Operating Instructions
Single Conveyor Unit
SSV 05/2R
Sterling Material Processing
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SSV 05/2R
Sterling Material Processing
5200 West Clinton Ave.
Milwaukee, WI 53223
Telephone: (414) 354-0970
Fax: (414) 354-6421
Technical service:
Service department
Telephone: (800) 423-3183
Edition: 08/99
This operation manual is for*:
(* Please fill in personally)
Serial number:
Built in:
Date of delivery:
Number of delivery:
Date of commissioning:
Location:
Group of machines:
2
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SSV 05/2R
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.
All rights reserved.
3
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SSV 05/2R
Table of contents
1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1. Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2. Explanations and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3. For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4. For the safety of the units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2. Installation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2. Installing the conveyor hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3. Installing the control and maintenance unit . . . . . . . . . . . . . . . . . 16
2.4. Connecting the compressed-air supply . . . . . . . . . . . . . . . . . . . . 17
2.5. Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1. Method of functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2. Control and maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4. Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2. Setting the mixing ratio of the components . . . . . . . . . . . . . . . . . 22
4.3. Basic setting of the filling level in the conveyor hopper . . . . . . . 23
4.3.1. Fine adjustment of the filling level in the
conveyor hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1. Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2. Cleaning/replacing the filter cartridge . . . . . . . . . . . . . . . . . . . . . 28
5.3. Adjusting the level probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.4. Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4
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SSV 05/2R
6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.1. Dimension sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5
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SSV 05/2R
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
equipment.
Safety instructions 6
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SSV 05/2R
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
observed.
L
This symbol indicates that extensive damage to equipment
is possible if the corresponding instructions, regulations or
warnings are not observed.
F
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 7
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SSV 05/2R
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 8
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SSV 05/2R
1.3. For your safety
The operators of this unit must be at least 16 years old.
·
Before initial operation, read this operating manual carefully. Observe all points.
Inquire in case of uncertainties.
This will avoid danger to persons and damage of material!
·
Store this operating manual in such a way that it is always available on the site of
operation for the unit. Faulty operation may lead to accidents!
·
·
·
·
Note that, for reasons of clarity, not every possible case of operation or mainte-
nance can be mentioned.
Note the instructions for safety and the danger signs on the unit.
This will avoid danger to persons and damage of material!
All work on the unit may only be carried out by persons whose qualification corre-
sponds with the individual chapters of the operating manual.
Faulty operation may lead to accidents!
For all types of work on the unit, proper working clothes must be worn.
This will avoid danger to persons!
·
·
·
Compare the connected loads to those of the mains supply.
Danger of electrical shock!
When using lifting gear, observe the specific instructions.
Danger of accidents!
Observe the local regulations and requirements concerning the plant.
·
·
Interrupt the mains supply for all types of work on electrical components.
Danger to life due to electrical shock!
Safety instructions 9
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SSV 05/2R
Do not carry through modifications, attachments or alterations of the unit without
the manufacturer’s permission. Danger of accidents!
·
·
By means of this operating manual, prepare precise instructions for use of this
unit. Faulty operation may lead to accidents!
Designate a unit leader responsible for the unit.
·
·
In any case, the operators of this unit must be thoroughly instructed.
Faulty operation may lead to accidents!
If the unit has been switched off for reasons of safety, it must be protected from
unathorised activation. Danger of accidents!
·
Before beginning maintenance work, designate a supervisor.
·
·
Before beginningmaintenance work, inform the responsible operating personnel.
Danger of accidents!
Before beginning maintenance work, interrupt the mains supply so that the unit is
not switched on unintentionally. Danger of accidents!
·
·
·
·
·
·
Repair work may only be carried through by trained personnel.
Danger of accidents!
The unit may never be operated when it is partially disassembled.
Limbs may be drawn in! Electrical shock!
In case of functional disturbances, switch off the unit immediately. Errors must be
eliminated immediately. Danger of accidents!
The unit is exclusively intended for conveying plastic granules and regrind. Any
other usage is not permitted.
This unit is not suitable for processing foods.
Safety instructions 10
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SSV 05/2R
Attachments which are not delivered by Sterling must be constructed according
to the safety standard EN 294. Danger of accidents!
·
·
Check all lines, hoses and coupling pieces in regular intervals for leakages and
damage. Any errors must be eliminated immediately.
Danger of accidents!
Before beginning maintenance work, set all compressed-air lines on the unit at
zero pressure. Danger of accidents!
·
·
·
The unit may only be operated if all corresponding components have been prop-
erly connected and are in accordance with the relevant regulations.
Observe the safety instructions for the connected units.
Safety instructions 11
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SSV 05/2R
1.4. For the safety of the units
The unit may only be used for conveying cylindrical plastic granules and regrind
on injection moulding machines.
·
·
Never change settings unless you are able to precisely foresee the conse-
quences.
Use only original Sterling spare parts.
·
·
·
·
·
Observe the maintenance intervals.
Keep a book on all maintenance and repair work.
Note that electronic subassemblies may be damaged by static discharge.
Before initial operation and in regular intervals, check all electrical connections for
proper fit.
Never modify sensors without knowing their precise functions.
Make sure that all plugs are connected properly.
·
·
·
·
Observe the carrying capacity of the machine flange.
Observe the operating manuals of the connected units.
Safety instructions 12
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SSV 05/2R
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
disconnected from electrical power and compressed air supply.
For installation work taking place at heights of over approx.
1829 mm. (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.
L
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 accessi-
ble; this facilitates maintenance and repair work.
F
Installation instructions 13
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SSV 05/2R
2.1. General information
Unpack all parts of the single conveyor unit and make sure that everything is
available:
conveyor hopper with level probe (1)
·
control and maintenance unit (2)
·
2 x injector tube (3)
·
2 x supply hose (4) with 4 hose clamps
·
compressed-air hose
·
operating instructions
·
4
1
0
3
Installation instructions 14
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SSV 05/2R
2.2. Installing the conveyor hopper
The single conveyor unit is not sensitive to shocks and can be installed directly on
the processing machine.
Make sure that all connections are tight so that the conveying performance is not
impaired.
The conveyor hopper is equipped with a universal flange.
Depending on the position, drill the holes for fastening the conveyor hopper to the
processing machine.
Mount the conveyor hopper on the processing machine.
Install the supply hoses on the conveyor hopper and on the injector tubes by
means of the hose clamps which are part of the supply.
Note that the hopper may not touch any other component.
F
Installation instructions 15
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SSV 05/2R
2.3. Installing the control and maintenance unit
Install the control and maintenance
unit at a freely accessible site.
Observe the length of the connection
cable.
1
0
Observe the length of the supplied
hoses to the injector tubes.
During installation, observe the length of the supply lines.
F
Installation instructions 16
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SSV 05/2R
2.4. Connecting the compressed-air supply
Check compressed-air piping for correct installa-
tion and assembly.
Check fittings, length and quality of the hose con-
nections for agreement with requirements.
Check all compressed-air lines for leakages.
You need a compressed-air supply with 5 - 6 bar
(72.52-87.02 PSI) system overpressure. The air
should be free from oil and water, if possible.
Connect the compressed-air hose, which is part
of the supply, to the injector tube and to the control
and maintenance unit. To this end, the com-
pressed-air hose is firmly pressed into the con-
necting sockets.
Connect the control and maintenance unit to the compressed-air supply (max. in-
put pressure 10 bar (145.04 PSI) system overpressure).
Set the pressure on the pressure reducer at 5 - 6 bar (72.52-87.02 PSI).
Maximum input pressure 10 bar (145.04 PSI) (system
overpressure).
F
Maximum output pressure 6 bar. (87.02 PSI)
Installation instructions 17
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SSV 05/2R
2.5. Electrical connection
Observe the regulations of the local electricity board.
»
The operating voltage is 230 V, AC, PE, 50/60 Hz.
Special voltages available on request.
The connected load is approx. 15 W.
The connection takes place by means of a mains connector.
A separate protection of the socket is not necessary.
Connect the plug of the probe cable to the control unit.
Plug the mains connector into a corresponding socket.
Installation instructions 18
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SSV 05/2R
3. Functional description
This functional description is intended for the operating person-
nel of the equipment.
»
General knowledge of operating conveyor units is prerequisite.
Ensure in each case that the operating personnel are
sufficiently informed.
The single conveyor unit SSV 05/2R is designed for convey-
ing 2 dust-free components (plastic granules and/or regrind)
directly on the injection moulding machine.
F
Functional description 19
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SSV 05/2R
3.1. Method of functioning
The single conveyor unit works according
to the venturi principle. An external com-
pressed-air supply is needed.
A venturi meter (A) is integrated in the in-
jector tube. The venturi meter aspirates
the material in the lower part of the tube (C)
and then conveys the material into the con-
veyor hopper by means of compressed air
in the upper part (B). In the hopper loader,
the material is separated from the air.
B
C
A
The filling level in the conveyor hopper is
monitored and controlled by means of a
level probe.
3.2. Control and maintenance unit
The unit is switched on and off at the control and maintenance unit.
On the pressure reducers, the operat-
ing pressure and the mixing ratio be-
tween component 1 and component 2
is adjusted.
1
0
A water separator is integrated.
Functional description 20
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SSV 05/2R
4. Set-up
This chapter is intended for the operating personnel of the
equipment.
»
General knowledge of operating conveyor units is prerequisite.
The functional description must have been read and under-
stood.
Ensure in each case that the operating personnel are
sufficiently informed.
Set-up 21
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SSV 05/2R
4.1. Preparations
Check whether the injector tubes are inserted in the material to be conveyed.
Switch on the compressed-air supply.
Switch on the conveyor unit at the control and maintenance unit.
The conveyor unit should now convey until the conveyor hopper is filled up to the
level probe.
4.2. Setting the mixing ratio of the components
The mixing ratio of the components is adjusted on the pressure reducers.
The adjustment on the pressure reducers will vary according
to the material, flow properties, particle size and conveying
distance.
&
Set-up 22
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SSV 05/2R
4.3. Basic setting of the filling level in the conveyor hopper
The filling level in the conveyor hopper is mainly determined by the level probe.
Filling level too low
By means of a screwdriver, turn the adjust-
ment screw of the level probe (A)
¼ rotation counterclockwise.
Observe the filling level during the next con-
veying procedure.
Repeat the process until the desired filling
level in the conveyor hopper is reached.
A
Filling level too high
By means of a screwdriver, turn the adjustment screw (A) of the level probe ¼ ro-
tation clockwise.
Observe the filling level during the next conveying procedure.
Repeat the process until the desired filling level in the conveyor hopper is
reached.
Set-up 23
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SSV 05/2R
4.3.1. Fine adjustment of the filling level in the conveyor hopper
Before the fine adjustment, carry through a basic adjust-
ment.
&
During operation, carefully turn the adjustment screw (A) of the level probe by
means of a screwdriver until the desired fill-
ing level is reached.
A
Clockwise rotation makes
the filling level fall.
&
Counterclockwise rotation makes the filling level rise.
If the filling level in the conveyor hopper cannot be lowered far enough by means
of the level probe, the pressure on the control and maintenance unit can be re-
duced step by step.
Set-up 24
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SSV 05/2R
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 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
1829 mm.(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
authorized personnel (appointed by Sterling).
Maintenance 25
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SSV 05/2R
Disconnect the equipment from mains supply before starting
maintenance procedures to ensure that it cannot be
switched on unintentionally.
L
Depressurize all compressed air piping of the equipment be-
fore starting maintenance work.
Please observe the maintenance intervals.
F
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 en-
vironmentally sound manner.
Use only original Sterling spare parts.
Keep record of all maintenance and repair procedures.
Maintenance 26
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SSV 05/2R
5.1. Maintenance intervals
daily: Check the setting of the pressure reducer.
Empty the water separator.
Check the danger signs on the unit for legibility
and completeness.
monthly:
Clean the filter and sieve
(depending on accumulation of dust!).
Blow out the filter from the inside out by means
of compressed air.
Check the unit plugs for proper functioning.
every six months: Check all electrical and mechanical connections
for proper fit.
Replace the filter and the sieve
(depending on accumulation of dust!).
The given maintenance intervals are average values.
F
Check whether in your individual case the maintenance in-
tervals must be shortened.
Maintenance 27
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SSV 05/2R
5.2. Cleaning/replacing the filter cartridge
Switch off the unit.
»
Disconnect the mains plug.
Disassembly
Remove the filter cartridge (A).
Blow out the filter cartridge (A) from the inside out by means of compressed air or
replace the filter.
Open the toggle-type fastener (B) and fold the hopper lid upwards.
Check the sieve (C) within the lid for material residue. Disassembling the sieve for
cleaning: draw the sieve out of the fit of the sealing ring.
Clean the sieve (C) by means of compressed-air.
Replace the sieve and sealing ring in case of damage.
A
C
A
B
Maintenance 28
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SSV 05/2R
Assembly
Assemble the sieve and the sealing ring.
Check the sieve for proper fit.
Clean the hopper loader by means of a vacuum cleaner.
Close the hopper lid.
Close the toggle-type fastener.
Assemble the filter cartridge.
Order number
filter cartridge:
&
ID 98171
Sieve:
Sealing ring:
ID 29252
ID 28628
5.3. Adjusting the level probe
See chapter “set-up”.
F
Order number
level probe:
&
ID 85480
Maintenance 29
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SSV 05/2R
5.4. Trouble-shooting
Problem
Remedy
The unit is not conveying
and is not active
a, b, g, h
The unit is not conveying;
the compressed-air valve is switched
when the device is switched on
c, f
The unit is not conveying,
the compressed air is flowing audibly
c, d, e, f, i, j, k
g, l, m
The unit is overfilled
The unit is not filled properly
Test steps
c, d, e, f, i, j, k, l
a) Check whether the unit is switched on.
b) Check whether the mains connector is connected and mains voltage is pres-
ent.
c) Check whether sufficient compressed air is available.
d) Check whether the injector tube is inserted in the material.
e) Check whether the compressed-air hose is properly connected to the injector
tube.
f) Check whether the compressed-air hose is properly connected to the mainte-
nance unit.
g) Check whether the level probe is properly adjusted.
h) Check whether the cable of the level probe is properly connected.
i) Check whether the filter is clogged.
j) Check whether the sieve is clogged.
k) Check whether the conveyor hose is properly connected.
l) Check whether the compressed-air supply is properly adjusted.
Maintenance 30
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SSV 05/2R
6. Technical data
Max. permissible shot weight
of the injection moulding machine: . . . . . . . . . . . . . . . 100 kg/h (with 0.6 kg/l)
(220.56 lbs/hr) (1.32 lbs./l)
Weight: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 3 kg
(6.61 lbs.)
Operating voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 V, AC, PE, 50/60 Hz
Special voltage on request
Connected load: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 15 W
Total noise level: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 75 dB (A)
Compressed-air supply: . . . . . . . . . . . . . . . . . . 5-6 bar (system overpressure)
(72.52-87.02 PSI)
Max. product temperature:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 °C
( 176°F)
Technical data 31
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SSV 05/2R
6.1. Dimension sheet
Dimensions and data are not binding. All dimensions are in mm. (in.) All data are subject to change.
Technical data 32
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SSV 05/2R
6.2. Spare parts list
2
3
1
6
1
0
4
5
Technical data 33
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SSV 05/2R
Pos.
ID-No.
Designation
1
2
85480
level probe
98171
29252
28628
filter cartridge
sieve
sealing ring
3
84426
97784
conveyor hose
hose clamp
4
5
6
31683
31177
88351
injector tube
maintenance and control unit
compressed-air hose
Technical data 34
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