Powder Hopper Loaders Part Number: 882.00238.00 Bulletin Number: CV1-605.
Write down your Powder ________________ ________________ Hopper Loader(s) 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.
Safety Considerations Powder 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: ; Follow all SAFETY CODES. ; Wear SAFETY GLASSES and WORK GLOVES.
Annex B Information The following design information is provided for your reference: 1. 2. 3. 4. 5. 6. 7. 8. No modifications are allowed to this equipment that could alter the CE compliance Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit) Humidity range: 50% relative humidity Altitude: Sea level Environment: Clean, dust-free and non-explosive Radiation: None Vibration: Minimal, i.e. machine mounting Special installation requirements: Clean, dry compressed air 1 cfm @ 60 psi (1.
Table of Contents 1 General Information ................................................. 7 1-1 Introduction ..................................................................................... 7 1-2 Equipment Function ........................................................................ 7 1-3 Accessories ....................................................................................... 7 1-4 Customer Service............................................................................
The adjustments listed in this section must be performed ONLY by a qualified, safety-conscious technician. ............................... 29 5-5 Selecting the Most Efficient Loading Sequence ............................ 30 5-6 Shutting Down the Hopper Loader Using the Series One Controller32 6 Maintenance ............................................................ 33 6-1 6-2 7 8 9 Routine Maintenance .................................................................... 33 Replacing Motor Brushes.......
1 1-1 General Information Introduction Powder hopper loaders economically and efficiently load freeflowing 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. They’re engineered construction permits easier cleaning and maintenance, and they can be quickly and easily reconfigured to accommodate future production requirements.
1-4 Customer Service The intent of this manual is to familiarize the operator and maintenance personnel with this equipment and help your organization get the maximum service from your equipment. If you have any questions regarding installation, service, repair, custom equipment, or applications, please do not hesitate to contact us for the information required. Prices for additional equipment, accessories, or repair parts will be furnished promptly upon request.
1-7 Models Covered in this Manual Models are designated by capacity. Powder hopper loaders are available in 1.6 cu. ft. (45.3 liters) capacities and hold approximately 50 lbs. of material. Powder Hopper Loaders models 50(E) Capacity cu. ft. 1.6 liters 45 lbs. 50 kg 22 Note: (E) Denotes “CE” models, including 220/1/50 operation and CE mark.
1-8 Standard Features Powder Hopper Loaders • Stainless steel vacuum receiver • Page 10 Tangential 11/2” (38mm) OD material inlet • High flow blowback valve with electrical quick disconnect and accumulator • Twin bag filter assembly with glazed polyester filter bags • Receiver-mounted junction box with 8 feet (2.6 m) of cable to a field-mounted control box • Material demand/level sensor • High-performance centrifugal motor with electrical quick disconnect • Sound enclosure • 9-foot (2.
2 Safety 2-1 Work Rules Install, operate, and maintain this equipment according to applicable work and safety codes for your location. This includes OSHA, CE, NEC, CSA, SPI, and many other local, national, and international regulations. Obey these specific work rules: Read and follow the instructions in this manual before installing, operating, or maintaining any equipment. Additional copies are available from the manufacturer. Only qualified persons should work on, or with, this equipment.
2-3 Mechanical Installation Loaders are typically mounted on the machine supply hopper. Be sure it is securely attached and additional bracing is used if necessary. The sections on the following pages explain general installation rules. Read manual thoroughly before installing loader. Use approved safety straps or chains to lift the loader at the marked lifting points. 2-4 Safety Considerations The terms NOTICE, CAUTION, WARNING, and DANGER have specific meanings in this manual.
The term IMPORTANT emphasizes areas where equipment damage could result, or provides additional information to make a step or procedure easier to understand. Disregarding information marked IMPORTANT would not be likely to cause personal injury. REPORTING A SAFETY DEFECT NOTE: If you believe that your equipment has a defect which could cause injury, you should immediately discontinue its use and inform the manufacturer at our address listed in this manual.
Hold daily equipment inspections in addition to regular maintenance checks. You will keep your equipment safe for production and exhibit your commitment to safety. Please read and use this manual as a guide to equipment safety. This manual contains safety warnings throughout, specific to each function and point of operation. 2-6 Operator Responsibility The operator’s responsibility does not end with efficient production.
• If your blender has been inoperative or unattended, check all settings before starting the unit. • At the beginning of your shift and after breaks, verify that the controls and other auxiliary equipment are functioning properly. • Keep all safety guards in place and in good repair. NEVER attempt to bypass, modify, or remove safety guards. Such alteration is not only unsafe, but will void the warranty on your equipment.
• BLEED all air pressure from system components (refer to the Maintenance Section of this manual.) • TURN OFF all air and electric supplies and all accessory equipment at the machine. • DISCONNECT AND LOCK OUT electrical and pneumatic power, and attach warning tags to the disconnect switch and air shutoff valve. When you need to perform maintenance or repair work on a loader above floor level, use a solid platform or a hydraulic elevator.
2-8 Safety 2-8-1 Description and Objectives This section includes information on safety devices and procedures that are inherent to the Powder Hopper Loading system. This manual is not intended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained in this section is recommended to supplement these procedures in order to provide a safer working environment.
Every effort has been made to incorporate these standards into the design of the Powder Hopper Loading system; however, it is the responsibility of the personnel operating and maintaining the equipment to familiarize themselves with the safety procedures and the proper use of any safety devices. 2-8-3 Fail Safe Operation If a safety device or circuit should fail, the design must be such that the failure causes a “Safe” condition. As an example, a safety switch must be a normally open switch.
2-8-5 Lock-Outs, Plugs, and Other Safety Devices The Powder Hopper Loading system utilizes several types of safety devices. The Line Cord Plug This line cord plug allows the operator or maintenance personnel to unplug the loading system from its power source and tag it out. This plug may be tagged with any number of approved electrical lockout tags. These tags are available at most electrical supply stores.
Figure 1 Typical Powder Hopper Loader Figure 2 Powder Hopper Loader Dimensions, Specifications, and Maximum Machine-Side Throughput Specifications Model Powder Hopper Loader Hopper capacity cu. ft. Liters lbs. Kg 1.6 45 50 22 Full-load amps (FLA) 11 Inlet size range inches mm 1½” Shipping weight lbs. Kg 120 55 38 mm Maximum Machine-Side Throughput Model lbs./hr. Kg/hr. Powder Hopper 1000 454 Loader Note: Twelve (12) -foot (3.66 m) vertical 1½” OD (approx.
3 Shipping Information 3-1 Unpacking and Inspection You should inspect your powder 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 hardware and mounting screws, etc. In case of breakage, damage, shortage, or incorrect shipment, refer to the following sections.
Parcel Post Shipment ; 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. ; Hold the damaged goods with the container and packing materials for possible inspection by postal authorities. United Parcel Service Shipment ; Contact your local UPS office regarding damage and insurance claims. ; Retain the container and packing. ; Notify the manufacturer at once.
3-4 If the Shipment is Not Correct If the shipment is not what you ordered, contact the parts and service department immediately at (262) 641-8610. Have the order number and item number available. Hold the items until you receive shipping instructions. 3-5 Returns Important! Do not return any damaged or incorrect items until you receive shipping instructions from the manufacturer.
4 4-1 Installation & Setup 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. ; Do not use hopper loaders in explosive atmospheres. ; Do not use outdoors or in wet environments. Moisture damages the motor and can create an electric shock hazard. ; Operate hopper loaders at the rated voltage.
Important! The manufacturer is not responsible for equipment damage from excessive processing machine movement or vibration. 4-5 4-6 Mounting Tips • Run a bead of silicone sealant around the mounting flange before seating the hopper loader. This provides an additional seal. • Use rivets to mount the hopper loader. Bolts, nuts, and washers can loosen, fall into, and damage process equipment. • Check across the mounting flange with a bubble level.
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 1/2” diameter pipe or tubing when making connections. 4-8 Making Electrical Connections The controller you selected is shipped pre-wired to the hopper loader.
5 5-1 Operation Pre-Startup Checklist ; Are all electrical connections correct, secure, and to code? ; Is the compressed air connection secure and safe? ; Is the receiver level and mounted securely? ; Are the flex hose and pick-up wand secure? ; Is the flexible hose properly grounded? ; Can the material level switch activate without obstruction? ; Can the material discharge valve swing without obstruction? 5-2 Operating Sequence 1. Blowback sequence. 2. Motor starts. 3.
Figure 4 Series One Control Panel TM AUTOLOADER SERIES ONE ON OFF A0542127 Page 28 Powder Hopper Loaders
5-3 Starting the Loader 1. Insert the pickup probe into the material supply. 2. Turn on compressed air to the unit. 3. Plug in power to the control enclosure. 4. Move the power switch on the Series One graphic panel to the ON position. 5-4 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.
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 operation. Note: Figure 7 contains two (2) different programs (12 and 14 blowback pulses).
Figure 5 Conveying Sequence DIP Switch Chart, Program A0536814 10 SECONDS 6 1 2 3 15 SECONDS 4 BLOWBACK PULSES 1 2 OFF OFF OFF OFF 1 1 2 6 3 PULSES OFF 1 2 OFF 2 3 PULSES OFF OFF OFF 4 1 ON OFF OFF 1 ON ON OFF 2 3 OPEN OFF 1 2 ON ON OFF 4 1 OFF OFF OFF 40 SECONDS 45 SECONDS 2 3 ON ON 4 1 2 3 ON ON ON OFF 2 OFF 3 4 OFF OPEN 70 SECONDS 4 1 2 ON ON ON 3 OFF 4 ON OFF OPEN 90 SECONDS 4 OPEN ON OPEN 3 OPEN 60 SECONDS ON OFF 8
5-6 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.
6 6-1 Maintenance Routine Maintenance Cleaning Filters Check the condition of the filter assembly 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 reduce the overall capacity of the loader. Replace the filter bags if they show any signs of wear. You can obtain replacements from the manufacturer.
6-2 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. Powder 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.
Following steps 5 and 6 above, perform the same procedure for the opposite side. 2. Remove the armature assembly at the top portion of the hopper loader to properly seat the replacement brushes. 3. Insert a strip of 600-grit sandpaper with the rough side facing the brush. 4. 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 the commutator. 5.
7 Troubleshooting Powder Hopper Loaders Problem Possible cause No power to control box. Power switch is off. Fuse is blown. The bin below the hopper loader is filled to capacity. Hopper loader does not work. Fouled flapper discharge valve. Build-up on flapper. Loose control wiring. Blowback and motor connections are not secure. Power switch has failed. Reed switch has failed. Circuit board has failed. The bin below the hopper loader is filled to capacity. Vacuum motor does not work.
Powder Hopper Loaders Cont’d. Problem Possible cause Air pressure is too low. Air supply to blowback is restricted. Blowback does not work properly. Blowback valve assembly is not connected to controller. Control wiring connections are loose on the circuit board. Solenoid valve or valve coil has failed. Material supply is low. Selected conveying sequence is too short. Material probe not properly positioned in material supply. Hopper does not completely fill.
8 Loader Options Your loader may have been equipped with the following options: Special Voltages Models are also available in 230/1/50 and 230/1/60 supply voltages.
9 9-1 Spare Parts Powder Hopper Loader System Component Description This section describes the various components of the loading system. The loading system is made up of the following components: • Stainless steel vacuum receiver • Tangential 11/2” OD (about 38.1 mm OD) material inlet • High flow blowback valve with electrical quick disconnect and accumulator • Twin bag filter assembly with glazed polyester filter bags • Receiver-mounted junction box with 8 feet (2.
10 Technical Assistance 10-1 Contact Information for Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [262] 641-8610, 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.
3. ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge. 4. ALL returns are to be shipped prepaid. 5. The invoice number and date or purchase order number and date must be supplied. 6. 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. 10-2-2 Warranty Returns Powder Hopper Loaders 1.
11 Safety Tag Information 11-1 Powder Hopper Loader Safety Tags Pinch Point Slide Gate Read Operation and Installation Manual High Voltage Inside Enclosure Earth Ground PE Protected Earth Ground Lifting Point 11-2 Pushbutton and Keypad Tags Button Position Function Turns power on to the loader. ON Turns power off to the loader.
11-3 Loader Identification (Serial Number) Tag (Located on back of mixing chamber) Series Powder Hopper Loader Model Number 50E Max Capacity 227 KG/HR 220V Serial Number 060701 1Ǿ Date of Manufacture 06/2002 A Over-current Protection Device (s) A Total Frequency 50/60Hz Compressed air supply 4.14 bar (60 psi) Mass 110 lbs/(50 KG) Electrical Diagrams Pneumatic Diagram 2900 S.
