Sterling 882.00268.00 Marine Radio User Manual
Contents
1. SPV Remote Proportioning Valve Part Number 882 00268 00 Bulletin Number CV4 600 Effective 11 26 05 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No O Copyright 2005 All rights reserved Please note that our address and phone information has changed Please reference this page for updated contact information These manuals are obsolete and are provided only for their technical information data and capacities AXCAUTION Portions of these manuals detailing procedures or precautions in the operation inspection maintenance and repair of the products may be inadequate inaccurate 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 e2. i d rrect as n Minimum non proportioning unit Inadequate air pressure Correct as needed u 60 psi required for operation Worn plungers Replace plungers Part No W00533565 Clogged filter hopper Clean or replace filter Excessive vacuum leaks loose Repair replace as needed connections to valve Plungers move slowly stick or Inadequate air pressure Correct as needed Minimum do not seal properly 60 psi required for operation Inadequate lubrication of air Lubricate air cylinder cylinder Solenoids are malfunctioning Repair replace as needed Worn malfunctioning plungers Repair replace plungers as needed Sticking plungers Replace air cylinder Consult factory Remote Proportioning Valve Chapter 6 Troubleshooting 26 of 30 Chapter 7 Appendix 7 1 Customer Satisfaction Warranty Program The manufacturer warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions The Company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the Company s op
3. CYCLE TIME BRE nr DUTY RATIO A B WIRING DIAGRAM D s INSIDE OF BOX CONNECTION DIAGRAM ASSEMBLY L FOR HOLE LOCATION REFERENCE DRAWING A0 3Se1l FDR HOPPER LOADER CONTROL ENCLOSURE REFERENCE 110 VOLT PART NUMBER A0533910 CONNECTION DIAGRAM A0533918 220 VOLT PART NUMBER A0533912 CONNECTION DIAGRAM A0 333920 3 Remote Proportioning Valve Chapter 4 Installation 17 of 30 Installing the RPV B and RPV D Standalone for Central Vacuum Systems This control configuration is used to convert a central system vacuum hopper into a proportioning vacuum hopper The stand alone control can be used in systems with 24 VDC or 110 VAC T valve solenoids The RPV B requires an external 110 60 1 VAC power supply The RPV D requires a 220 50 60 1 power supply and the proper plug and power cable supplied by customer The power supply can be provided through a grounded duplex plug or the control can be connected to a power main where codes permit If your RPV has the RPV B or RPV D control package use the following procedure to install it See Figure 5 for more information l 5 Remove the cover from the Standalone control enclosure Turn it over to gain access to the eight pin socket at the base of the timer See Figure 6 on page 19 Using 14AWG leads wire terminals three 3 and six 6 to Solenoid 1 material A located in the RPV Splice the leads together within the RP
4. RPV can be controlled by one of three different controls See Chapter 4 Installation for installation instructions e Knob box Used with Autoloader hopper loaders This control is supplied with Model RPV A e Stand Alone control Used with central vacuum system vacuum hoppers This control is supplied with models RPV B and RPV D e Hopper loader control Used with 9953 and 9963 hopper loaders The existing control box for these models has the circuitry to control model RPV C Remote Proportioning Valves already installed 5 1 Knob Box Operation Knob box controls are used with Autoload Hopper Loaders and are supplied with the RPV A The Knob Box has two knobs a power switch and a power indicator light Install the knob box as described in Section 4 2 on page 16 Ratio Knob The knob labeled RATIO controls the relative delivery proportion of Material A to Material B typically virgin and regrind This knob may be adjusted in a range from all Material A and no Material B to no Material A and all Material B These ratios are approximate For a known proportion use the weight test procedure in Section 5 4 on page 24 Cycle Seconds Knob The knob labeled CYCLE SECONDS controls the total length of each proportioning cycle This knob may be adjusted from zero 0 to twenty 20 seconds to fine tune the proportioning operation to the convey time of the vacuum receiver being loaded For example if the cycle time is 20 seconds and th
5. adjusting these intervals the proportioning is controlled Under ideal conditions with identical total resistance in both material hoses and the Material A and B timers set at 10 and 5 seconds respectively a 2 to 1 mixture is delivered to the vacuum receiver Under actual conditions total resistances will not be identical Two materials with different conveying characteristics such as regrind and virgin conveyed from differing pickup devices over differing distances are not be conveyed at the same rate To ensure a mixture of known proportions a weight test as described in Section 5 4 on page 24 should be performed for each application Remote Proportioning Valve Chapter 3 Functional Description 10 of 30 3 4 Typical Features and Components The RPV is available with a variety of control choices designed to suit your particular operation RPV A The A model Remote Proportioning Valve is designed exclusively for use with the Autoload Hopper Loader RPV Band D The B and D model RPV s are designed for use with central vacuum systems These models will convert any existing vacuum hopper into a proportioning unit regardless of manufacturer The RPV B uses 110 VAC supply voltage The RPV D is designed to be used outside of North America with 220 VAC supply voltage RPV C The RPV C model is designed to convert existing 9953 and 9963 Hopper Loaders into proportioning units Remote Proportioning Valve Chapter 3 Funct
6. 7 439 5655 Our qualified service department is ready to help Service contracts are available for most of our products Sales Department Call 630 595 1060 Monday Friday 8am 5pm 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 630 350 7283 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 as built drawings equipment labor and construction materials union or non union installations and field supervision Remote Proportioning Valve Chapter 7 Appendix 30 of 30
7. B will alternate ON three times a cycle for ten seconds each creating a 1 1 ratio Example 2 If Pot 3 is set at the maximum setting and Pot 4 is turned to a middle setting Material A would be conveyed for ten seconds and Material B would convey for five seconds The resulting fifteen second proportioning cycle would repeat four times during a sixty second convey cycle This setting would creates a 2 1 proportion ratio under ideal conditions Adjust the pots to suit your unique processing requirements noting the concepts described in Section 3 3 How it Works on page 10 Refer to Section 5 4 on page 24 for instructions on delivering known proportions Remote Proportioning Valve Chapter 5 Operation 23 of 30 5 4 Weight Test for Accurate Proportioning To get an accurate proportion of regrind and virgin materials run the test described below to determine the conveying rate of your particular installation using your materials The test will determine the ratio settings needed to deliver the desired mix 1 B DOP dede a pat 10 Determine the total throughput of the machine This is equal to the amount pounds of material your processing machine uses in an hour Weigh out a known quantity of regrind into the container from which the regrind is conveyed This amount should be enough to service the processing machine for the duration of the test This test should be run for at least fifteen minutes Set the Remote Proportion
8. V shroud Using 14A WG leads wire terminals four 4 and five 5 to solenoid 2 material B located within the RPV Splice the leads together within the RPV shroud Using 14AWG leads wire terminals one 1 and eight 8 to the existing sequence tee valve Replace the cover of the enclosure and tighten the screws Figure 5 RPV B or RPV D Standalone Connection Diagram Remote Proportioning Valve Chapter 4 Installation 18 of 30 Figure 6 Standalone Junction Box Assembly RONT VIEW EXPLODED Remote Proportioning Valve Chapter 4 Installation VIEW A A VIEW B B TOP VIEW E 19 of 30 Installing the RPV C 9953 and 9963 Hopper Loader Control Use this control configuration to convert an existing 9953 or 9963 hopper loader into a proportioning hopper loader The circuit board within these hopper loaders contains the circuitry necessary to control a Remote Proportioning Valve Wire the solenoids in the Remote Proportioning Valve as shown in Figure 7 Use 18AWG wire for the solenoid connections If your RPV has the RPV C control package use the following procedure to install it 1 Connect Solenoid 1 Material A to Terminal 7 on 2TB 2 Connect Solenoid 2 Material B to Terminal 8 on 2TB 3 Wire the solenoid common wires to Terminal 10 on 2TB Figure 7 RPV C to 9953 or 9963 Connection Diagram m Remote Proportioning Valve Chapter 4 Installation 20 of 30 Chapter 5 Operation The
9. a I APRES 22 Material B Tier 22 5 3 Hopper Loader Conversion Operation 000 enter 23 Example E 23 Example 2a E S 23 5 4 Weight Test for Accurate Proportioning c ccceeseecsseceeeeeeeseseeceneeeeeeeeeeeneeeeenees 24 Remote Proportioning Valve iii CHAPTER 6 TROUBLESHOOTING mH 25 0 1 ilntrodUctlori see eec th ete tei a Trot tec td rb vtr VEL Ed 25 CHAPTER 7 APPENDIX aaa ta aaa a 21 7 1 Customer Satisfaction Warranty Program 27 7 2 Technical Gpechicattons nnne a 27 Electrical Requirements sss nnne 27 Compressed Air Consumpton eene nn nn 27 Te Drawings and Daa hn a a a es d itaq itat aa 28 RPV DIMENSIONS tee Rp t deg d PE d RE doe dies 28 RPV Assembly Drawing and Parts Breakdown seen 29 7 4 Technical Aesistance 0000 30 Parts Department ceo n a aa dEEEN 30 Service Department 30 Sales Department 30 Contract Department en eet i A ies Av iex Eque ded 30 Remote Proportioning Valve iv Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your granulator The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description
10. ackage Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Remote Proportioning Valve Chapter 2 Safety 7 of 30 2 2 General Safety Information These Remote Proportioning Valves or RPVs 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 always use good judgment and follow these safe practices M M M Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Have a STABLE WORK PLATFORM when installing or maintaining RPVs mounted above floor level Disconnect and or lock out power before servicing or maintaining the RPV Re
11. ditional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the granulator We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the granulator These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the granulator safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your granulator provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part numbers specific to your machine is provided with your shipping paperwork p
12. e Ratio knob is at 50 50 Material A will convey for 10 seconds and Material B will convey for 10 seconds The cycle repeats automatically Power Switch and Indicator The power toggle switch can be used to turn the Autoload Hopper Loader On and Off if the power switch on the Autoloader is ON The POWER ON light is illuminated when power is applied The knob box is supplied with twelve 12 feet of cable and can serve as a remote On Off switch Note The knob box and Autoloader hopper loader power switches must both be ON for the loader to operate Remote Proportioning Valve Chapter 5 Operation 2 of 30 5 2 Standalone Control Operation The Stand Alone Control is provided with RPV models B and D and is used with central vacuum system operated vacuum hoppers The Stand Alone control box has these features Power Switch The power switch on the stand alone box must be in the ON position during operation If the power switch is turned off during operation the RPV will stop conveying and the central vacuum system will sense a high vacuum condition and initiate a blowback cycle Fuse Holder The 2 amp fuse for the Stand Alone Box is conveniently located on the faceplate of the enclosure and can be easily replaced Keep a spare fuse on hand Conveying Time Range Selector Potentiometer The conveying time range can be set in seconds minutes hours or tens of hours by turning the unit selector potentiometer or pot located in the lower rig
13. ectrical work must conform to all codes in effect at the installation site Installing the RPV A Autoload Knob Box Control If your RPV has the RPV A control package use the following procedure to install it 1 Disconnect and lock out power to the Autoloader Hopper Loader 2 Wire the RPV Material A and B solenoids to the Autoloader Hopper Loader control box using 16AWG wire See Figure 3 3 Remove Jumper W3 installed between Terminals 13 and 14 on Terminal Block TBI in the Autoloader Hopper Loader control box Note The knob box control will not function properly unless you remove this jumper 4 Toggle the power switch on the Autoload Hopper Loader to the ON position This switch must be ON to use the Knob Box Control as a remote ON OFF switch 5 Plugthe white logic plug connected to the RPV knob box into the receptacle marked J2 on the left side of the Autoloader control enclosure See Figure 4 on page 17 6 Re connect power Figure 3 RPV A to Autoloader Wiring Diagram TB3 1 NOT a USED 3soL o mz SOLENOID B Gi LS wiet TB3e3 DW REMOTE ouse oT PROP sa OH valve Lo HI EH DIN 2S0L sx ETT pepe SOLENOID A oss iN i TS BACK CH JB J4 1SOL BLOWBACK o o BLK RS 183 7 ele 783 8 EH 1FU Remote Proportioning Valve Chapter 4 Installation 16 of 30 Figure 4 Knob Box Assembly BACK OF COVER 4 Tt s O a POWER
14. fety Information EE 8 2 3 Warnings and e EE 9 CHAPTER 3 FUNCTIONAL DESCRIPTION 10 3 1 Models Covered in This Manual 10 3 2 General Description ss ccm eed ee p a a a 10 BES JHOWJtNVOIKS e neret ce eerte e bentes due o er o esed Ee e e EPOR EE evades 10 3 4 Typical Features and Components 0000 eeen 11 agi d ten MEER EH REOR Ee 11 RPV Band D EEN 11 RPV C EE 11 CHAPTER 4 INSTALLATION eene en nnne 12 4 1 Mountingine RPV o ceci ce eae eet EEN 12 Wall Mount Installation sessi 12 Floor Mount installation 14 Machine Mount Installation esses 15 4 2 Installing the RPV Controls seess ede bre rto ERR repe he o etel ag tee eng 16 Installing the RPV A Autoload Knob Box Control 16 Installing the RPV B and RPV D Standalone for Central Vacuum Systems 18 Installing the RPV C 9953 and 9963 Hopper Loader Control 20 CHAPTER 5 OPERA TION sasssa n irr Uc code vo uote a 21 5 1 Knob Box Operation 21 Ratio Knob EE 21 Cycle Seconds Knob epo oe Etude caben a 21 Power Switch and Indicator sisse 21 5 2 Standalone Control Operation 22 Power SWIC DEE 22 F se ele EE ER Conveying Time Range Selector Potentiometer AA 22 Timer Dial Increment Selector Potentiometer sss 22 Material A Timer sie diced t ri im asta o dl e M E da eor i R
15. ht corner of the timer face Timer Dial Increment Selector Potentiometer The timer dial increments may be set by turning the increment selector potentiometer or pot located in the lower left corner of the timer face Material A Timer The conveying time for Material A is controlled by dialing the orange or ON axial dial to the desired time Material B Timer The conveying time for Material B is controlled by dialing the yellow or OFF radial dial to the desired time Note Due to the variance of flow characteristics between different materials the ratio set by the two material dials will not necessarily provide the same ratio of material Some adjustment of convey times may be necessary to achieve the desired mixture See Section 5 4 on page 24 for an explanation and a method of determining and tuning actual conveying rates Remote Proportioning Valve Chapter 5 Operation 22 of 30 5 3 Hopper Loader Conversion Operation The RPV C converts 9953 and 9963 hopper loaders into proportioning hopper loaders using the controls included with existing AEC models If you are familiar with the operation of 9955 and 9965 proportioning hopper loaders the RPV C is operated in the same manner Adjust the potentiometers in the control enclosure as you would with a 9955 or 9965 Refer to the Operation and Installation Manual supplied with your existing proportioning hopper loader for complete information If you are not familiar with the proportioni
16. ide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section Remote Proportioning Valve Chapter 6 Troubleshooting 25 of 30 Control is on and working but Faulty compressed air Repair connection replace valve does not work connection to valve connector Must have minimum 60 psi Inadequate incoming vacuum Locate problem repair replace signal and voltage as needed Loose connection wiring in Repair replace as needed control box Improper shroud solenoid Compare voltage rating of voltage compared to control solenoids in shroud to output output voltage voltage of controls Check solenoids in shroud and replace as needed Control does not work Inadequate voltage Check supply voltage Make sure the unit has power Loose control wiring in control Repair as needed box Sudden loss in conveying rate Control malfunction Repair as needed Possible Joss ofupta Vue hamar 20 conveying rate compared to BA
17. ing Valve controls to approximate the desired proportions of virgin and regrind Note the time and begin processing Stop processing after at least twenty minutes Note the total processing time Weigh the regrind remaining in the container Determine the amount of regrind that would have been used if the test had been run for an hour Lbs Regrind Hour For example if you tested for fifteen minutes multiply by four Divide the Lbs Regrind Hour by the Lbs hour throughput figure to determine the percentage of regrind at the current setting If the percentage is not acceptable re adjust the controls and repeat steps 2 through 9 until the proportions are correct Remote Proportioning Valve Chapter 5 Operation 24 of 30 Chapter 6 Troubleshooting 6 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshooting is indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to prov
18. inion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The Company is not liable for any incidental consequential or special damages or expenses The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts Any sales use excise or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty Many types of the manufacturer s equipment carry an additional one year service policy Consult your sales representative for specific details 7 2 Technical Specifications Electrical Requirements Remote Proportioning Valves are available with standard voltage requirements of 110 60 1 and 220 60 1 They are offered with control voltages of 110 VAC 220 VAC and 24 VDC RPV solenoids consume 7 watts each at 110 VAC Compressed Air Consumption Your Remote Proportioning Valve requires a 60 to 80 psi supply of clean dry com
19. ional Description 11 of 30 Chapter 4 Installation 4 1 Mounting the RPV The RPV can be mounted to a machine on the floor or on a wall The optional floor stand provides installation location flexibility The RPV can be used with more than one machine by switching hoses and positioning the floor mounted RPV in a convenient place Wall Mount Installation This type of installation uses the optional wall mounting bracket to mount the Remote Proportioning Valve to a convenient wall pipe or other structural member Use the following procedure to install the RPV using the wall mount configuration See Figure 1 for more information 1 Selecta location for the RPV that allows access to the clean out and viewing hatch Plan ahead for a spot where the two material supply hoses and the material delivery hose do not interfere with your workspace or create a tripping hazard 2 Secure the wall bracket to a suitable wall beam etc that can support 250 Ibs of weight hanging from it 3 Prepare the RPV for installation by removing the four bolts that attach the single outlet tube to the valve body Note The outlet tube is embedded in silicone sealant and should stick to the valve body during installation Do not pull them apart If the seal between the outlet tube and the valve body fails apply a new bead of silicone sealant before mounting the RPV 4 Insert the RPV outlet tube through the hole in the bracket and secure it with the longe
20. m 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 Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have M Remote Proportioning Valve M Bill of lading M Packing list M Operating and Installation packet V Electrical schematic and panel layout drawings KM Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately Call 1 630 475 7413 have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department Remote Proportioning Valve ii Table of Contents CHAPTER 1 SAFETY sasssa sad Dave ioo 5 1 1 How to Use This Manual eene nnne 5 Safety Symbols Used in this Manual eene 5 CHAPTER 2 SAFETY i iso tes ect sa ala ume ea aueh 7 2 1 How to Use This Manual 7 Safety Symbols Used in this Manual 7 2 2 General Sa
21. mote Proportioning Valves Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment It is a good idea to remove the fuses and carry them with you Make sure the machinery is properly GROUNDED before you switch on power When welding in or near this unit be sure VENTILATION is ADEQUATE PROTECT adjacent materials from sparks An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed Do not jump or bypass any electrical safety control Do not restore power until you remove all tools test equipment etc and the unit is fully reassembled Only PROPERLY TRAINED personnel familiar with the information within this manual should work on this equipment Remote Proportioning Valve Chapter 2 Safety 8 of 30 2 3 Warnings and Precautions The installation operation and maintenance of this equipment is to be conducted in accordance with all applicable work and safety codes for the location where it is used This may include but is not limited to OSHA NEC CSA SPI and any other local national and international regulations In addition the following specific work rules must be observed WI Always keep these operating instructions on hand and follow them when performing installation operation and maintenance procedures If the instructions become damaged or unreadable additional c
22. n support 250 lbs of downward force If you are installing your RPV on equipment from another manufacturer consult them for advice on support capabilities 1 Check the RPV single outlet tube diameter and the hopper loader inlet size to be sure you have the necessary coupler and transition tube if needed to connect the RPV to the hopper inlet 2 Chamfer and smooth the hopper loader or vacuum hopper inlet tube to prevent damage to the O rings inside the tube coupler 3 Apply silicone lubricant or equivalent to the inside of the tube coupler to ease insertion 4 Insert the single material outlet tube into the tube coupler past the O ring Be careful to avoid damaging the O ring 5 Slide the RPV onto the hopper loader or vacuum hopper with a side to side motion Be sure the tube passes the O ring for an air tight seal Avoid damaging the O ring 6 Tighten the set screws in the tube coupler to lock the RPV in place 7 Attach the material pick up wands to the RPV inlet tubes using flex hose and hose clamps Route the material conveying hoses so they don t interfere with workspace or create a tripping hazard Remote Proportioning Valve Chapter 4 Installation 15 of 30 4 2 Installing the RPV Controls DANGER Disconnect and lock out power before working on equipment Do not reconnect electric power until the installation is complete the work has been checked and all tools are removed and all safety devices are activated All el
23. ng feature available in 9953 and 9963 Hopper Loaders read the following for the adjustment procedure and refer to Figure 8 Figure 8 Control Box Adjustment Diagram PULSE LENGTH BLOWBACK VACUUM MATERIAL A MATERIAL B io I i i Inc Inc Inc POT 1 POT 2 POT 3 POT 4 Inc DANGER The adjustment procedure described below involves working inside the control box Dangerous electrical current may be present during potentiometer adjustment Only qualified safety conscious personnel may make these adjustments The adjusting potentiometers or pots are located in the hopper loader control box Pots 1 2 and 3 control the pulse blowback and vacuum times These pots have already been adjusted to your application and need no further adjustment Pots 4 and 5 are used to control the Remote Proportioning Valve These thirty turn pots control a twenty second maximum length proportioning cycle that runs independently of the conveying Vacuum Pot 3 time Turn pots 3 and 4 clockwise to increase the respective material ON times Turn them counter clockwise to reduce the material ON times Example 1 If both Pots 3 and 4 were turned to their maximum setting each material would be conveyed for ten seconds alternating until the convey Vacuum pot 3 cycle times out The proportioning cycle time is at its maximum length 20 seconds If the conveying cycle is set at sixty 60 seconds three 20 second proportioning cycles Materials A and
24. numbers specific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that if not avoided may result in minor or moderate injury or in property damage Remote Proportioning Valve Chapter 1 Safety 5 of 30 Notes Remote Proportioning Valve Chapter 1 Safety 6 of 30 Chapter 2 Safety 2 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your granulator The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Ad
25. opies may be obtained from the manufacturer s Parts Department Kl Only qualified personnel can work on or with this equipment Kl Work only with approved tools and devices M The electrical power and compressed air must be disconnected when performing maintenance or service If the unit is installed with a power cord that can be unplugged be sure to unplug it If the unit is permanently wired to a power main a fused power disconnect must be installed to allow the disconnect to be locked in the OFF position It is advisable to remove the disconnect fuses and carry them with you Remote Proportioning Valve Chapter 2 Safety 9 of 30 Chapter 3 Functional Description 3 1 Models Covered in This Manual This manual offers a general reference for the installation and operation of the Remote Proportioning Valve RPV with control configurations A B C and D Material inlets and outlet sizes range from 1 5 to 2 5 3 2 General Description The Remote Proportioning Valve is an efficient and economical means to proportion two 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 The design of the Remote Proportioning Valve lends itself to use in both central and machine side conveying systems The RPV also can turn a standard hopper loader or anyone s vacuum hopper into a proportioning unit Mounting of a Remote Pro
26. portioning Valve can be at a convenient location away from the hopper or loader or on the material inlet tube of a vacuum hopper or hopper loader Two urethane plungers operated by compressed air are positioned in a central vacuum chamber to provide airflow control between two separate material conveying lines The operator controls the positioning of the plungers and dictates the percentage of the two materials to be delivered through a single hose to a material receiver Plunger operation can be governed by a variety of control alternatives depending on the installation 3 3 How it Works The Remote Proportioning Valve proportions two free flowing dry materials into a single vacuum conveyed stream It can be mounted some distance from or directly on the vacuum receiver Two material inlets lead into a central vacuum manifold Compressed air operated plunger valves switch the vacuum supplied by a hopper loader or central system between two material pick up devices Switching between the inlets at timed intervals creates a known mixture of virgin and regrind materials The mixture can have a minimum accuracy of 5 depending on how controlled the set up of the Remote Proportioning Valve is The controls are set up on a timing cycle The Material A plunger is opened to the vacuum stream for an adjustable period of time and then closes The Material B plunger opens immediately and conveys the second material for an adjustable period of time By
27. pressed air The maximum SCFM required is 5 The connection size is 1 8 NPT Remote Proportioning Valve Chapter 7 Appendix 27 of 30 7 3 Drawings and Diagrams RPV Dimensions COMPRESSED AIR CONNECTION 60 PS MIN 5 SCFM MAX NOTES MATERIAL ALUMINUM WT 108 49S Remote Proportioning Valve Chapter 7 Appendix 28 of 30 RPV Assembly Drawing and Parts Breakdown a ee Len Lem Lee wun INN GL KP W E OE 9 Dw wm ES 1001 M ML VEA GH ANOA men Loe rect 00 pom 2 AWM 004 AL R R weree y 1 A la creak a LOTTE we pins ees HILL Bi rT sll SANT J ld A008 AWA C ALVA 131M ony HS AQ08 JAWA N334138 SIN AY 025 36 01 ENVIVIS 3NOOTNS umezaa ATquessy Ady nog eanbta MOO 0N023S OL 1 WA 29 of 30 Chapter 7 Appendix Remote Proportioning Valve 7 4 Technical Assistance Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 630 595 1060 The Parts Department is ready to provide the parts to keep your systems up and running Our replacement parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included in your information packet for replacement part numbers Service Department Call toll free 8am Spm CST 800 233 4819 or call 630 595 1060 Emergencies after 5pm CST call 84
28. r 4 20 x 1 bolts and the flat and locking washers provided 5 Connect the RPV material outlet tube to the vacuum receiver using flex hose and hose clamps 6 Connect the two material inlet tubes to the pickup wands with flex hose and hose clamps Remote Proportioning Valve Chapter 4 Installation 12 of 30 Figure 1 Wall Mount Configuration Remote Proportioning Valve Chapter 4 Installation 13 of 30 Floor Mount Installation Use the following procedure to install the RPV using the floor stand See Figure 2 for more information 1 Assemble the stand by inserting the standard into the floor plate and tightening the set screw 2 Complete the assembly by following steps 3 throuh 6 on page 12 3 Position the floor stand so the clean out and inspection hatches are accessible and the material hoses do not interfere with workspace or create a tripping hazard Figure 2 Floor Mount Configuration Remote Proportioning Valve Chapter 4 Installation 14 of 30 Machine Mount Installation In this installation the RPV is mounted directly to the material inlet of the hopper loader or vacuum hopper it will serve The hopper loader or vacuum hopper inlet tube provides the support for the RPV WARNING Make sure that the hopper loader or vacuum hopper inlet can support the weight of the RPV approximately 10 lbs and any unsupported material supply hose A properly installed hopper loader or vacuum hopper ca
29. r more information please visit us at www acscorporate com United States Asia Australia India ACS India ACS Schaumburg Corporate Offices ACS Suzhou Gat No 191 1 Sandbhor Complex 1100 E Woodfield Road 109 Xingpu Road SIP Mhalunge Chakan Tal Khed Suite 588 Suzhou China 215126 Dist Pune 410501 India Schaumburg IL 60173 Phone 86 8717 1919 Phone 91 21 35329112 Phone 1 847 273 7700 Fax 86 512 8717 1916 Fax 91 20 40147576 Fax 1 847 273 7804 R A 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 eee a Phone 48 22 390 9720 Fax 48 22 390 9724 Shipping Info Unpacking and Inspection You should inspect your granulator for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the clai
30. section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the granulator We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the granulator These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the granulator safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your granulator provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options A spare parts list with part
31. xcellent customer service For immediate assistance please contact North Central and South America 8am 5pm CST 1 800 483 3919 for drying conveying heating and cooling and automation For size reduction 1 800 229 2919 North America emergencies after 5pm CST 847 439 5855 North America email acsuscanadacustserv corpemail com e Mexico Central amp South America Email acslatinamericacustserv corpemail com e Europe Middle East amp Africa 48 22 390 9720 Email acseuropecustserv corpemail com India 91 21 35329112 Email acsindiacustserv corpemail com e Asia Australia 86 512 8717 1919 Email acsasiacustserv corpemail com Sales and Contracting Department Our products are sold by a worldwide network of independent sales representatives 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 Fo
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