Sterling Food Processor SSK 5 User Manual

Operating Instructions

Conveyor Hopper

SSK-5

Sterling Material Processing

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SSK-5

Sterling Material Processing

5200 West Clinton Ave.

Milwaukee, WI 53223

Telephone: (414) 354-0970

Fax: (414) 354-6421

www.sterlco.com

Parts & Service:

Telephone: (800) 423-3183

Edition: 07/03

These operating instructions are for:*

(* Please fill in personally)

Serial number:

Built in:

Date of delivery:

Number of delivery:

Date of commissioning:

Location:

Group of machines:

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SSK-5

Sterling Material Processing retains all rights to change the information in these

operating instructions at any time without notice.

We assume no liability for any errors or direct or indirect damage resulting in con-

text with these operating instructions.

Copying, translation or publication in any form except for personal use of pur-

chaser requires approval from Sterling Material Processing.

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SSK-5

TABLE OF CONTENTS

1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1. Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2. Explanations and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.3. For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4. For the safety of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2. Installation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.2. Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3. Compressed-air supply (only with compressed-air valves) . . . . 12

2.4. Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3. Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.1. Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2. Servicing the hopper loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2.1. Replace the sealing rings . . . . . . . . . . . . . . . . . . . . . . . 20

4.2.2. Adjust the flap switch . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.2.3. Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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SSK-5

1. Safety instructions

These safety instructions apply to all persons within the range of

action of the equipment.

Please inform all persons within the range of action of the equip-

ment of the direct and indirect hazards connected with the

equipment.

These operating instructions are to be used by all persons as-

signed activities connected with the equipment.

Knowledge of the English language is prerequisite.

Ensure in each case that the operating personnel are familiar

with the operating instructions and the function of the equip-

ment.

Observe the safety instructions of the connected conveying

system.

Safety instructions 5

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SSK-5

1.1. Warnings and symbols

The following warnings and symbols are used in these operating instructions:

This symbol indicates danger to life! Fatal or serious injury is

possible if the corresponding instructions, regulations or warn-

ings are not observed.

This symbol indicates that serious injury is possible if the cor-

responding instructions, regulations or warnings are not ob-

served.

This symbol indicates that extensive damage to equipment is

possible if the corresponding instructions, regulations or

warnings are not observed.

This symbol indicates information important for becoming fa-

miliar with the equipment, i.e. technical correlations.

This symbol indicates that a technical term is explained at this

point.

Safety instructions 6

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1.2. Explanations and information

Various terms and designations are used frequently in these operating instruc-

tions to ensure clarity. Therefore please note that the terms used in the text stand

for the corresponding explanations listed below.

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 re-

sponsibility or according to instructions (minimum age: 16).

Operator

The “operator” of the equipment (production manager, foreman, etc.) is the per-

son responsible for all production sequences. The operator instructs the operat-

ing personnel of what is to be done.

Operating instructions

The “plant operating instructions” describe the interaction of the equipment, pro-

duction sequences or methods. The plant operating instructions must be com-

piled by the operator of the equipment.

Equipment foreman

When several operating personnel work on one machine, the “equipment fore-

man” coordinates the sequences. The equipment foreman must be appointed by

the operator.

Trained personnel

“Trained personnel” are persons who, due to their training, are authorized to carry

out the required work in good practice.

Safety instructions 7

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SSK-5

1.3. For your safety

It is absolutely necessary that you observe the operating instructions for the cor-

responding conveying system.

The device is intended exclusively for conveying plastic granules and regrind.

Any other usage is not permitted.

This device is not suitable for processing foods.

Before beginning maintenance work, set all compressed air piping on the device

at zero pressure. Danger of accidents!

1.4. For the safety of the equipment

The device may only be operated if all corresponding components have been

properly connected and are in accordance with the relevant regulations.

It is absolutely necessary that you observe the operating instructions for the cor-

responding conveying system.

For the operation of the hoppers, a compressed-air supply is necessary.

Never set the operating pressure of the hoppers at more than 6 bar (system

overpressure) (87.02 PSI).

Install the hoppers in such a way that the outlet flap is hinged in a right angle to the

direction of movement of the machine.

Make sure that all plugs are connected properly.

Observe the carrying capacity of the machine flange.

Safety instructions 8

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SSK-5

2. Installation instructions

These installation instructions are intended for persons with

skills in electrical and mechanical areas due to their training, ex-

perience and received instructions.

Personnel using these installation instructions must be in-

structed in the regulations for the prevention of accidents, the

operating conditions and safety regulations and their implemen-

tation.

Ensure in each case that the personnel are informed.

The installation instructions provided in the corresponding oper-

ating instructions apply for all connected equipment.

Observe safety regulations with regard to lifting gear handling

All installation work must be carried out with the equipment dis-

connected from electrical power and compressed air supply.

For installation work taking place at heights of over approx.

1828.8mm (6 feet), use only ladders or similar equipment and

working platforms intended for this purpose. At greater

heights, the proper equipment for protection against falling

must be worn.

Use only suitable lifting gear which is in proper working order

and load suspension devices with sufficient carrying capac-

ity. Do not stand or work under suspended loads!

Use suitable workshop equipment.

Install the equipment such that all parts are easily accessible;

this facilitates maintenance and repair work.

Installation instructions 9

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SSK-5

2.1. Transport

For transport, only the appropriate lifting gear should be used (e.g. fork lift or work-

shop crane).

Observe the carrying capacity of the lifting gear.

Observe the safety instructions for the handling of lifting gear.

Installation instructions 10

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SSK-5

2.2. Set-up

The arrangement of the hopper loaders may vary depending on the type of de-

vice to be conveyed on and the material used. Fastening onto fixed machine

throats is provided by means of strap retainers. However, additional support of

the hopper loader is necessary if the devices are not sufficiently capable of bear-

ing the load.

Mount the hopper loader in such a way that the outlet flap swings in a right-hand

angle to the direction of machine movement. Please check during assembly that

the admissible bearing loads are not exceeded.

Please check that all connecting points are tight to ensure that the conveying per-

formance is not impaired.

It should moreover be observed, particularly if custom produced connecting parts

are used, that the material discharged from the hopper loader must neither get

into the open nor must it clog the filter surfaces (observe angle of repose!).

Do not excessively load inlet nozzle of hopper loader, remove

hose separately, if necessary!

Assembly

Installation instructions 11

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SSK-5

2.3. Compressed-air supply (only with compressed-air valves)

For operating the control valves, a compressed-air supply is necessary.

Check compressed-air piping for correct installation and assembly.

Check fittings, length and quality of the hose connections for agreement with re-

quirements.

The operating pressure is 5-6 bar (72.52-87.02 PSI) (system overpressure).

Check the compressed-air supplied by the plant’s supply network.

Adjust compressed-air pressure to 5-6 bar (72.52-87.02 PSI) (system

overpressure).

Connect the unit to the plant’s supply network by means of a hose.

Depressurize compressed-air supply lines which must be

opened.

Compressed air must be dewatered, dust-free and oil-free.

Install a maintenance unit if required.

Adjust pressure to a max. value of 6 bar (87.02 PSI) (system

overpressure).

Installation instructions 12

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SSK-5

2.4. Electrical connection

The electrical connection may only be carried out by trained per-

sonnel.

Other persons are not permitted to carry out the electrical con-

nection.

The rules of the local electricity board must be observed.

Before beginning the electrical connection, make sure that the

mains voltage and the power frequency are in accordance with

the data on the name plate of the device.

All work may only be carried out when the unit is at zero voltage

and at zero pressure.

connection point diaphragm valve (SV)

connection point SKW

connection point probe

connecting plug “flap switch (KL)”

connecting plug “conveyor control”

Plug connection connection housing hopper

Installation instructions 13

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SSK-5

Installation instructions 14

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SSK-5

3. Functional description

The conveyor hopper is used for the automatic conveyance of freely flowing plas-

tic granules. The hopper can only function in connection with a vacuum conveyor

plant.

The hopper works without a filter. Depending on the type of valve, the shut-off

valve of the vacuum line is operated with compressed air (compressed-air valve)

or with the vacuum air (diaphragm valve).

On the hopper, there is a separate on/off switch (A) and a function controlling de-

vice which indicates the following operational modes:

(B): lamp on - hopper switched on at the on/off switch (A); lamp flashes - the hop-

per is conveying

(C): lamp flashes - error

(D): lamp is on - hopper signals lack of material

Connection housing hopper

Functional description 15

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SSK-5

4. Maintenance

This chapter is intended for persons with skills in electrical and

mechanical areas due to their training, experience and received

instructions.

Personnel using the instructions in this chapter must be in-

structed of the regulations for the prevention of accidents, the

operating conditions and safety regulations and their implemen-

tation.

Ensure in each case that the personnel are informed accord-

ingly.

For maintenance work taking place at heights of over

approx.1828.8mm ( 6 ft.), use only ladders or similar equipment

and working platforms intended for this purpose. At greater

heights, the proper equipment for protection against falling

must be worn.

Use only suitable lifting gear which is in proper working order

and load suspension devices with sufficient carrying capacity.

Do not stand or work under suspended loads!

Ensure that the electric motors/switch cabinets are sufficiently

protected against moisture.

Use only suitable workshop equipment.

Before starting maintenance work, appoint a supervisor.

Inform the responsible personnel before maintenance work on

the system is started.

Never operate the equipment when partially dismantled.

All maintenance and repair work not described in this chapter

may only be carried out by Sterling service personnel or autho-

rized personnel (appointed by Sterling ).

Maintenance 16

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SSK-5

Disconnect the equipment from mains supply before starting

maintenance procedures to ensure that it cannot be switched

on unintentionally.

Depressurize all compressed air piping of the equipment be-

fore starting maintenance work.

Please observe the maintenance intervals.

Before starting maintenance work, clean the equipment of oil,

fuel or lubricants.

Ensure that materials and incidentals required for operation

as well as spare parts are disposed of properly and in an envi-

ronmentally sound manner.

Use only original Sterling spare parts.

Keep record of all maintenance and repair procedures.

Maintenance 17

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SSK-5

4.1. Maintenance intervals

Daily:

Check warning signs on equipment for good

legibility and completeness.

with compressed-air valve:

check the oil level in the oiler

empty the water separator

check the operating pressure in the factory

ductwork system

(max. 6 bar (87.02 PSI) system overpressure)

every six months:

check all electrical and mechanical connections for

for proper fit

check the settings of the level probes

check the sealing rings on the locking flaps

replace the sealing rings on the locking flaps

yearly:

The given maintenance intervals are average values.

Check whether in your individual case the maintenance inter-

vals must be shortened.

Maintenance 18

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SSK-5

4.2. Servicing the hopper loader

Individual hoppers can also be maintained during operation.

However, Sterling recommends that you switch off the con-

veying plant for all types of work on the hopper.

Switch off the hopper by means

of the on/off switch (A) on the

connection housing.

Wait until the conveying proce-

dure has stopped.

Disassemble the vacuum line on

the hopper.

Close the disassembled vacuum

line so that the vacuum for the ac-

tive hopper-loaders does not

break down.

Depressurize

the

pressed-air line to the hopper

com-

(only

valve).

with

compressed-air

Connection housing hopper

Disassemble the material line on

the lateral inlet of the hopper.

Remove the connecting plug (B) “conveyor control” on the connection housing of

the hopper.

Disassemble the hopper.

Maintenance 19

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4.2.1. Replace the sealing rings

Nonreturn valve

Open the toggle-type fasteners (A)

between the hopper lid and the

hopper loader.

Fold the hopper lid upwards.

Draw the old sealing ring off the

nozzle (B).

Install the new sealing ring. Ob-

serve the direction of installation

(C).

Close the hopper lid.

Close the toggle-type fasteners

(A).

Install the hopper.

SSK-5

Order number sealing ring: ID 85610

Maintenance 20

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SSK-5

Outlet flap

Remove the connecting plug “flap switch” (A) from the connection housing of the

hopper.

Remove the tension ring (B) and the sealing ring on the hopper loader.

Remove the upper part of the hopper loader (C) from the lower part of the hopper

loader (D).

Draw the old sealing ring (E) off the nozzle of the material outlet.

Install the new sealing ring (E).

Observe the direction of installation (F).

180 °

Installation sealing ring

Maintenance 21

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SSK-5

Install the upper part of the hopper loader (C) on the lower part of the hopper

loader (D).

Install the sealing ring and the tension ring (B) on the hopper loader.

Connect the connecting plug “flap switch” (A) to the connection housing of the

hopper.

Install the hopper.

Order number sealing ring: ID 23098

Maintenance 22

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SSK-5

4.2.2. Adjust the flap switch

Remove the connecting plug “flap switch” from the connection housing of the

hopper.

Connect an ohmmeter to PINS 2 and 3 of the connecting plug “flap switch”.

Release the nuts (A) of the flap switch (B) until the support can be displaced.

Open the outlet flap (C) so far that

the front tip of the outlet flap is

approx. 30 mm (1.18 in.) away

from the sealing surface.

Displace the flap switch (B) until

the contact of the magnet switch

is closed.

Tighten the nuts (A) of the flap

switch.

Check the adjustment:

In case of free hanging outlet flap

(empty hopper loader) the con-

tact of the magnet switch must be

closed.

Outlet flap

If the outlet flap cannot be properly adjusted, replace the flap switch or the outlet

flap with magnet.

Install the hopper.

Order numbers

flap switch:

outlet flap with magnet:

ID 28839

ID 23093

Maintenance 23

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SSK-5

4.2.3. Cleaning the hopper

Open the toggle-type fasteners (A)

between the hopper lid and the

hopper loader.

Fold the hopper lid upwards.

Check the sieve (B) within the hop-

per for material residue. For clean-

ing, disassemble the hopper: turn

the hopper approx. 1/2 rotation

counterclockwise.

Clean the sieve by means of com-

pressed-air.

Install the hopper: turn the hopper

approx. 1/2 rotation clockwise.

Check the hopper for proper fit.

Clean the hopper loader by means

of a vacuum cleaner.

Close the hopper lid.

Close the toggle-type fasteners

(A).

Open the toggle-type fasteners (C)

on the flap of the hopper loader.

SSK-5

Check the filter cloth (D) and the wire cloth (E) for material residue. Clean the fil-

ters by means of compressed air.

Close the toggle-type fasteners (C) on the flap of the hopper loader.

Install the hopper.

Maintenance 24

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5. Spare parts list

This parts list is only for the use of trained personnel only.

All other persons are not permitted to repair or to change the

equipment.

Wear Code:

A = Wearing part, fast used up

B = Wearing part

C = Spare part, storekeeping for 1 year

D = Spare part, storekeeping for 2 years

E = Spare part, storekeeping for more than 2 years

Execution free of silicone on request.

Spare parts list 25

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SSK-5

26493

Hopper complete

23, 24, 25, 26

1, 2

16,

17, 18

13,

14, 15

7, 8, 9, 10, 11

Spare parts list 26

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SSK-5

Wear Code

Pos.

Order no.

26454

85610

28626

23091

28625

28839

26462

23093

85477

85471

93358

23098

Designation

flap

sealing

filter cloth

wire cloth

sealing

flap switch with plug

cover

outlet flap

nut

screw

disc

sealing ring

13, 14, 15 82555

tension ring with sealing ring and lock

84555

86152

86151

23069

95881

23092

26491

26495

09646

23066

85489

26497

connection housing

plug

hopper with sieve

sealing

diaphragm valve, complete (optional)

compressed-air valve, complete

sealing ring

cylinder

sieve

dedusting valve, complete (optional)

Spare parts list 27

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SSK-5

6. Technical data

Basic Version

Hopper loader capacity approx. 5 l (0.16 cu. ft. )

Made of stainless steel

Cleaning opening

Pneumatic valve (B)

On/off switch on the hopper loader

Indication of operating conditions at the hopper loader: demand, conveying,

alarm

ZKW output

Voltage 24 VDC

Maximum material temperature approx. 160 °C (320 °F)

Optional Features

Diaphragm valve (A)

Maximum level probe (D)

High abrasion resistant option

Dust separating module (C)

Extension module for hopper loader capacity of approx. 15 l ( 0.5 cu. ft.) (E)

Connection modules (F)

Blow back module for automatic cleaning of the hopper loader sieve

Technical data 28

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6.1 Dimension Sheet

253 mm

9.96"

43O mm

16.9"

2O8 mm

8.18"

15Ox15O mm; 5.9x5.9"

Dimensions and data without obligation. Dimensions in mm. Specifications may be subject to alterations.

Technical data 29

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SSK-5

6.2 Control Cable Wiring Schematic

SOL

Cx-3

DEMAND

0VDC

Cx-2

Cx-5

NOTE 1.

NOTE 2.

Cx-6

JMP TO PIN 4

+24VDC

ON/OFF

HOPPER FULL

(OPTIONAL)

Cx-1

VALVE

JMP TO PIN 2

GROUND

DEMAND RS

Cx-4

Technical data 30

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SSK-5

Electrical manual

This electrical manual is intended to be used only by Sterling

service personnel and trained personnel authorized by Sterling

Other persons are not permitted to modify or repair the equip-

ment.

Technical data 31

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