Sterling SSK-30 User's Manual
Contents
1. 8 1 4 For the safety of the equipment 8 2 Installation instructions cerle RR RE ee NNN 9 CM Trans pO bd bd die bd Aer AE Glede E A 10 2 2 VU T 10 2 3 Compressed air supply only with compressed air valves 12 2 4 Electrical 13 3 Functional description a a 90923909 2429492943529 9209293 ee 15 4 Maintenance 2 0 cee nnn nh 16 4 1 Maintenance intervals 18 4 2 Servicing the hopper oader ee eeee 19 4 2 1 Replacing the nonreturn valve sealing ring 21 4 2 2 Replacing the outlet flap sealing 22 4 2 3 Adjust the flap switch 24 4 2 4 Cleaning the hopper loader 25 9 Spare parts IE uou uox uox RR OR 1D vn RE 26 SM3 626 SSK 30 1 Safety instructions These safety instructions apply to all persons within the range of action of the equipment Please inform all persons within the range of action of the equip ment of the direct and indirect hazards connected with the equipment These operating instructions are to be used by all persons as signed activities connected with the equipment Knowledge of the English language is prerequisite Ensure in each case that the operating personnel are familiar with the operating instructions and the2. Please check that all connecting points are tight to ensure that the conveying performance is not impaired It should moreover be observed particularly if custom produced connecting parts are used that the material discharged from the hopper loader must neither get into the open nor must it clog the filter surfaces observe angle of repose Do not excessively load inlet nozzle of hopper loader remove hose separately if necessary Installation instructions 11 SM3 626 SSK 30 2 3 Compressed air supply only with compressed air valves For operating the control valves a compressed air supply is neces sary Check compressed air piping for correct installation and assembly Check fittings length and quality of the hose connections for agree ment with requirements The operating pressure is 5 6 bar 72 52 87 02 PSI system overpressure Check the compressed air sup plied by the plant s supply network Adjust compressed air pressure to 5 6 bar 72 52 87 02 PSI system overpressure Compressed air must be dewatered and oiled Maintenance unit Install a maintenance unit pressure reducer with water separator and oiler if re quired Connect the unit to the plant s supply network by means of a hose Gi Depressurize compressed air supply lines which must be opened Compressed air must be dewatered and oiled Adjust pressure to a max value of 6 bar 87 02 PSI system overpr
3. within the hop per for material residue For clean ing disassemble the hopper turn the hopper approx 1 2 rotation counterclockwise Clean the sieve by means of com pressed air Install the hopper turn the hopper approx 1 2 rotation clockwise Check the hopper for proper fit Clean the hopper loader by means of a vacuum cleaner Mount the hopper loader lid Close the tension ring A Open the toggle type fasteners C on the flap of the hopper loader Check the filter D and the filter mat E in the flap for material resi due Clean the filter by means of compressed air SSK 30 ac Ee A TT TL e 79 SSK 30 Close the toggle type fasteners C on the flap of the hopper loader Install the hopper loader Maintenance 25 SM3 626 SSK 30 5 Spare parts list Eg fi I Chi SW 8 20 4 15 Spare parts list 26 SM3 626 Pos a A CO 13 14 15 18 20 21 22 32 Part number 29699 23069 26454 26487 23092 28418 33152
4. CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 262 641 8600 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 Sterling 2900 S 160th Street New Berlin WI 53151 These operating instructions are for Please fill in personally Serial number Built in Date of delivery Number of delivery Date of commissioning Location Group of machines SM3 626 SSK 30 Sterling Material Processing retains all rights to change the information in these operating instructions at any time without notice We assume no liability for any errors or direct or indirect damage resulting in con text with these operating instructions Copying translation or publication in any form except for personal use of pur chaser requires approval from Sterling Material Processing All rights reserved SM3 626 SSK 30 Table of contents T Safety InstFUCU DIIS n e ce a eee 5 1 1 Warnings and 5 6 1 2 Explanations and 7 S For your Safety
5. function of the equip ment Observe the safety instructions of the connected conveying system Safety instructions 5 SM3 626 SSK 30 1 1 Warnings and symbols The following warnings and symbols are used in these operating instructions This symbol indicates danger to life Fatal or serious injury is possible if the corresponding instructions regulations or warn ings are not observed This symbol indicates that serious injury is possible if the cor responding instructions regulations or warnings are not ob served This symbol indicates that extensive damage to equipment is er possible if the corresponding instructions regulations or warnings are not observed LO This symbol indicates information important for becoming fa miliar with the equipment i e technical correlations This symbol indicates that a technical term is explained atthis point Safety instructions 6 SM3 626 SSK 30 1 2 Explanations and information Various terms and designations are used frequently in these operating instruc tions to ensure clarity Therefore please note that the terms used in the text stand for the corresponding explanations listed below e Equipment Equipment can mean an individual unit a machine or an installation e Operating personnel The operating personnel are persons operating the equipment on their own re sponsibility or according to instructions minimum age 16 e Operator The ope
6. of the hopper Disassemble the hopper Maintenance 20 SM3 626 SSK 30 4 2 1 Replacing the nonreturn valve sealing ring Open the tension ring A Remove the hopper lid Draw the old sealing ring off the HE nozzle B eee TE i Install the new sealing ring Ob EN serve the direction of installation p Mount the hopper lid Close the tension ring A UD C Install the hopper loader M ee B SSK 30 Maintenance 21 SM3 626 SSK 30 4 2 2 Replacing the outlet flap sealing Remove the connecting plug flap switch A from the connection housing of the hopper Remove the tension ring B and the sealing ring on the hopper loader Remove the upper part of the hopper loader C from the lower part of the hopper loader D Remove the old outlet flap sealing E and the adhesive from the slot Check that no sticky rests are left behind Glue the new outlet flap sealing into the slot Use a suitable adhesive e g Pattex Set the flap switch BN Assembly sealing Maintenance 22 SM3 626 SSK 30 Install the upper part o
7. 31183 31182 84555 88635 95881 84940 85610 99880 SSK 30 Designation Outlet flap Hopper with sieve Flap Valve Sealing Sealing Flap switch Filter Filter mat Control Sealing Sealing Tension ring Sealing Sealing Spare parts list 27 SM3 626 6 Technical Data 6 1 Control Cable Wiring Schematic JMP TO PIN 4 DEMAND VALVE GROUND 24VDC JMP TO PIN 2 CSK 30 Co SOL NOTE Cx 2 NOTE Orcs 6 ON OFF HOPPER FULL OPTIONAL o DEMAND RS Cx4 Spare parts list 28
8. 9 Xingpu Road SIP Mhalunge Chakan Tal Khed Suite 588 Suzhou China 215126 Dist Pune 410501 India Schaumburg IL 60173 Phone 86 8717 1919 Phone 91 21 35329112 Phone 1 847 273 7700 Fax 86 512 8717 1916 Fax 91 20 40147576 Fax 1 847 273 7804 i Europe Middle East Africa ACS New Berlin Manufacturing Facility 2900 S 160 Street ACS Warsaw New Berlin WI 53151 Ul Dzialkowa 115 Phone 1 262 641 8600 et sy as Phone 48 22 390 9720 Fax 48 22 390 9724 SM3 626 SSK 30 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 783 7835 or call 262 641 8600 Fax 262 641 8653 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 Service Department Call toll free 8am 5pm CST 800 783 7835 or call 262 641 8600 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 262 641 8600 Monday Friday 8am 5pm
9. SM3 626 Sterling Operating Instructions Conveyor Hopper SSK 30 Part Number 882 00437 00 Bulletin CV5 680 www sterlco com Sterling Material Processing Please note that our address and phone information has changed Please reference this page for updated contact information These manuals are obsolete and are provided only for their technical information data and capacities AXCAUTION Portions of these manuals detailing procedures or precautions in the operation inspection maintenance and repair of the products may be inadequate inaccurate and or incomplete and shouldn t be relied upon Please contact the ACS Group for more current information about these manuals and their warnings and precautions Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service For immediate assistance please contact North Central and South America 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reducti
10. essure Installation instructions 12 SM3 626 SSK 30 2 4 Electrical connection 64 10 0183GBO1 03 99 The electrical connection may only be carried out by trained per sonnel Other persons are not permitted to carry out the electrical con nection The rules of the local electricity board must be observed Before beginning the electrical connection make sure that the mains voltage and the power frequency are in accordance with the data on the name plate of the device All work may only be carried out when the unit is at zero voltage and at zero pressure connection point diaphragm valve SV gt HEB connection point ZKW connection point probe connecting plug flap switch KL connecting plug conveyor control Plug connection connection housing hopper Installation instructions 13 SM3 626 SSK 30 Sonde Binders on the card e WE 1 KL flap switch bridged with 4 SV diaphragm valve bridged with 2 24V OV PE O A W M Pin connection connecting plug conveyor control Installation instructions 14 SM3 626 SSK 30 3 Functional description The conveyor hopper is used for the automatic conveyance of f
11. f the hopper loader C on the lower part of the hopper loader D Install the sealing ring and the tension ring B on the hopper loader Connect the connecting plug flap switch A to the connection housing of the hopper Install the hopper loader Part number sealing ID 99880 Maintenance 23 SM3 626 4 2 3 Adjust the flap switch SSK 30 Remove the connecting plug flap switch from the connection housing of the hopper Connect an ohmmeter to PINS 2 and 3 of the connecting plug flap switch Release the nuts A of the flap switch B until the support can be displaced Open the outlet flap C so far that the front tip of the outlet flap is approx 50 2 mm 1 97 0 18 in away from the sealing surface Displace the flap switch B until the contact of the magnet switch is closed Tighten the nuts A of the flap switch Check the adjustment In case of free hanging outlet flap empty hopper loader the contact of the magnet switch must be closed x mm SN Outlet flap If the outlet flap cannot be properly adjusted replace the flap switch or the outlet flap with magnet Install the hopper loader Part numbers E flap switch outlet flap with magnet ID 33152 ID 29699 Maintenance 24 SM3 626 4 2 4 Cleaning the hopper loader Open the tension ring A Remove the hopper loader lid Check the sieve B
12. ing instructions for the cor responding conveying system e For the operation of the hoppers a compressed air supply is necessary Never set the operating pressure of the hoppers at more than 6 bar 87 02 PSI system overpressure e Install the hoppers in such a way thatthe outlet flap is hinged in a right angle to the direction of movement of the machine e Make sure that all plugs are connected properly Observe the carrying capacity of the machine flange Safety instructions 8 SM3 626 SSK 30 2 Installation instructions These installation instructions are intended for persons with skills in electrical and mechanical areas due to their training ex perience and received instructions Personnel using these installation instructions must be in structed in the regulations for the prevention of accidents the operating conditions and safety regulations and their implemen tation Ensure in each case that the personnel are informed The installation instructions provided in the corresponding oper ating instructions apply for all connected equipment Observe safety regulations with regard to lifting gear handling All installation work must be carried out with the equipment dis connected from electrical power and compressed air supply For installation work taking place at heights of over approx 1829 mm 6 ft use only ladders or similar equipment and working platforms intended for this purpose At grea
13. on 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 21 35329112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Let us install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations For assistance with your sales or system contracting needs please Call North Central and South America 1 262 641 8600 or 1 847 273 7700 Monday Friday 8am 5pm CST Europe Middle East Africa 48 22 390 9720 India 91 21 35329112 Asia Australia 86 512 8717 1919 Facilities ACS offers facilities around the world to service you no matter where you are located For more information please visit us at www acscorporate com United States Asia Australia India ACS India ACS Schaumburg Corporate Offices ACS Suzhou Gat No 191 1 Sandbhor Complex 1100 E Woodfield Road 10
14. oper working order and load suspension devices with sufficient carrying capacity Do not stand or work under suspended loads Ensure that the electric motors switch cabinets are sufficiently protected against moisture Use only suitable workshop equipment Before starting maintenance work appoint a supervisor Inform the responsible personnel before maintenance work on the system is started Never operate the equipment when partially dismantled All maintenance and repair work not described in this chapter may only be carried out by Sterling service personnel or autho rized personnel appointed by Sterling Maintenance 16 SM3 626 SSK 30 Disconnect the equipment from mains supply before starting maintenance procedures to ensure that it cannot be switched on unintentionally Depressurize all compressed air piping of the equipment be fore starting maintenance work Please observe the maintenance intervals Before starting maintenance work clean the equipment of oil fuel or lubricants Ensure that materials and incidentals required for operation as well as spare parts are disposed of properly and in an envi ronmentally sound manner Use only original Sterling spare parts Keep record of all maintenance and repair procedures Maintenance 17 SM3 626 SSK 30 4 1 Maintenance intervals Daily every six months yearly check warning signs on equipment for good legibility and completeness
15. rator of the equipment production manager foreman etc is the per son responsible for all production sequences The operator instructs the operat ing personnel of what is to be done e Operating instructions The plant operating instructions describe the interaction of the equipment pro duction sequences or methods The plant operating instructions must be com piled by the operator of the equipment e Equipment foreman When several operating personnel work on one machine the equipment fore man coordinates the sequences The equipment 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 in good practice Safety instructions 7 SM3 626 SSK 30 1 3 For your safety e tis absolutely necessary that you observe the operating instructions for the cor responding conveying system e The device is intended exclusively for conveying plastic granules and regrind Any other usage is not permitted e This device is not suitable for processing foods e Before beginning maintenance work set all compressed air piping on the device at zero pressure Danger of accidents e The device may only be operated if all corresponding components have been properly connected and are in accordance with the relevant regulations 1 4 For the safety of the equipment e tis absolutely necessary that you observe the operat
16. reely flowing plas tic granules The hopper can only function in connection with a vacuum conveyor plant The hopper works without a filter Depending on the type of valve the shut off valve of the vacuum line is operated with compressed air compressed air valve or with the vacuum air diaphragm valve On the hopper there is a separate on off switch A and a function controlling de vice which indicates the following operational modes B lamp on hopper switched on at the on off switch A lamp flashes the hopper is conveying C lamp flashes error D lamp is on hopper signals lack of material gt o Connection housing hopper Functional description 15 SM3 626 SSK 30 4 Maintenance This chapter is intended for persons with skills in electrical and mechanical areas due to their training experience and received instructions Personnel using the instructions in this chapter must be in structed of the regulations for the prevention of accidents the operating conditions and safety regulations and their implemen tation Ensure in each case that the personnel are informed accord ingly For maintenance work taking place at heights of over approx 1829 mm 6 ft use only ladders or similar equipment and working platforms intended for this purpose At greater heights the proper equipment for protection against falling must be worn Use only suitable lifting gear which is in pr
17. ter heights the proper equipment for protection against falling must be worn Use only suitable lifting gear which is in proper working order and load suspension devices with sufficient carrying capac ity Do not stand or work under suspended loads Use suitable workshop equipment Install the equipment such that all parts are easily accessible CE this facilitates maintenance and repair work Installation instructions 9 SM3 626 SSK 30 2 1 Transport For transport only the appropriate lifting gear should be used e g fork lift or workshop crane Observe the carrying capacity of the lifting gear Observe the safety instructions for the handling of lifting gear 2 2 Set up The arrangement of the hopper loaders may vary depending on the type of de vice to be conveyed on and the material used Fastening onto fixed machine throats is provided by means of strap retainers However additional support of the hopper loader is necessary if the devices are not sufficiently capable of bear ing the load Mount the hopper loader in such a way that the outlet flap swings in a right hand angle to the direction of machine movement Please check during assembly that the admissible bearing loads are not exceeded BE mM gt A Assembly Installation instructions 10 SM3 626 SSK 30
18. with compressed air valve check the oil level in the oiler empty the water separator check the operating pressure in the factory ductwork system max 6 bar system overpressure check all electrical and mechanical connections for proper fit check the settings of the level probes if available check the sealing ring on the locking flap check the sealing on the outlet flap replace the sealing ring on the locking flap replace the sealing on the outlet flap The given maintenance intervals are average values Check whether in your individual case the maintenance inter vals must be shortened Maintenance 18 SM3 626 SSK 30 4 2 Servicing the hopper loader Individual hoppers can also be maintained during operation However Sterling recommends that you switch off the con veying plant for all types of work on the hopper Switch off the hopper by means of the on off switch A on the connection hous ing Wait until the conveying procedure has stopped Disassemble the vacuum line on the hopper Close the disassembled vacuum line so that the vacuum for the active hop per loaders does not break down Connection housing hopper Maintenance 19 SM3 626 SSK 30 Depressurise the compressed air line to the hopper only with compressed air valve Disassemble the material line on the lateral inlet of the hopper Remove the connecting plug B conveyor control on the connection housing
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