Operating Instructions Machine-Side Hopper Loader SSE Series Machine-Side Hopper Loaders
Machine-Side Hopper Loaders Sterling Material Processing 5200 West Clinton Ave. Milwaukee, WI 53223 Telephone: (414) 354-0970 Fax: (414) 354-6421 www.sterlco.com Technical service: Service department Telephone: (800) 423-3183 Edition: 03/04 Bulletin #: SM4-615.
Machine-Side Hopper Loaders 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 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.
Machine-Side Hopper Loaders iv
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Machine-Side Hopper Loaders Table of Contents 1. General instructions......................................................................................................... 1-1 1.1. Warnings and symbols ......................................................................................................................... 1-2 1.2. Explanations and information .............................................................................................................. 1-3 1.3. Legal basis ..............
Machine-Side Hopper Loaders 8. Maintenance..................................................................................................................... 8-1 8.1. Maintenance intervals........................................................................................................................... 8-3 8.2. Servicing the loader..............................................................................................................................
Machine-Side Hopper Loaders 1. General instructions M These instructions apply to all persons within the range of action of the equipment. These operating instructions are to be used by all persons assigned activities connected with the equipment.
Machine-Side Hopper Loaders 1.1. Warnings and symbols The following warnings and symbols are used in these operating instructions: M L F & $ 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.
Machine-Side Hopper Loaders 1.2. Explanations and information Various terms are used 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. • Operating personnel: The ”operating personnel” are persons operating the equipment on their own responsibility or according to instructions.
Machine-Side Hopper Loaders 2. Safety instructions M These safety instructions apply to all persons within the range of action of the equipment, and should be used by all persons assigned activities connected with the equipment. Please inform all persons within the range of action of the equipment of the direct and indirect hazards connected with the equipment. Knowledge of the English language is prerequisite.
Machine-Side Hopper Loaders 2.1. For your safety 2.1.1. General To prevent injury and/or damage to equipment, observe the following safety rules: • Read these operating instructions carefully before operating for the first time. Contact us should questions arise. • These operating instructions must be kept available at all times at the place of operation of the equipment.
Machine-Side Hopper Loaders 2.1.2. Assembly To prevent injury and/or damage to equipment, observe the following safety rules: • Compare the connected loads with those of the main supply. • Use care when using lifting gear, and observe any pertaining regulations. • Do not modify, add other equipment or change the design of the equipment without the approval of the manufacturer. • Attachments not supplied by the manufacturer must be manufactured in accordance with safety regulation EN 294.
Machine-Side Hopper Loaders 2.1.3. Operation To prevent injury and/or damage to equipment, observe the following safety rules: • Appoint an equipment foreman to be responsible for the equipment. • Ensure that the operating personnel are provided detailed instruction in the operation of the equipment. • When the main switch is switched off for reasons pertaining to safety, it must be secured against unauthorized activation. • Repair work may be carried out by trained personnel only.
Machine-Side Hopper Loaders 2.2. For the operating safety of the equipment Never change settings if the consequences are not precisely known. Use only original manufacturer-approved spare parts. Please observe the maintenance schedule. Keep record of all maintenance and repair work. Please note that electronic components may be damaged by static discharge. Check all electrical connections for proper fit before the equipment operated for the first time and at regular intervals.
Machine-Side Hopper Loaders 3. Transport, assembly and storage M This chapter is intended for all operating personnel of the equipment. Personnel using these 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 operating personnel are sufficiently informed.
Machine-Side Hopper Loaders 3.1. Transport and packing M Please ensure adequate carrying capacity of the lifting equipment. The equipment passes rigorous testing in the factory and is packed carefully to avoid transport damage. Please check packing on delivery for transport damage. The inlet and discharge flanges are sealed with plugs, so that no dirt can enter during transport. Plugs must be removed before assembly. Packing materials should be disposed of according to environmental laws or reused.
Machine-Side Hopper Loaders 4. Assembly instructions M 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 sufficiently knowledgeable about the equipment.
Machine-Side Hopper Loaders 4.1. Unpacking The loader is insensitive to shocks and can be mounted directly onto the processing machine, on a machine hopper, a drying hopper or a dosing and blending unit. The equipment is delivered as a complete assembly. Use the following procedure to prepare the machine for assembly: 1. Unpack the equipment. A 2. Remove the plastic stopper (A) from the material inlet nozzle. 3. Open the access door (B) and remove the adhesive tape from the dump valve.
Machine-Side Hopper Loaders 4.2. Installing the dump valve sensor The controller uses a dump valve sensor (A) with a magnet (B) to determine demand. When the dump valve is closed, indicating demand, the magnet is pushed towards the sensor. The presence of the magnet near the sensor indicates demand and triggers a new conveying cycle. When the dump valve is open, indicating that no material is needed, the magnet is pushed up and away from the sensor.
Machine-Side Hopper Loaders 4.3. Attaching the pickup wand Use the following procedure to attach the pickup wand: 1. The pickup wand must be connected to flexible hose to allow sufficient movement. The length of the hose should not exceed 10 feet (3 meters). Push the free pipe end approximately 1.5” to 2” (4-5 cm) into the hose. Use a hose clamp to secure the connection. The flex hose should not cover the aeration holes on the pickup wand. 2. Slide the flexible hose onto the material inlet.
Machine-Side Hopper Loaders 4.4. Mounting Please check during assembly that the admissible bearing loads are not exceeded. Mount the loader in such a way that the outlet flap swings in a right angle to the direction of machine movement. Please check that all connecting points are tight to ensure that the conveying performance is not impaired.
Machine-Side Hopper Loaders 4.4.1. Mounting on the processing machine A VT Series adapter is required to mount the loader on the processing machine. Two-liter models require a VT 1.0 adapter. Five-liter models require a VT 2.3/70 or VT 2.8/70 adapter. Use the following procedure to mount the loader to the processing machine: 1. Mount the VT Series adapter onto the flange of the processing machine. Figure 5: VT Adapter 2. Mount the loader onto the adapter.
Machine-Side Hopper Loaders 4.4.3. Mounting onto mixing hoppers with lateral inlet A VT Series adapter is required to mount the loader on a mixing hopper with a laterial inlet. Two-liter models require a VT 1.0 adapter. Fiveliter models require a VT 2.3/70 or VT 2.8/70 adapter. Use the following procedure to mount the loader to the mixing hopper: 1. Mount the adapter onto the swan-neck of the mixing hopper. Figure 8: VT Adapter 2. Mount the loader onto the adapter.
Machine-Side Hopper Loaders 4.5. Electrical connection M The regulations of the local electrical codes must be observed. Before connection to the electricity supply, ensure that the supply voltage and the power frequency are in accordance with the data on the nameplate of the machine. The electrical connection may only be carried out by the manufacturer’s service staff or trained personnel authorized by the manufacturer. It is not permitted for other persons to undertake the electrical connection.
Machine-Side Hopper Loaders 4.7. Installation of the optional proportioning valve & Before proceeding, review the connecting diagram included with the unit. For more information, refer to the manual that shipped with the proportioning valve. Connecting the proportioning valve: Control and power of the proportioning valve is supplied through a 4-wire control connection. Brown – Positive Power X7, L Blue – Negative power X7, N Black – Line signal X7, ZKW Green w/ Yellow – Ground X3 1.
Machine-Side Hopper Loaders Connecting Material Lines: Component 1 – connected to the intake port furthest from the air cylinder (regrind) Component 2 – connected to the intake port closest to the air cylinder (virgin) Setting the ratio: When the loader motor is not running, pressing the arrow key on the valve’s controller will change the percentage of component 1. This can be set from 0% to 99% Set the cycle switching: Press and hold the percentage key on the valve’s controller.
Machine-Side Hopper Loaders 5. Functional description M This functional description is intended for all operating personnel of the equipment. General knowledge of conveying systems is required to operate the equipment Ensure in each case that the operating personnel are sufficiently knowledgeable about the equipment.
Machine-Side Hopper Loaders 5.1. Sequence of operation The sequence of operation is as follows: 1. Plug in the machine and move the on/off switch to the “on” position 2. All LEDs on the controller blink, and the software version is displayed on the screen. 3. A 2-second blowback pulse cleans the filter. During blowback, the screen displays “A2.” 4. The motor starts, and conveying begins. The screen displays a countdown of the conveying time. Conveying time can be set for 1-99 seconds. 5.
Machine-Side Hopper Loaders 6. Operation M This chapter is intended for operating personnel. General knowledge of the operation of conveying systems is required to perform these tasks. Make sure you have read and understood the Functional Description chapter in this manual before operating the equipment. Ensure that all operating personnel are sufficiently knowledgeable about the equipment. F Make sure the plastic stopper has been removed from the material inlet nozzle.
Machine-Side Hopper Loaders 6.1. Switching on the unit Locate the power switch on the left side of the control box and switch it to the “on” position. 6.2. Checking the flexible hose Before operating the equipment, check to make sure the suction is working: 1. Remove the pickup wand from the flexible hose. 2. Cover the open end of the hose with your hand. 3. Connect the unit to the main power supply and turn the machine on. a. If the motor is operating, your hand will feel the suction within few seconds.
Machine-Side Hopper Loaders 6.3. Setting the conveying time F & Do not overfill the hopper loader The conveying time cannot be set while the unit is in the process of conveying material. By correctly setting the conveying time, you can reduce vacuum motor wear, save energy, and reduce your need to maintain filters: 1. Turn on the hopper loader 2. Observe the flex hose and the material in which you buried the pickup probe.
Machine-Side Hopper Loaders 6.4. Setting the purge time (optional) To set the purge time, press and hold the “change-over” key while using the “arrow key” to adjust the time. & The purge time that was last selected appears in the display. The purge time can be set at 1 to 99 seconds. F If no line clearing valve has been installed, enter “0". 1. Turn the hopper loader off. 2. Disable the conveying cycle by disconnecting the dump valve sensor from the controller.
Machine-Side Hopper Loaders 6.5. Initial operation Metal shavings may be inside the pipe from cutting down pipes into lengths. These are pulled during the first conveying process and collected in the separator. F This material should not be used again. 6.6. Switching off the unit Locate the power switch on the left side of the control box and switch it to the “off” position.
Machine-Side Hopper Loaders 7. Troubleshooting M This chapter is intended for the operating personnel of the equipment. General knowledge of the operation of conveying systems is required to perform these tasks. Make sure you have read and understood the “Start-up” section of this manual before proceeding. Ensure that the operating personnel are sufficiently knowledgeable about the equipment.
Machine-Side Hopper Loaders 7.1. Alarms An alarm will be triggered if there is no material to convey or if the loader overheats. & An “E” appears in the display and an error number. And alarm will sound. F Do not restart operation until the malfunction has been corrected. The following error messages can be displayed: “E1" The alarm message “E1" is displayed when no material has been conveyed during 3 consecutive conveying cycles. • Check that sufficient material is being conveyed.
Machine-Side Hopper Loaders 8. Maintenance M 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 sufficiently knowledgeable about the equipment.
Machine-Side Hopper Loaders F 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 environmentally sound manner. Use only original Sterling spare parts. Keep record of all maintenance and repair procedures.
Machine-Side Hopper Loaders 8.1.
Machine-Side Hopper Loaders 8.2. Servicing the loader M Disconnect the unit from main power supply by unplugging it. Depressurize all system sections of the equipment (only units with active cleaning). 8.2.1. Changing the sealing ring of the outlet flap 1. Open the toggle fasteners (A) and the access door (B) of the hopper loader. 2. Draw the old sealing ring (C) off the nozzle of the material outlet. 3. Install the new sealing ring (C). F Make sure the new sealing ring (C) in installed properly.
Machine-Side Hopper Loaders 8.2.2. Adjusting the dump valve sensor 1. Stop the conveying cycle by disconnecting the dump valve sensor from the controller. With the dump valve sensor disabled, no demand will be indicated, and conveying will stop. 2. Connect an ohmmeter to PINS 2 and 3 of the dump valve sensor. 3. Release the nuts (A) of the dump valve sensor (B) until the support can be displaced. Figure 13: Dump Valve 4. Open the dump valve (C) so far that the front tip of the outlet flap is approx. 1.
Machine-Side Hopper Loaders 8.2.3. Cleaning the unit 1. Open the toggle fasterner on the tension ring. 2. Tilt the turbine head upwards. 3. Remove the filter. 4. Clean the filter by means of compressed-air. 5. Clean the hopper loader by means of a vacuum cleaner. 6. Mount the filter. Pay attention for proper fit. 7. Mount the turbine head. 8. Mount the tension ring and close the toggle fastener.
Machine-Side Hopper Loaders Cleaning the filter cloth: 1. Open the toggle fasteners (A) and the access door (B) of the hopper loader. 2. Check the filter cloth (C) and the wire cloth (D) for material residue. Clean the filter by means of compressed air. 3. Close the access door (B) and the toggle fasteners (A) on the access door of the hopper loader.
Machine-Side Hopper Loaders 8.2.4. Replacing carbon brushes at the motor The carbon brushes in the motor must be replaced after approximately 1000 hours of operation. The brushes can be replaced twice before the entire motor has to be replaced. “BL” model loaders feature brushless motors, and do not require this procedure. M This work must be carried out by qualified personnel only. Disconnect the unit from main power supply before working on the controller.
Machine-Side Hopper Loaders F Verify that no cables are pinched or cut. Carbon brushes can be replaced twice. After that the turbine has to be completely replaced.
Machine-Side Hopper Loaders 8.3. Taking out of service, dismantling, disposal M Only skilled personnel qualified for this work may dismantle the individual product modules. Parts that are under mechanical stress should be dissembled with utmost care to avoid the energy trapped in these parts from unleashing and causing injury. 8.3.1. General To dispose of the products, you should take the following action: • Remove and destroy the nameplate with the CE sign.
Machine-Side Hopper Loaders 9. Technical data M These instructions apply to all persons within the range of action of the equipment. These operating instructions are to be used by all persons assigned activities connected with the equipment.
Machine-Side Hopper Loaders Standard Features: Integrated control with: - LED-display - indication of the respective modes of operation - adjustable conveying time - adjustable line clearing time Integrated vacuum pump Integrated filter with automatic cleaning Parts coming in contact with material are made of stainless steel Simple mounting to dosing and blending units due to compact and weight saving design Alarm output Automatic shut-down with lack of material Display of error codes Optional Features - M
Machine-Side Hopper Loaders Dimension Sheet Two-liter model: Technical data 9-3
Machine-Side Hopper Loaders 5-liter model: 5-liter brushless model: 9-4 Technical data
Machine-Side Hopper Loaders 10. Spare parts list M This spare parts list is intended to be used only by trained personnel. Other persons are not permitted to modify or repair the equipment.
Machine-Side Hopper Loaders 10.1.
Machine-Side Hopper Loaders 10.2. Parts lists, 2-liter model 10.2.1. 230 V, 50 Hz Pos. 1 Order no.
Machine-Side Hopper Loaders 10.2.2. 110 V, 60 Hz Pos. 1 Order no.
Machine-Side Hopper Loaders 10.2.3. Pos. 1 2 3 4 5 Order no. Designation 37755 Filter with sealing 37222 Basket 82593 Solenoid valve 97745 Bush 37800 Breather tube 10.2.4. Pos. 1 2 3 4 5 230 V, 50 Hz with active cleaning Wear Code A B D D 110 V, 60 Hz with active cleaning Order no.
Machine-Side Hopper Loaders 10.3. Parts list, 5-liter model 10.3.1. 230 V, 50 Hz (V66372, V66363) Pos. 1 Order no.
Machine-Side Hopper Loaders 10.3.2. 110 V, 60 Hz (V66378US) Pos. 1 Order no.
Machine-Side Hopper Loaders 10.3.3. Pos. 1 2 3 Order no. 34179 37222 82593 10.3.4. Pos. 1 2 3 230 V, 50 Hz with active cleaning (V66364) Designation Filter with sealing Basket Solenoid valve Wear Code A B 110 V, 60 Hz with active cleaning Order no.
Machine-Side Hopper Loaders 10.4.
Machine-Side Hopper Loaders 10.5. 230 V, 50 Hz Pos. 1 2 3 4 8 5 6 7 8 9 10 Order no.
Machine-Side Hopper Loaders 11.
Machine-Side Hopper Loaders 12. Electrical manual This electrical manual is intended to be used only by the manufacturer’s service personnel and trained personnel authorized by the manufacturer. Other persons are not permitted to modify or repair the equipment.
Machine-Side Loaders Quick Start Guide Connecting the proportioning valve: Turning on the loader: Control and power of the proportioning valve is supplied through a 4-wire control connection. • Locate the power switch on the left side of the Brown – Pos. Power X7, L Blue – Neg. power X7, N Black – Line signal X7, ZKW –Ground X3 control box and move to the ‘ON’ position.
