8 pick the next shorter sequence For example if the hopper is full by the 90 second point of the conveying sequence select the 80 second conveying sequence SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 27 Figure 8 Conveying Dip Switch Chart Program A0536814 SRL02 SRLO4 SRILO2 amp SRILO4 Models 10 Seconds 15 Seconds 20 Seconds 25 Seconds 1 2 3 4 BLOWBACK olo PULSES o ore 30 Seconds 35 Seconds 40 Seconds 45 Seconds 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 lon on on on on BLOVBACR ore ore ore lor forr lor Jorr lor PULSES 50 Seconds 55 Seconds 60 Seconds 70 Seconds BLOWBACK 1 2 3 4 a EEE ALA LEA BLE LI or gt 80 Seconds 90 Seconds 100 Seconds 120 Seconds BLOWBACK 2 3 1 4 ESE EEES EER LS SS 4 6 Shutting Down the Hopper Loader Using the Series One Controller Move the power switch on the Series One graphic panel to the OFF position For maintenance or for a long term shutdown unplug the unit from the power source and shut off the compressed air supply SRL SLC 8 SRIL Series Sight Glass Hopper Loaders 28 Chapter 5 Series One Plus Controller Operation The Series One Plus controller is an optional controller that includes the follovving features
17. pellets or granular materials from supply containers into machine bins or other receivers They are a modular stainless steel component design using significant operational advantages Their engineered construction permits easier cleaning and maintenance and they can be quickly and easily reconfigured to accommodate future production requirements Simple electrical and compressed air connections are all that s needed for operation central vacuum systems are not necessary SRL and SLC Series hopper loaders use an integral mount three stage centrifugal motor with a quick disconnect plug power cord The hopper mounted junction box is pre wired to the field mounted 115 1 60 control box The SRL and SLC feature a high flow blowback valve to enhance cleaning its acrylic mesh flat filter providing excellent filtration of conveying arr SLC loaders feature a counter vveighted flapper assembly SRIL Series sight glass hopper loaders have the features of the SRL Series hopper loader but include a high visibility Pyrex sight glass for easy monitoring of material load discharge cycles The sight glass assembly is equipped with an adjustable proximity sensor to ensure full material discharge on each cycle Like the SRL Series hopper loader SRIL Series hopper loaders feature a quick release design no tools are needed to remove the hopper cover or the sight glass Necessary Documents The items listed here are required for installation operation an
18. perform a complete reset EM reapply power to the control while pressing both the Taw UP key and DOWN key together simultaneously All parameters reset to the factory defaults so make a note of the parameter settings you want to retain If the Series One Plus screen alternates displays of the numbers 85 and 170 a self test is successful This condition continues until you do a complete reset During the test the number 85 continuously transmits out the port When the controller receives an 85 it echoes a 170 SRL SLC amp SRIL Series Sight Glass Hopper Loaders 48 Menu 9 SPI Address Range 32 to 254 Default 32 Each auxiliary device on an SPI network must be assigned a unique address to identify it to the IMM controlling the network Do not assign the same address to any two auxiliary machines on the network or line contention will occur Menu 10 SPI Baud Rate Range 300 to 19 200 bps Default 4 800 bps The baud rate in bits per second bps is the data transmission rate All units on the network must be set at the same baud rate In general this rate should be set to the fastest common speed available to the controllers on the network where satisfactory communication occurs Operating under SPI Control If you enabled the SPI function by setting the Menu set value Co to 1 and you press the SCROLL key the screen displays SPI instead of displaying vacuum time All control is now through the SPI network and you
19. voltage Operation at other than design voltage can result in at best poor performance and can cause damage to the vacuum motor control and personnel 3 3 Necessary Tools M Hand drill M Pop rivet gun M 3 46 about 4 8 mm diameter rivets 3 4 Mounting SRL and SRIL Hopper Loaders You can mount your SRL or SRIL hopper loader directly to the processing machine by cutting a hole in the machine bin lid and fastening the hopper loader to it The hopper loader mounting flange mates with the equipment and uses the same mounting holes as previous models For new installations or mounting on other manufacturer s equipment a hole location template 1s included in the information packet SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 19 3 5 3 6 3 8 Important We are not responsible for equipment damage caused by excessive processing machine vibrations Mounting Tips e Runa bead of silicone sealant around the mounting flange before seating the hopper loader This provides an additional seal e Use rivets to mount the hopper loader Bolts nuts and washers can loosen fall into and damage process equipment e Check across the mounting flange with a bubble level Level installation ensures proper material discharge valve operation e Install controller boxes to a non moving solid structure to avoid loosening any wiring from vibration e Remove all rubber banding and any other packaging materials from aroun
20. 11 Menu 1 The MATERIAL A and MATERIAL B LEDs alternate on and off as set in Steps 4 to 6 above This indicates the proportioning valve cycle Example Ifthe percent of Material B was set at 50 in Step 4 the MATERIAL A and MATERIAL B LEDs alternate ON for ten second periods this equals 50 of the factory default thirty 30 second proportioning cycle Note The proportioning RPV total cycle time 1s adjustable see Section 5 11 Menu 4 for more information This time is not the same as total vacuum time To see the relationship between these two time parameters see Figure 10 Proportioning Cycle When the proximity sensor trips or sixty 60 seconds elapses the vacuum motor shuts off for three 3 seconds to relieve vacuum in the hopper and to allow the material to dump The BLOWBACK LED flashes and the screen displays as a four 4 pulse blowback cycle occurs Note You can adjust number of blowback pulses from 0 to 16 pulses See Section 5 11 Menu 2 The conveying cycle repeats automatically until the Bin Full switch senses that the material receiver machine hopper is full The hopper loader stops in Standby mode and the screen displays FULL until the machine bin level drops and automatic operation resumes 5 5 Operating a Hopper Loader at Factory Defaults Series One Plus Controller Models The Series One Plus controller factory set defaults are suitable for most conveying requirements SR
21. 4 When enabled if the proximity switch senses an empty machine bin the screen displays the Er 2 error message and an optional alarm activates The hopper loader does not stop SRL SLC amp SRIL Series Sight Glass Hopper Loaders 44 Note When operating in this mode the Er 2 error message displays at startup or after material changes To clear the error code and silence the alarm if installed press the Clear key combination by pressing and holding both the ue UP key and DOWN key together simultaneously e enable a customer supplied auxiliary proximity switch 1 This proximity switch 1s typically mounted low in the machine bin below the hopper loader and is wired into the hopper loader as shown in Figure 14 When enabled in this mode the hopper loader fills the machine bin below it then stops operation Operation does not resume until the auxiliary proximity switch senses that the material level has dropped below the proximity switch The hopper loader then refills the machine bin e disable a customer supplied proximity switch 0 Set this parameter to 0 if you aren t using an auxiliary proximity switch or if you won t be disabling an installed auxiliary proximity switch Menu 8 SPI Communication Enable Enable Disable Default Disable 0 The SPI Communication Enable menu lets you e enable the SPI communication function 1 if the hopper loader has the SPI communication option installed and is on an
22. 6 3 PULSES s DISPLAY MENU S CURRENT SETTINGS 3 OFMATL B 0 100 0 MAT L B ADJUST MENU S SETTING tl PROPORTIONING CYCLE TIME 0 60 0 SEC s SAVE NEW SETTING ER 1 NO CONVEY 1 8 CYCLES 3 0 NEVER 1 N EXTERNAL CONTROL AUXILARY PROX SWITCH E O 8 MANUAL SPI NETWORK OPERATION ES loli NA E FF Mu ru PP VA L kl A0541568 SRL SLC SRIL Series Sight Glass Hopper Loaders 30 5 2 Operating Sequence 1 Blowback sequence Motor starts The flapper discharge valve seals under vacuum Material conveys Hopper loader hopper fills Vacuum timer times out Motor stops peo sb ou Mu ee A A Blowback sequence begins the flapper discharge valve opens under the weight and material dumps Steps 1 through 8 repeat automatically If the level switch remains open the hopper loader remains idle until the material level in the bin drops and frees the discharge valve Steps 1 through 8 in the loading sequence listed here resume automatically 5 3 Series One Plus Controls and Displays Series One Plus Controller Keys UP Key A Press the UP key to increment up parameter values DOWN Key Press the NJ DOWN key to decrement down parameter values N fy AN UP Rey and DOVVN Rey Press Together Press the Taw UP key and DOWN key together simultaneously while turning on power to reset to factory default values SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 31
23. L SLC amp SRIL Series Sight Glass Hopper Loaders 23 Figure 6 Series One Graphic Panel AUTOLOADER SERIES ONE ON OFF A0542127 SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 24 4 3 Starting the Hopper Loader 1 Insert the pickup probe into the material supply 2 Turn on compressed air to the unit 3 Plugin power to the control enclosure 4 Move the power switch on the Series One graphic panel to the ON position 4 4 Changing the Conveying Sequence DANGER DISCONNECT POWER BEFORE OPENING THE CONTROL BOX Electric current CAPABLE OF CAUSING INJURY OR DEATH MAY BE PRESENT in the controller enclosure during these procedures The adjustments listed in this section must be performed ONL Y by a qualified safety conscious technician The Series One controller is a time fill mode controller and has sixteen 16 loading sequences to select Make sure you avoid over filling the hopper Figures 7 and 8 list loading times and number of blowback pulses in each sequence Use the chart as your model select a sequence that suits your needs To select a sequence 1 Turn off and disconnect power to the unit 2 Remove the controller box cover 3 Move the DIP switches on the DIP switch array labeled SW1 to one of the sixteen 16 available configurations as shown in Figure 8 4 Replace the controller box cover 5 Reconnect power to the Series 1 controller and prepare the unit for operatio
24. L SLC 8 SRIL Series Sight Glass Hopper Loaders 36 Install your SR Series hopper loader apply power press the 1S START STOP key and operation begins The hopper loader loads itself until full then dumps and repeats pausing only when the machine bin below it is full The screen displays the vacuum timer while the vacuum motor is on If the hopper loader is a PP proportioning model follow the instructions in Section 5 6 below Stop your hopper loader at any time by pressing the IS START STOP key 5 6 Operating the Proportioning Feature Series One Plus Models Only The proportioning feature allows layering of two materials in the machine bin below the hopper loader Install the hopper loader and put both the material pickup wands in the material supply gaylords and follow the instructions that follow Adjusting Proportioning While the Hopper Loader is in Standby Mode Co 1 When the standby mode displays press the SCROLL key until the Proportioning Menu displays as 3 2 Press the S START STOP SELECT SET key to access Menu 3 The current percentage of Material B displays 3 Press the UP key or the CC DOWN key to change the setting as needed 4 When the percentage of Material B you want displays press the 1S START STOP SELECT SET key to set it OV e Press the SCROLL key to leave the menu unchanged SRL SLC amp SRIL Series Sight Glass Hopper Loaders 37 5 Adjusting Proportioning On the Fl
25. TOR vaste TUBE IN OUT 1 5 SRX02 04 15 SCREW CAP HEX SOC HD 10 32 x 1 2 W00002373 WASHER FLAT WI 3 16 100 PCS SCREW SHC SS 1 4 20 x 314 O ala N CO W00016426 NUT STOP 1 4 20 PLD A0541036 BOX GANG SGL 4 x 2 x 2 UL WETLOC BOX COVER GANG SGL BLNK GSKT A0541039 CORD GRIP 1 2 270 480 3231 WASHER RDUC 75 x 50 STEEL WI CDUT NIP 1 2 REGAL 791 PLUG HEYCO BLK 5 8 42663 BE O NINI N On BIN s O All All All All All All All All All All All A0556805 LEVEL SENSOR SVVITCH ASSEMBLY NC SRH L A0559402 FLAT COUNTERSUNR SCREVV 10 32 x 3 8 NYLOC NIN N SRL SLC SRIL Series Sight Glass Hopper Loaders 57 Figure 14 Typical SLC Series Hopper Loader Version 1 Exploded vievv A 0080 pp TIT e IG A MO G0 SRL SLC SRIL Series Sight Glass Hopper Loaders 58 Figure 15 Typical SLC Series Hopper Loader Parts List Version 1 Refer to Figure 14 on the previous page for parts location Item Model No Quantity Partno X Description 6 SRC SLC 1 A0563513 GASKET THROAT SEAL FIBER 9 SRC SLC 1 A0563520 __ RING 4 THROAT SS 116 1 A0541039 CORD GRIP 12 0 170 0 470 PLUG BOX GANG 77 18 __ 1 A0003254 WASHER REDUCER 75 X4 NIPPLE CONDUIT 72 120 po 0548359 PLUG NYLON 5 8 a
26. The discharge flapper valve requires proper venting a clogged filter prevents proper flapper valve operation Replace the filter if it shows any signs of wear You can obtain replacements and spares from the manufacturer To gain access to the filter release the cover latches and lift the hopper lid assembly off grasping the lip of the cover CAUTION Do not lift the cover assembly by the motor piping or accumulator These components are not designed to support the assembly Checking Flex Hose for Wear Worn hose reduces conveying rates Check the hose regularly Inspect Material Discharge Valves Look for signs of wear improper operation or material obstruction Make sure that the flapper discharge valve is secure and free from all obstructions Note SR Series hopper loaders that convey very abrasive and or very dusty materials may require more frequent maintenance SRL SLC SRIL Series Sight Glass Hopper Loaders 92 7 2 Replacing Motor Brushes Note Make sure that you replace motor brushes before the brush shunt touches the commutator Replacements and spares are available from the manufacturer SR Series hopper loader vacuum motor brushes require periodic replacement Maintain a supply of motor brushes and establish a preventive maintenance program to reduce downtime Make sure that you properly seat replacement brushes to achieve maximum service life Unseated brushes may fail prematurely and increase your m
27. aintenance workload WARNING HAZARDOUS ELECTRICAL CURRENT PRESENT Secure the machine BEFORE servicing WEAR SAFETY GLASSES BEFORE performing this procedure Use a stable platform if working above floor level SRL SLC SRIL Series Sight Glass Hopper Loaders 53 Removing Old Motor Brushes l If you haven t already done so disconnect the hopper loader from the electrical supply Disconnect motor and blowback connection receptacles at the control enclosure Release the latches that secure the cover assembly Lift off the cover assembly by the edges Remove the motor from the cover assembly by carefully releasing the springs Springs are under tension so be very careful Remove the brush end cap then the two brush clips from the brush holder Remove the two brushes from the brush holder and replace with new brushes Replacement and Reassembly l Re attach the brush clips and the end cap after you make sure that the brush assembly is properly seated Following steps 5 and 6 above perform the same procedure for the opposite side Remove the armature assembly at the top portion of the hopper loader to properly seat the replacement brushes Insert a strip of 600 grit sandpaper with the rough side facing the brush Release the brush and rotate the commutator back and forth by hand See the alternative seating procedure on the facing page so that the brush is sanded to match the arc of th
28. ardware and mounting screws etc In case of breakage damage shortage or incorrect shipment refer to the following sections In the Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment M Notify the transportation company s local agent if you discover damage M Hold the damaged goods and packing material for the examining agents inspection Do not return any goods to the manufacturer before the transportation company inspection and authorization M File a claim against the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill M Advise the manufacturer regarding your wish for assistance and to obtain an RMA return material authorization number Parcel Post Shipment M Notify the manufacturer at once in writing giving details of the loss or damage This information is required for filing a claim with our insurance company M Hold the damaged goods with the container and packing materials for possible inspection by postal authorities United Parcel Service Shipment M Contact your local UPS office regarding damage and insurance claims M Retain the container and packing M N
29. ccc S WHITLOCK MATERIAL HANDLING Operation Installation amp Service Manual SRL SLC and SRIL Series Sight Glass Hopper Loaders Important Read Carefully Before Attempting to Install or Operate Equipment Part No A0556539 Revision D Bulletin No CV1 600 3 SRL SLC amp SRIL Series Sight Glass Hopper Loaders Write down your hopper loader serial numbers here for future reference Performance figures stated in this manual are based on a standard atmosphere of 59 F 15 C at 29 92 Hg 1 014 millibars at sea level using 60 Hz power Altitude is an important consideration when specifying hopper loaders ACS can advise you on proper selection and sizing of systems for your operating environment ACS is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice O Copyright ACS Inc 2006 All rights reserved Effective 02 16 2010 Part No A0556539 Revision D Bulletin No CV1 600 3 SRL SLC SRIL Series Sight Glass Hopper Loaders Shipping Information Unpacking and Inspection Y ou should inspect your SRL SLC or SRIL hopper loader for possible shipping damage If the container and packing materials are in reusable condition save them for reshipment if necessary Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose h
30. d High vacuum alarm central system units only No Convey alarm e Mode material m Machine on off Alarm acknowledgment e Set point Material A load time e Set point Material B load time e Blanket poll system use only SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 47 Remember to properly terminate the first and last units Jumper ON Jumper OFF on an SPI network If the Series One Plus controller is the first or last unit in the daisy chain terminate the transmission line by placing the jumper on JMP1 as shown here 6 2 Setting Up the SPI Function You ll need to set several Series One Plus controller parameters before network communication can occur These parameters are set in expanded service menus To gain access to expanded service menus disconnect and unplug the SR Series hopper loader open the control box and place a jumper across the SERVICE pins Close the box and re apply power You now have six 6 additional menus available three 3 of these menus are related to SPI operation Menu 8 SPI Enable Disable 8 Loopback Test Range 0 to 1 Default 0 When the expanded service menus are enabled an additional parameter becomes available on this menu Set this parameter to 1 to enable SPI communications Set it to 2 to perform an internal self test Disconnect all communication cables before performing the internal self test no loopback cable is needed Note To exit the self test you ll need to
31. d valve as needed Select a more suitable Selected conveying sequence sequence from the 16 is too short selections see Section 4 4 on for more information positioned in material supply material pickup point Adjust material probe to Material probe not adjusted for compensate for flow flow characteristics of material characteristics see Section 3 8 for more information E l l Clear all obstructions in the Obstructions in supply line line Filter is dirty Clean or replace filter as needed A clogged Replace filter as needed the flapper discharge valve E Secure terminal connections Terminal connection is loose l on the terminal board CES TA Replace light Wire has been cut Replace wire replace light Select a more suitable Hopper over fills The loading sequence is too sequence from the 16 Blowback does not work properly Blowback valve assembly is not connected to controller Hopper does not completely fill repeatedly long selections see Section 4 4 for more information SRL SLC amp SRIL Series Sight Glass Hopper Loaders 65 SRL SLC and SRIL Series Hopper Loaders vvith Optional Series One Plus Controllers Problem possible cause Souto No power to control box Plug ERRE cord check main disconnect Power switch is off Turn ON control box External fuse 1FU is blown Replace fuse 1FU No LED display _ Internal fuse FU2 is blown Replace fuse FU2 TB1 is discon
32. d maintenance of SR Series hopper loaders Additional copies are available from the manufacturer e This product manual e Product manuals for accessories and options selected by the customer where installed SRL SLC SRIL Series Sight Glass Hopper Loaders 8 2 3 Equipment Function SR Series hopper loaders are efficient conveyers of free flowing pelletized or granular materials from supply containers into machine bins or other receivers You can customize operation by adjusting operating parameters accessible through a menu system built into the control Simple electrical and compressed air connections are all that s needed for operation a central vacuum system 1s not necessary 2 4 Models Covered in this Manual SR Series models are designated by volume and if the unit has the sight glass feature designated with IL SLC02 models are hopper loaders with 0 2 cu ft 5 6 liter capacity SRIL04 models are sight glass hopper loaders with a sight glass capacity of 0 09 cu ft 2 55 liters and a hopper capacity of 0 4 cu ft 11 3 liters see Figures 2 and 4 for more information on capacities SR Series models are available in 0 1 0 2 and 0 4 cu ft 2 8 5 6 and 11 3 liter capacities with or without the 0 09 cu ft 2 55 liter sight glass feature SRL Series SRIL Series liters lbs liters lbs models cu ft Kg models cu ft SRIL Series models have an added 0 09 cu ft 2 55 liter sight g
33. d the flapper dump valve before installation for proper operation Attaching the Pickup Wand Slide the flex hose onto the material inlet and pickup wand Use the hose clamps supplied to secure the flex hose The flex hose should not cover the aeration holes on the pickup wand The pickup wand needs no adjustment for most applications Insert it into the material to be conveyed and it will work Some applications require a more defined air to material ratio Cover one or more of the holes at the top of the pickup wand Making Compressed Air Connections Your SRL SLC or SRIL hopper loader requires a clean dry 80 to 120 psi 551 6 to 827 4 kPa 5 52 to 8 27 bars compressed air supply A filter regulator and shutoff valve are recommended components of your in plant compressed 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 4 diameter pipe or tubing when making connections Making Electrical Connections The controller you selected 1s shipped pre wired to the SRL SLC or SRIL Series hopper loader Units are supplied with a power cord with plug wired to the control unit ready to plug into an appropriately grounded three prong receptacle SRL SLC amp SRIL Series Sight Glass Hopper Loaders 20 Make sure that the material demand sensor 1s installed with the proper amount of clearance
34. e Set g Repair or replace motor as Motor requires service needed Clean and readjust for material flovv characteristics Increase sensitivity of the Proximity sensor sensitivity is proximity sensor to match the not properly adjusted characteristics of material being conveyed Buildup on flapper valve Hopper over fills repeatedly LIBUS Sensor conneclons Secure terminal connections are loose l Proximity sensor has failed Replace proximity sensor SRL SLC amp SRIL Series Sight Glass Hopper Loaders 68 SRL SLC and SRIL Series Hopper Loaders with Optional Series One Plus Controllers Cont d Problem Possible cause Solution The customer supplied auxiliary proximity switch is Correct the material supply tripped because of a low problem The screen displays the Er 2 material level in the machine error message bin An auxiliary proximity switch is Install an auxiliary proximity enabled Menu 7 set to 2 switch or disable this feature by but one isn t installed setting Menu 7 to zero 0 The screen displays PLUS at Batte ry backed RAM has See the last step of Section 5 10 power up Set parameters are for information on restoring failed not being retained factory settings The screen displays EEEE PC board failure man No compressed air Connect to 80 psi 551 6 kPa 9 92 bars air supply Proportioning valve doesn t shift PP models only Defective valve or s
35. e commutator In older motors the wear of the brushes creates a shallow trough in the commutator Sand the brush to conform to the contour Remove the sandpaper and repeat steps 5 and 6 as needed until all brushes are replaced Reinstall the armature assembly SRL SLC amp SRIL Series Sight Glass Hopper Loaders 54 Seating Motor Brushes You have two 2 options for seating motor brushes Steps 5 to 11 Option 1 Run the SR Series hopper loader at 50 to 75 voltage for about 30 minutes Apply power from a variable transformer at the motor disconnect not at the control box Option 2 Connect two 2 SR Series hopper loader motors in series and run them for about 30 minutes WARNING On motors using white AMP disconnects make sure power is not applied to the green ground wire otherwise the motor housing becomes electrically hot Reducing line voltage may be accomplished by using a variable transformer or by connecting two identical motors in series SRL SLC SRIL Series Sight Glass Hopper Loaders 55 Figure 12 Typical SRL Series Hopper Loader Exploded Vievv SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 56 Figure 13 SRL Series Hopper Loader Parts List Refer to Figure 12 on the previous page for parts location item Model no Quantity Partno Description HE era CONE WELD 6 ID SSTL SRX01 2 Shar TT COVER WELD 6 ID SSTL SRL01 Dr Ha MO
36. erial until the proximity sensor indicates the hopper loader is full or the factory pre set default maximum vacuum time of sixty seconds passes whichever comes first The VACUUM and MATERIAL A LEDs light and the LED display shows the elapsed conveying time SRL SLC amp SRIL Series Sight Glass Hopper Loaders 33 Note You can adjust the maximum vacuum time from 0 to 360 seconds See Section 5 11 Menu 1 When the proximity sensor trips or sixty 60 seconds elapses the vacuum motor shuts off for three 3 seconds to relieve vacuum in the hopper and to allow the material to dump The BLOWBACK LED flashes and the screen displays as a four 4 pulse blowback cycle occurs Note You can adjust number of blowback pulses from 0 to 16 pulses See Section 5 11 Menu 2 The conveying cycle repeats automatically until the Bin Full switch senses that the material receiver machine hopper is full The hopper loader stops in Standby mode and the screen displays FULL until the machine bin level drops and automatic operation resumes Notes e If the Series One Plus screen displays the Er 1 No Convey error code and shuts down after three 3 conveying cycles but you do not have a material supply problem then you need to lengthen the maximum vacuum time to fill the hopper sufficiently to trigger the proximity sensor See Section 5 11 Menu 1 e The maximum number of consecutive unsuccessful conveying cycles before an alarm condi
37. lass feature 2 5 Standard Operational Features SRL and SLC Series Hopper Loaders e Brushed stainless steel construction with stainless steel product contact surfaces e about 9 5 mm high flow blowback valve with electrical quick disconnect and accumulator e l 2 OD about 38 1 mm OD material inlet SRL SLC amp SRIL Series Sight Glass Hopper Loaders Removable inlets on 0 2 and 0 4 cu ft 5 6 and 11 3 liter models Glazed polyester reinforced flat filter Hopper mounted junction box with 12 feet 3 6 m of cable to a field mounted 115 1 60 control box Material demand level sensor High performance centrifugal motor with electrical quick disconnect 9 foot 2 7 m power cord Aluminum pickup wand with ten 10 feet 3 m of flexible vinyl hose and two 2 hose clamps SLC02 and SLC04 include a counter weighted type flapper and accumulator blowback for improved filter cleaning Series One Plus models include a proximity level sensor for volume filling built in proportioning and a batch counter RPV available separately Note The Series One Plus controller option upgrade is required for remote proportioning valve RPV operation RPV is sold separately SRIL Series Sight Glass Hopper Loaders Pyrex M 0 09 cu ft 2 55 liter sight glass Brushed stainless steel construction with stainless steel product contact surfaces High performance centrifugal motor 3 s about 9 5 mm high flow blowback va
38. lve with electrical quick disconnect and accumulator Glazed polyester reinforced flat filter Aluminum pickup wand with ten 10 feet 3 m of flexible vinyl hose and two 2 hose clamps Minimum inventory on molding machine 9 foot 2 7 m power cord 4 101 6 mm square flange on 0 1 cu ft 2 8 liter model 7 177 8 mm square flange on 0 2 and 0 4 cu ft 5 6 and 11 3 liter models 112 OD about 38 1 mm OD material inlet SRL SLC 8 SRIL Series Sight Glass Hopper Loaders 10 e Hopper capacities of 0 1 0 2 and 0 4 cu ft 2 8 5 6 and 11 3 liters side outlet e Hopper mounted junction box with 12 feet 3 6 m of cable to a field mounted 115 1 60 control box e Removable inlets on 0 2 and 0 4 cu ft 5 6 and 11 3 liter models e Accumulator blowback is standard on 0 2 and 0 4 5 6 and 11 3 liter models only e Series One Plus models option upgrade include a proximity level sensor for volume filling built in proportioning control capacity and a no convey alarm Note The Series One Plus controller option upgrade is required for remote proportioning valve RPV operation RPV is sold separately 2 6 Available Options Special Voltages Models are also available in 230 1 50 VAC and 230 1 60 VAC voltages Series One Plus Controller The Series One Plus controller is a sensor driven volume fill cycle controller with available proportioning outputs It permits operator programming of blowback pulses for o
39. ly an paa spaced on an 11 DDD circle SLC Mounting Flange SALIA 10 31 0 312 H Ger PLACES B iN Ta ERUALI SPACED AS SH WN A sl 9 2 A N A 211 00 BC 20 375 00 000 SRL SLC amp SRIL Series Sight Glass Hopper Loaders 14 Figure 3 SRL Series Dimensions Specifications and Maximum Machine Side Throughput American Standards O EN paga in inches LE F 2154 271 8 Metric Standards Dimensions in cm A AE EL 54 9 M E ae O 5 A6 0 313 8 0 mm diameter holes 6 2 places equally Ta 5 6 0 313 8 0 mm diameter holes four 4 places equally spaced O 1 4 10 250 3 3 mm diameter holes six 6 places equally spaced J is standard mounting hole pattern SRL and SLC Series Specifications Hopper capacity EE Fa NN MNT Kg _ 11 3 SRL and SLC Series Maximum Machine Side Throughput Model Non Proportioning Proportioning number Ibs hr Ibs hr SRLO1 150 68 Not available Maximum throughput beside the press loading includes 12 foot 3 6 m vertical lift 172 OD approx 38 mm flex hose pellets 35 Ibs cu ft 560 Kg cu m SRL SLC amp
40. mum Vacuum Cycle Time 0 to 360 Seconds Default 60 Seconds For volume fill operation the Maximum Vacuum Cycle Time menu lets you set the maximum vacuum motor time during a conveying sequence If the level sensor in the hopper loader does not detect a full loader when the time you set elapses the vacuum motor stops and the loader dumps Increase this time setting if it takes longer than sixty 60 seconds to fill the loader Note To optimize operation set the timer in this menu to approximately ten 10 seconds longer than the time it takes to fill the loader under your current conveying conditions To determine how long it takes to fill the loader watch the timer count up during operation When the display changes to dashes the loader is full Add ten 10 seconds to the value displayed right before the display changes to dashes For time fill operation more frequent loading cycles or less material conveyed per cycle you can set this parameter so the vacuum motor stops and the loader dumps before it is full Set the timer as needed and be sure to disable the alarm Menu 5 set to zero 0 to prevent tripping the No Convey alarm Er 1 SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 41 Menu 2 Number of Blowback Pulses 0 to 16 Pulses Default 4 Pulses The Number of Blowback Pulses menu lets you e control the number of blowback pulses discharged from the compressed air solenoid during the hopper dum
41. n SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 25 Figure 7 Conveying Sequence DIP Switch Chart Program A0541578 SRLO1 and SRILO1 Models Only Note Chart contains two 2 different programs 12 and 14 blowback pulses 1 5 Seconds 3 Seconds 4 Seconds 6 Seconds BLOWBACK PULSES 9 Seconds 12 Seconds 15 Seconds 18 Seconds 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 2 lon lon BLOVBACR ore Lorr ore dor lor Lore doc lor PULSES 20 Seconds 25 Seconds 30 Seconds 35 Seconds BLOVVBACR PULSES 40 Seconds 45 Seconds 50 Seconds 55 Seconds BLOVVBACR 0 Ee EE SRL SLC amp SRIL Series Sight Glass Hopper Loaders 26 4 5 Selecting the Most Efficient Loading Sequence By selecting the best sequence you can reduce vacuum motor wear save energy and reduce your need to maintain filters 1 Begin with a sequence time longer than what is required for your process 2 Start up the hopper loader with the Series One controller 3 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 1t enters the hopper loader 4 When the hopper loader 1s 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
42. nected or loose Reconnect or tighten TB1 loose both ends Wait for machine bin material level to drop then manually re start the hopper loader Bin full sensor reed switch is tripped AEC is displayed at power up but vacuum ee bin full sensor reed motor doesn t start when switch woe lil Realign magnet Bin full sensor reed switch has failed START STOP SELECT Bin full sensor reed switch A Banta SET key is pressed The wiring is loose disconnected P 9 screen continues to TB2 is loose or disconnected Re connect or tighten display AEC Ribbon cable to the display is pe oo act or tiahten loose or disconnected 9 Defective keypad Call the Service Department Vacuum motor unplugged from Plug in the vacuum motor the control Control and display appear Vacuum time is set to zero 0 Reset Menu 1 to an to operate normally but on Menu 1 appropriate time the vacuum motor never Repair or replace vacuum The vacuum motor has failed starts motor as needed Solid state relay has failed The circuit board has failed Call the Service Department Control and vacuum motor No or insufficient compressed e ON are operating normally but Connect to 80 psi 551 6 kPa the blowback cycle isn t bars supply working The blowback solenoid clicks Restricted Restricted compressed air ine air line Find and fix restcton and Find and fix restcton restriction SRL SLC amp SRIL Series Sight
43. nse most conveyed materials accurately and provides volume fill control When the hopper loader is full the LED on the proximity switch should light and trigger the dump sequence If the switch does not reliably sense the material you are conveying adjust switch sensitivity Turn the potentiometer or pot clockwise to increase sensitivity counterclockwise to decrease sensitivity SRL SLC 8 SRIL Series Sight Glass Hopper Loaders 22 Chapter 4 Series One Controller Operation 4 1 Pre Startup Checklist M M M M M M Are all electrical connections correct secure and to code2 Is the compressed air connection secure and safe Is the hopper level and mounted securely Are the flex hose and pick up wand secure Can the material level switch activate without obstruction Can the material discharge valve swing without obstruction 4 2 Operating Sequence l a Sh AG E dis Blowback sequence Motor starts Flapper discharge valve seals under vacuum Material conveys Hopper loader hopper fills Vacuum timer times out Motor stops Blowback sequence begins the flapper discharge valve opens under the weight and material dumps Steps 1 through 8 repeat automatically If the level switch remains open the hopper loader remains idle until the material level in the bin drops and frees the counterbalanced dump valve Steps 1 through 8 in the loading sequence as listed above then resumes automatically SR
44. olenoid Repair or replace as needed TB1 loose or disconnected Tighten TB1 connections Defective PC board Call the Service Department Correct material supply problem Only one material is conveyed Material supply problem Replenish move pickup wand during proportioning operation remove obstructions PP models only y Man Missal tozero 0 Set Menu 2 to the percentage of Material B you want SPI communication feature Make sure all networked equipment in the network are transmitting at the same baud rate Set each unit on the network to a unique address The SR Series hopper loader address is set on Menu 9 Contact your sales The screen displays 0 when The SPI option wasn t representative to purchase an an internal test is attempted purchased with this unit SPl ready SR Series hopper SPI equipped models only loader PC board failure Call the Parts Department The screen displays HOLD External input enabled not No SPI communication SPI SPI baud rate is incorrect equipped models only The unit address is incorrect or two units on the network have the same address SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 69 Returned Material Policy Credit Returns Prior to the return of any material authorization must be given by the manufacturer A RMS number vvill be assigned for the equipment to be returned Reason for requesting the return must be given All returned material purcha
45. otify the manufacturer at once SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 3 If the Shipment is Not Complete Check the packing list The apparent shortage may be intentional Bach ordered items are noted on the packing list You should have EK K 4 SRL Series or SRIL Series hopper loader s with controller s Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings Component instruction manuals Re inspect the container and packing material to see 1f you missed any smaller items during unpacking Determine that the item was not inadvertently taken from the area before you checked in the shipment Notify the manufacturer immediately of the shortage If the Shipment is Not Correct If the shipment is not what you ordered contact the parts and service department immediately at 847 273 7700 Include the order number and item number Hold the items until you receive shipping instructions Returns Important Do not return any damaged or incorrect items until you receive shipping instructions from the manufacturer SRL SLC SRIL Series Sight Glass Hopper Loaders 4 Table of Contents CHAPTER 1 SAFETY cunas 7 CHAPTER 2 FUNCTIONAL DESCRIPTION 8 dE ME aiio e cle RETE 8 2 7 Necessary DOCUS tie 8 253 EQUIPMENT FUNCION sia A e 9 2 4 Models Covered in this Manual occooccccccocccccncocncocnnonnco
46. p sequence e increase the number of pulses if the material conveyed exhibits bridging problems or otherwise dumps slowly e decrease the number of pulses to optimize the cycle time and increase throughput when conveying free flowing material Menu3 Percentage of Material B 0 to 100 Percent Default 0 Percent PP Models Only The Percentage of Material B menu lets you increase or decrease the percentage of Material B in the proportioning cycle Menu 4 RPV Total Cycle Time 0 to 60 Seconds Default 30 Seconds PP Models Only The RPV Total Cycle Time menu lets you e control the duration of a complete proportioning cycle this time is not the same as the vacuum time the vacuum and proportioning timers operate concurrently as shown in Figure 10 e decrease the RPV total cycle time to increase the layering of the two materials in the hopper loader as it fills e increase the RPV total cycle time to reduce the layering of the two materials in the hopper loader as it fills Example Ifthe percent of Material B Menu 3 is set at 20 and the RPV total cycle time Menu 4 is set at 40 seconds Material B conveys for twenty percent 20 of 40 seconds or eight 8 seconds Material A conveys for the remaining 32 seconds Figure 10 Proportioning Cycle SRL SLC amp SRIL Series Sight Glass Hopper Loaders 42 gt VACUUM DOWN TIME VACUUM TIME Se Li r9 BLOWBACK CYCLE be RPV CYCLE TME am i a xor ee 00 i
47. ptimum operating efficiency It keeps an accurate count of up to 9 999 batches even in the event of a power failure and the controller includes a No Fill alarm to notify the operator of an empty gaylord or lack of material flow SERIES ONE PLUS ADJUSTMENTS SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 11 Remote Proportioning Valve The remote proportioning valve RPV option lets you economically and efficiently proportion two 2 different free flowing granulated materials in a material conveying system The most common application is mixing virgin and regrind materials in a plastic processing operation RPV installation options include a wall mount bracket and floor stand SRL SLC amp SRIL Series Sight Glass Hopper Loaders 12 Figure 1 Typical SRL Series Hopper Loader SRL 02 04 Hopper Loader e 10 Clearance Cutout with 6 bolt holes equally spaced on an 11 circle SRL01 Hopper Loader OH 9 NS Da Rsa EC AP 60 2500 HOLE THRU EQ SPACES N 01100 BC lt 6 PLES e a 64 7500 THRU H N 13 00 BC Ng dm xa i 606250 THRU H SRL Flange 0 3130 THRU H 180 APART 2 PLECS SRL SLC amp SRIL Series Sight Glass Hopper Loaders 13 Figure 2 Typical SLC Series Hopper Loader SLC 02 16 Hopper Loaders S e 10 Clearance Rel Cutout with 6 Y bolt holes equal
48. r SR Series hopper loader now operates as instructed by the IMM control Press the IS START STOP SELECT SET key to view vacuum time blowback pulse settings proportioning percentage and batch count SPI is still in control so return the display to SPI before leaving the machine unattended You can stop the Series One Plus controller in the normal manner by pressing the ss START STOP SELECT SET key but it may restart at any time if so instructed by the IMM control To avoid this condition press both the Tau UP key and DOWN key together simultaneously while the screen displays SPI This disables SPI communication To re enable set Menu set value to 1 SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 49 TERMINATION RESISTOR EIA485 DRIVER ELECTRONICS Figure 11 Typical SPI Network Wiring Diagram 3 DB 9 FEMALE DB 9 FEMALE 1 DB 9 FEMALE SRL SLC SRIL Series Sight Glass Hopper Loaders SHIELD COMMON CONNECTOR N DB 9 FEMALE TERMINATION RESISTOR 50 Notes SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 51 Chapter Maintenance 7 1 Routine Maintenance Cleaning Filters Check the condition of the filter frequently until you can determine a filter cleaning interval Units conveying dusty or fine materials need more frequent cleaning Note that a clogged filter can cause the discharge flapper valve to stay open critically reducing overall system effectiveness
49. rocanoconononconnnonncnrocnocanonnnos 9 2 5 Standard Operational Features viii di 9 2 0 sAVallable OBUORS a 11 CHAPTER 3 INSTALLATION rr 19 SL ebrietatis M aci epin blo tT ELI 19 0 2 Salte GConsSIderallOlls ataca di 19 9 Necessary escrites Sets ito 19 3 4 Mounting SRL SLC and SRIL Hopper Loaders 19 Ss EM ella Mlerc c 20 9 5 JAHtaching the PICKUP VV ANG ue 20 3 Making Compressed Air Connections occcocccocnconnconcconcconoccnnoononcnnonnnornonnnonnconnnonnnos 20 3 8 Making Electrical 6061005 iunc oca oii aa 20 3 9 Installing the Remote Control BOX ccocccocccocccoccconcooccconcocnconncornconoconononnonnnonnnnnncnnnnns 21 3 10 Adjusting ine Proximity SWIG A este mentides a e E OE OMS 22 CHAPTER 4 SERIES ONE CONTROLLER OPERATION 23 421 jPresstartup Checa a aus eed tau la Seni cioe oa hU psa dava ec ie dew eat ER 23 4 2 Operating SEQUENCE a NANA AA NG 23 4 3 Starting the Hopper Loader nnn nnns 25 4 4 Changing the Conveying Sequence nennen nnn nnns rsen is 25 4 5 Selecting the Most Efficient Loading Sequence QQ Xa 27 4 6 Shutting Down the Hopper Loader Using the Series One Controller 28 CHAPTER 5 SERIES ONE PLUS CONTROLLER OPERATION 29 9 1 checklist eee vir nane T ap GAAN 29 952 Operaung enean A a 31 5 3 Series One Pl
50. sed from the manufacturer is subject to 15 75 00 minimum restocking charge All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMS number will be assigned for the equipment to be returned Reason for requesting the return must be given All returns are to be shipped prepaid The invoice number and date or purchase order number and date must be supplied After inspecting the material a replacement or credit will be given at the manufacturer s discretion if the item is found to be defective in materials or workmanship Purchased components are covered under their specific warranty terms SRL SLC SRIL Series Sight Glass Hopper Loaders 70 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 847 273 7700 Fax 847 273 7812 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 par
51. tion occurs is adjustable from 0 to 8 cycles See Section 5 11 Menu 5 First Time Startup for Proportioning Models 1 Insert the pickup wand into the material supply 2 Turn on the compressed air to the hopper loader 3 Apply power to the controller SRL SLC 8 SRIL Series Sight Glass Hopper Loaders 34 Note N Press and hold the UP key and DOWN key together simultaneously while applying power to restore all factory defaults As the controller powers up the screen displays in succession e PLUS for three seconds e the software version number n nn e the standby mode display Co Press the SCROLL key repeatedly until the screen displays 3 the percentage of Material B menu Press the 1S START STOP SELECT SET key to select this menu Press the UP key to increase the percentage of material B press the NJ DOWN key to decrease the of material B When the screen displays the percentage of Material B you want press the suse START STOP SELECT S ET key to set that value Press the S START STOP SELECT SET key to start the hopper loader The Vacuum LED lights and the vacuum motor conveys material until the proximity sensor indicates the hopper loader 1s full or sixty seconds passes whichever comes first The LED display shows the elapsed conveying time SRL SLC 4 SRIL Series Sight Glass Hopper Loaders 35 Note You can adjust the maximum vacuum time from 0 to 360 seconds See Section 5
52. truction check for Fouled flapper discharge free movement of flapper valve Hopper loader does not assembly work Clean and readjust for material Build up on sensor arm ia flow characteristics a Secure all terminal Loose control wiring connections Blowback and motor Reattach blowback and or connections are not secure motor connections Power switch has failed Replace switch Reed switch has failed Replace reed switch adjust magnet Circuit board has failed Replace circuit board The bin below the hopper en binis Operation I n f the material level drops this is loader is filled to capacity normal animarse Motor assembly is not properly Plug motor assembly into the man connected to the controller controller enclosure Replace fuse vvith an MDL 0 Fuse is blown fuse M Repair or replace motor as otor requires servicing needed SRL SLC amp SRIL Series Sight Glass Hopper Loaders 64 SRL SLC and SRIL Series Hopper Loaders vvith Standard Series One Controllers Cont d Increase air pressure to at Air pressure is too low least 80 psi 551 6 kPa 5 52 bars Air supply to blowback is Make sure piping is full size sure piping E Make sure piping is full size size supply Connect blowback assembly to controller at the proper receptacle Secure terminal connections of Control wiring connections are 0 the controller wiring on the loose on the circuit board ua circuit board has faile
53. ts 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 Service Department Call toll free 8am 5pm CST 800 423 3183 or call 847 273 7700 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most products Sales Department Call 847 273 7700 Monday Friday 8am 5pm CST Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 847 273 7700 Monday Friday 8am 5pm CST 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 AEC Inc 1100 E Woodfield Road Suite 588 Shaumburg IL 60173 SRL SLC amp SRIL Series Sight Glass Hopper Loaders 71
54. us Controls and Displays 4 4444244 31 5 4 Starting Up the Hopper Loader for the First Time Using the Series One Plus CONTONE nada Ten LEM MT c EMI PCM 33 5 5 Operating a Hopper Loader at Factory Defaults ccoccooccconcconccocconcconnconnnns 36 5 6 Operating the Proportioning Feature i 37 57 USING the Bate 0 adi din 38 5 8 Operating in Single Shot Mode iii 39 5 9 Customizing Series One Plus Controller Operations 39 5 10 Navigating Series One Plus Controller Menus ooccocccocccocncocncoccconccorccncnonnconncnnnnns 40 5 11 Series One Plus Operating Parameter Menus aa 41 5 12 Shutting Down the Hopper Loader using the Series One Plus Controller 45 SRL SLC SRIL Series Sight Glass Hopper Loaders 5 CHAPTER 6 SERIES ONE PLUS SPI COMMUNICATIONS 47 bl SPINeiWwork FUNCIONS contreras a a e 47 6 2 Seng UPS cella aio 48 0 Operating Under SPI 600 is 49 CHAPTER 7 MAINTENANCE a 52 A Route iodo BAG Ee iden nos aci i e 52 2 Replacing Motor BUSES cacions as eta metes tant 53 CHAPTER 8 TROUBLESHOOTING 64 RETURNED MATERIAL POLICY eere 70 TECHNICAL ASSISTANCE ua 71 SRL SLC
55. y During Operation 1 Note 69 While the hopper loader is operating press the SCROLL key until the screen displays the percent of Material B as P nn Press the UP key or the DJ DOWN key to change the value as needed When the percentage of Material B you want displays press the 1S START STOP SELECT SET key to set it Or Co Press the SCROLL key to leave the menu unchanged The screen then displays the Vacuum Timer menu On the fly adjustments range between 1 and 99 To set the percentage of Material B from 0 to 100 stop the Series One Plus controller and reset proportioning while the unit is in Standby mode as described in the previous section Using the Batch Counter The Series One Plus controller features a batch counter you can view during operation The batch counter provides a rough approximation of total material throughput Viewing the Batch Counter While the hopper loader is operating and while the screen displays the vacuum timer display Co Press the SCROLL key until the screen displays the four digit batch counter Co The screen remains on the batch count display until you press the sx SCROLL key again SRL SLC amp SRIL Series Sight Glass Hopper Loaders 38 To return to the vacuum timer screen 2 Press the SCROLL key again The screen reverts to the vacuum timer display Resetting the Batch Counter To reset the batch counter to zero 0 AJ IX m
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