Operating Instructions SM3-640 Two component proportioning valve SKW Sterling Material Processing
SKW Sterling Material Processing 5200 West Clinton Ave. Milwaukee, WI 53223 Telephone (414) 354-0970 Fax: (414-354-6421 www.sterlco.
SKW Sterling Material Processing retains all rights to change the information in these operating instructions at any time without notice. SM3-640 We assume no liability for any errors or direct or indirect damage resulting in context with these operating instructions. Copying, translation or publication in any form except for personal use of purchaser requires approval from Sterling Material Processing. All rights reserved.
SKW Table of contents 1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1. 1.2. 1.3. 1.4. Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Explanations and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 For the operating safety of the equipment . . . . . . . . . . . . . . . . . .
SKW 5. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.1. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 5.2. Checking for smooth operation . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.1. Dimension sheet SKW 40/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SKW 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 equipment of the direct and indirect hazards connected with the equipment. These operating instructions are to be used by all persons assigned activities connected with the equipment. Knowledge of the English language is prerequisite.
SKW 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 warnings are not observed. This symbol indicates that serious injury is possible if the corresponding instructions, regulations or warnings are not observed.
SKW 1.2. Explanations and information Various terms and designations are used frequently in these operating instructions to ensure clarity. Therefore please note that the terms used in the text stand for the corresponding explanations listed below. · Equipment “Equipment” can mean an individual unit, a machine or an installation. personnel · Operating The “operating personnel” are persons operating the equipment on their own responsibility or according to instructions (minimum age: 16).
SKW 1.3. For your safety · The operating personnel of this equipment must be at least 16 years old. read these operating instructions carefully before taking into operation for · Please the first time. All points are to be observed. Contact us should questions arise. This avoids injury and damage to equipment! operating instructions must be kept available at all times at the place of · These operation of the equipment.
SKW local regulations and requirements pertaining to the equipment must be · The observed. “5 safety rules” as provided in DIN VDE 0105, Section 1, must be observed · The for all work carried out on the equipment. electrical components from the mains supply before work is carried · Disconnect out on these components. Caution: Danger to life through electrical shock! not modify, add other equipment or change the design of the equipment · Do without the approval of the manufacturer.
SKW the equipment from mains supply before starting maintenance · Disconnect procedures to ensure that it cannot be switched on unintentionally. Caution: Danger of accidents! work may be carried out by trained personnel only. · Repair Caution: Danger of accidents! operate the equipment when partially dismantled. · Never Caution! Limbs may be caught in machinery; danger of electrical shock! case of malfunction, shut down the equipment immediately. Have malfunctions · Incorrected immediately.
SKW equipment may only be operated when all appertaining components are · The connected properly and comply with applicable regulations. · The equipment may only be operated in conjunction with a conveyor unit. SM3-640 · Observe the safety instructions for connected equipment.
SKW 1.4. For the operating safety of the equipment · Never change settings if the consequences are not precisely known. · Use only original Sterlingspare parts. · Observe the maintenance instructions. · Keep record of all maintenance and repair procedures. · Please note that electronic components may be damaged by static discharge. all electrical connections for secure fit before the equipment is taken into · Check operation and at regular intervals.
SKW · Please note that SKW 65 may not be used for conveying abrasive materials. · Please note that the SKW can only be used in conjunction with a conveyor unit. SM3-640 observe the operating instructions of the connected conveyance control · Please system.
SKW 2. Installation instructions » These installation instructions are intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions. Personnel using these installation instructions must be instructed in the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation. Ensure in each case that the personnel are informed.
SKW SM3-640 F Install the equipment such that all parts are easily accessible; this facilitates maintenance and repair work.
SKW 2.1. Installation Installation is possible in any position. A mounting bracket is already attached. » The control unit must be accessible at any time Install VA-steel pipe bends (SKW 40, SKW 50) when conveying abrasive materials. SKW 65 may not be used for conveying abrasive materials. Install the SKW in such manner that differences in conveying distances for the two components are avoided. Please note that the maximum ambient temperature near the SKW must not exceed 45 °C (113°F).
SKW 2.2. Electrical connection 2.2.1. Connection to a single conveyor unit CSE 2/CSE 5 » Electrical connections are to be made by trained personnel only. Observe the regulations of your local Electricity Board. All work is to be carried out with the equipment disconnected from electric power and compressed air supply. The power consumption value of the SKW is approx. 15 Watts. The operating voltage of the SKW is 100 V/60 Hz. Special voltage on request. Lay a cable (min.
SKW 2.2.2. Connection to a vacuum receiver unit SSK-05 1, 3, 5, & 30 » Electrical connections are to be made by trained personnel only. Observe the regulations of your local Electricity Board. All work is to be carried out with the equipment disconnected from electric power and compressed air supply. The power consumption value of the SKW is approx. 15 Watts. The operating voltage of the SKW is 24 V. Lay a cable (min. 3 x 1 mm ) from the single conveyor unit to the SKW. 2 Install the supplied plugs.
SKW 2.3. Compressed air supply For actuating the piston in the SKW a compressed air supply connection (1/4 inch) is required. Check compressed air piping for correct installation and assembly. Check fittings, length and quality of the hose connections for agreement with requirements. The operating pressure of the SKW is 5-6 bar (72.52-87.02 PSI) (system overpressure). Check the compressed air supplied by the plant’s supply network. Maintenance unit Adjust compressed air pressure to 5-6 bar(72.52-87.
SKW 3. Functional description » This functional description is intended for the operating personnel of the equipment. Prerequisite for this functional description is general knowledge of conveyor systems operation. Ensure in each case that the operating personnel are sufficiently informed. SM3-640 F The SKW can only be operated in conjunction with a conveyor unit.
SKW 3.1. General information The SKW has 2 elbows (virgin material intake port, regrind intake port) and an outlet pipe socket leading to the conveyor unit. With the SKW it is possible to convey two components to a hopper loader. The SKW works in dependence on the conveying cycles of the conveyor unit. It is only in operation when material is conveyed.
SKW 3.2. Control 3.2.1. SKW Version 1 The control unit is installed at the housing of the SKW. The conveying ratio as well as the switching cycles are set by means of the keys on the front side of the control system.
SKW 3.2.1.1. Conveying ratio The conveying ratio between component 1 (= regrind) and component 2 (= virgin material) can be freely selected. The control setting refers to the conveying time of component 1 (= regrind). The conveying time of component 1 can be set from 0 to 99 % of total conveying time. Example Proportioning valve setting: 22 % Conveying ratio: 22 % component 1 and 78 % component 2 Conveying ratio relates to conveying time, not to the amount of material conveyed.
SKW 3.2.1.2. Switching cycles During each switching cycle, the SKW switches back and forth one time. The pre-set conveying ratio is not affected by this. In order to prevent strong formation of layers in the conveyed material, the number of switching cycles per conveying procedure can be freely selected. Setting takes place by entry of one cycle period. The cycle period can be set between 5 and 50 seconds. The setting is carried out in five seconds.
SKW 3.2.2. SKW Version 2 On the SKW housing, a terminal box is installed (optional: terminal box with 3 light-emitting diodes = LEDs for limit position monitoring). & The two green LEDs indicate the limit positions of the rotary piston. The red LED goes on in case of a disturbance. The conveying ratio and the switching cycles are entered into the control system of the conveying control. SM3-640 Observe the operating manual of the conveying control.
SKW 4. Start-up » This chapter is intended for operating personnel. Prerequisite for this chapter is general knowledge of the operation of conveying units. Also prerequisite for this chapter is that the functional description has been read and understood. Ensure in each case that the operating personnel are sufficiently informed. F Check the compressed air supply (max. 6 bar system overpressure). (87.02 PSI) Check the connections of the conveying lines. Check the suction pipe adjustment.
SKW 4.1. Adjusting the conveying ratio Adjust the conveying ratio according to your specific requirements. SKW Version 1 By means of the arrow key, set the percentage of component 1 (= regrind). Example Desired conveying ratio: 40 % regrind and 60 % raw material. Press the arrow key until “40" appears on the display. F When conveying poorly flowing components, set higher values. SKW Version 2 Set the percentage of component 1 (= regrind) by means of the control system of the conveying control.
SKW 4.2. Determining the switching cycle duration Measure the conveying time of the respective hopper. Take out the table. Look for the value in the column “conveying time”. Select a number of switching cycles. Press the percentage key. By means of the arrow key, select the desired switching cycle. Carry through one conveying procedure. If you are not satisfied with the result, check the setting and correct, if necessary. F No thick layers may form in the hopper loader.
SKW The SKW switches twice; it conveys regrind for 20 seconds and virgin material for 30 seconds. Significant zoning. b.) Setting 10 = 5 switching cycles per conveying procedure The SKW switches ten times; it conveys regrind for 4 seconds and virgin material for 6 seconds. SM3-640 Insignificant zoning.
SKW c.) Setting 5 = 10 switching cycles per conveying cycle The SKW switches 20 times; it conveys regrind for 2 seconds and virgin material for 3 seconds. This process is repeated 10 times. No correct conveyance possible. SM3-640 With a conveying time of 2 to 3 seconds the material cannot be conveyed properly.
SKW 4.3. Setting the switching cycles SKW Version 1 Press the percentage key. By means of the arrow key, set the determined switching cycle. Check the result. If the result is not satisfactory, correct the setting. & If there are too many switching cycles, proper conveying is not possible. SKW Version 2 Set the determined value by means of the control system of the conveying control. Observe the operating manual of the conveying control. Check the result.
SKW 5. Maintenance » This chapter is intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions. Personnel using the instructions in this chapter must be instructed of the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation. Ensure in each case that the personnel are informed accordingly. For maintenance work taking place at heights of over approx.
SKW Never operate the equipment when partially dismantled. All maintenance and repair work not described in this chapter may only be carried out by Sterlingservice personnel or authorized personnel (appointed by Sterling). L 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 before starting maintenance work. F Please observe the maintenance intervals.
SKW 5.1. Maintenance intervals Daily: Check warning signs on equipment for good legibility and completeness. Check the oil level in the oiler. Empty the water separator. Check operating pressure of the plant’s supply network (5-6 bar (72.52-87.02 PSI) system over pressure). Every three months: Check the SKW for smooth operation. Every six months: Check all electrical and mechanical connections for secure fit.
SKW 5.2. Checking for smooth operation » Disconnect the equipment from mains power supply to ensure that it cannot be switched on unintentionally. In order to check for smooth operation compressed air supply to the SKW must be maintained. Danger! Limbs may be caught in machinery! Unscrew the plug at the solenoid valve. Remove the hose from the hopper loader outlet port.
SKW Versions: SKW 40 SKW 50 SKW 65 SKW 40 Height: 305 mm (12.01 in.) Width: 246 mm (10.79 in.) Depth: 235 mm (9.35 in.) Weight: 7.5 kg (16.53 lbs.) Compressed air supply: 5-6 bar (72.52-87.02 PSI) system overpressure Piping system: Æ 40 mm (1.67 in.) SKW 50 Height: 305 mm (12.01 in.) Width: 256 mm (10.18 in.) Depth: 235 mm (9.35 in.) Weight: 7.5 kg (16.53 lbs.) Compressed air supply: 5-6 bar (72.52-87.02 PSI) system overpressure Piping system: Æ 50 mm ((2.07 in.) SKW 65 340 mm (13.
SKW 6.1. Dimension sheet SKW 40/50 All di mensions in mm. (in.) Specifications may be subject to al teration. 6.2.
SKW SM3-640 All di mensions in mm (in.). Specifications may be subject to al teration.
SKW SM3-640 7.
SKW 7.1. Spare parts list » This spare parts list is intended to be used only by trained personnel. SM3-640 Other persons are not permitted to modify or repair the equipment.
18,31,32 8 7 4 3 2 1 SM3-640 25 12 24 23 5 16 20 15 28 27 6 bar 26 5 - 22 21 6 19 17 13 6 5 14 33 10 11 9 SKW SKW 40 (03596) Appendix 42
SKW SM3-640 03596 Pos. Orderno.
18,31,32 8 7 4 3 2 1 SM3-640 15 16 20 6 5 14 50 11 10 9 19 13 6 5 - 6 bar 28 27 26 25 12 24 23 5 22 21 17 SKW SKW 50 (03597) Appendix 44
SKW SM3-640 03597 Pos. Orderno.
4 3 50 2 51 SM3-640 8 14 1 9 7 6 5 20 19 18,31,32 17 28 27 26 25 12 24 23 5 22 16 5 - 6 bar 21 15 6 13 SKW SKW 65 (12446) Appendix 46
SKW SM3-640 12446 Pos. Orderno.
36 29 38,40 8 7 6 5 4 3 37 2 1 SM3-640 39 33 14 50 10 11 9 20 19 35 41 42 13 6 5 - 6 bar 34 28 27 26 12 24 23 5 22 21 17 SKW CLV 40 (10102) Appendix 48
SKW SM3-640 10102 Pos. Orderno.
SKW 11122 Housing 0039 99944 Coupling piece 0040 92470 SKW-MLV control card 0041 98609 Coupling piece 0042 93075 Welsh plug 0050 15475 Sealing 0051 85982 Distance bolt 0052 95946 Spring lock washer 0053 95970 Nut SM3-640 0038 Appendix 50
SKW SM3-640 Connection diagram Appendix 51
Number of switching cycles at cycle period (seconds) Conveying time (seconds) 50 45 40 35 30 25 20 15 10 5 5 * * * * * * * * * 1 10 * * * * * * * * 1 2 15 * * * * * * * 1 1,5 3 20 * * * * * * 1 1,3 2 4 25 * * * * * 1 1,3 1,7 2,5 5 30 * * * * 1 1,2 1,5 2 3 6 35 * * * 1 1,2 1,4 1,8 2,3 3,5 7 40 * * 1 1,1 1,3 1,6 2 2,7 4 8 45 * 1 1,1 1,3 1,5 1,8 2,3 3 4,5 9 50 1 1,1 1,3 1,4 1,7 2 2,5 3,3 5 1
