Sterling Marine Battery SSP 5 User Manual

Operating Instructions

Conveyor Hopper

SSP 5

Sterling Material Processing

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SSP 5

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: 04/01

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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SSP 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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SSP 5

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 equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Installation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.1. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.2. Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.3. Compressed-air supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.4. Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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

3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.2. Controller SSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4. Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.1. Setting the controller SSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.2. Alarm Messages displayed on the controller SSP . . . . . . . . . . . 20

5. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.1. Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.2. Replacing the nonreturn valve sealing ring . . . . . . . . . . . . . . . . . 24

5.3. Replacing the outlet flap sealing ring. . . . . . . . . . . . . . . . . . . . . . 25

5.3.1. Adjust the flap switch . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.4. Cleaning the hopper loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5.5. Cleaning/replacing the filter cartridges of the cleaning unit . . . . 28

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SSP 5

6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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SSP 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 6

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SSP 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 7

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SSP 5

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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SSP 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!

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

properly connected and are in accordance with the relevant regulations.

1.4. For the safety of the equipment

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 (87.02 PSI)

(system overpressure).

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 9

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SSP 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.1829mm (6 ft.), use only ladders or similar equip-

ment 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.

Installation instructions 10

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SSP 5

Install the equipment such that all parts are easily accessi-

ble; this facilitates maintenance and repair work.

2.1. Transport

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

workshop crane).

Observe the carrying capacity of the lifting gear.

Observe the safety instructions for the handling of lifting gear.

Installation instructions 11

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SSP 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 12

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SSP 5

2.3. Compressed-air supply

For operating the control valves and the cleaning unit, a compressed-air supply is

necessary.

Depressurize compressed-air supply lines which must be

opened.

Compressed air must be dewatered, dustfree and oilfree.

Install a maintenance unit if required.

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

overpressure).

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.

Installation instructions 13

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SSP 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.

Installation instructions 14

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SSP 5

3. Functional description

This functional description is intended for all operating person-

nel of the equipment.

Prerequisite for this functional description is general knowledge

of conveying units.

Ensure in each case that the operating personnel are suffi-

ciently informed.

Functional description 15

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SSP 5

3.1. General

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

tic granules, regrind and powder. The hopper can only function in connection with

a multi-station vacuum conveying system.

The conveyor hopper functions according to the principle of suction conveyance.

A high-performance turbine provides for the vacuum that is required to convey

the material into the separator.

In the separator the material is separated from air by several filter cartridges. Af-

ter the conveying time is finished the turbine is switched off and the material emp-

tied.

The automatic filter cleaning takes

place by adjustable compressed-air

shocks (pulse duration).

On the hopper, there is a separate

on/off switch (A) and a function con-

trolling device which indicates the fol-

lowing operational modes:

(B): lamp on - hopper switched on at

the on/off switch (A); lamp flashes -

the hopper is conveying

(C): lamp flashes - error

(D): lamp is on - hopper signals lack

of material

Connection housing hopper

The filter-cleaning process takes place during the conveying

process.

The filter cartridges are cleaned in adjustable intervals (time

interval).

Functional description 16

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SSP 5

3.2. Controller SSP

The setting for the conveying time and the line clear time are made via the keys

(A1: “change-over” key, A2: “arrow key”) on the front of the control system. The

values which have been set will be displayed on the display (B). The values which

have been set are maintained after the machine has been shut off.

3 LEDs indicate the respective modes of operation: pulse duration (C), time inter-

val (D), without function (E).

The pulse duration can be set to 0.5, 1.0 or 1.5 seconds.

The time interval can be set from 5 to 20 seconds.

When the unit is switched on all LEDs blink and the software

version is displayed.

Controller SSP

Functional description 17

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SSP 5

4. Putting into operation

This chapter is intended for operating personnel.

Prerequisite for this chapter is general knowledge of the opera-

tion of conveying units.

Also prerequisite for this chapter is that the functional descrip-

tion has been read and understood.

Ensure in each case that the operating personnel are suffi-

ciently informed.

Observe the manual of the conveying system.

Make sure that the On/Off switch of the hopper loader con-

nection housing is in position “1".

Putting into operation 18

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SSP 5

4.1. Setting the controller SSP

It is only possible to set the pulse duration / time interval

when the unit is not conveying any material.

Setting the pulse duration

Press the “arrow key”.

The pulse duration (= duration of a cleaning pulse) which

was last selected appears in the display.

0.5, 1.0 or 1.5 seconds may be set for the pulse duration.

Setting the time interval

Press the “arrow key” and

the “change-over” key.

The time interval which was last selected appears in the dis-

play.

5-20 seconds may be set for the time interval between 2

cleaning pulses.

Putting into operation 19

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SSP 5

4.2. Alarm Messages displayed on the controller SSP

If a disturbance occurs in the unit, an alarm message will be issued.

An “E” appears in the display and an error number.

“E2"

If the control system becomes too hot during operation >70°C (158°F) the “E2"

alarm message is displayed and the unit is switched off.

Ensure that the control system is sufficient cooled.

The unit starts automatically after the cooling down phase.

Putting into operation 20

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SSP 5

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 autho-

rized personnel (appointed by Sterling ).

Maintenance 21

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SSP 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 en-

vironmentally sound manner.

Use only original Sterling spare parts.

Keep record of all maintenance and repair procedures.

Maintenance 22

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SSP 5

5.1. Maintenance intervals

Daily:

check warning signs on equipment for good

legibility and completeness.

Weekly:

check the maintenance unit

check the operating pressure in the factory

ductwork system (max. 6 bar system overpressure)

Monthly:

check the sealings on the filter cartridges

(according to the accumulation of dust)

Every six months:

check filter contamination, if necessary clean or

replace the filter cartridges

check all electrical and mechanical connections

for proper fit

check the settings of the level probes (if available)

check the sealing ring on the locking flap

check the sealing ring on the outlet flap

replace the sealing ring on the locking flap

replace the sealing ring on the outlet flap

Yearly:

The given maintenance intervals are average values.

Check whether in your individual case the maintenance in-

tervals must be shortened.

Maintenance 23

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SSP 5

5.2. Replacing the nonreturn valve sealing ring

Stop the conveying procedure.

Switch off the hopper by means of the on/off switch on the con-

nection housing.

Switch off the conveying control by means of the main switch.

Disconnect the unit from mains supply.

Depressurize all system sections of the equipment.

Open the tension ring (A).

Remove the hopper lid.

Draw the old sealing ring off the

nozzle.

Install the new sealing ring. Ob-

serve the direction of installation

(B).

Mount the hopper lid.

Close the tension ring (A).

Install the hopper loader.

SSP 5

Order number sealing ring: ID 85610

Maintenance 24

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SSP 5

5.3. Replacing the outlet flap sealing ring

Stop the conveying procedure.

Switch off the hopper by means of the on/off switch on the con-

nection housing.

Switch off the conveying control by means of the main switch.

Disconnect the unit from mains supply.

Depressurize all system sections of the equipment.

Remove the tension ring (A).

Remove the upper part of the hopper

loader with hopper lid.

Draw the old sealing ring off the nozzle of

the material outlet.

Install the new sealing ring.

Observe the direction of in-

stallation (B).

Set the flap switch.

Install the upper part of the hopper loader.

Install the tension ring (A).

Install the hopper loader.

SSP 5

Order number sealing ring: ID 23098

Maintenance 25

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SSP 5

5.3.1. 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 (1.28 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 contact

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: ID 28839

outlet flap with magnet: ID 23093

Maintenance 26

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SSP 5

5.4. Cleaning the hopper loader

Stop the conveying procedure.

Switch off the hopper by means of the on/off switch on the con-

nection housing.

Switch off the conveying control by means of the main switch.

Disconnect the unit from mains supply.

Depressurize all system sections of the equipment.

Open the tension ring (A).

Remove the hopper loader lid.

Remove the cleaning unit.

Open the tension ring (B).

Remove the upper part of the hopper

loader.

Clean the hopper loader by means of a

vacuum cleaner.

Install the upper part of the hopper loader.

Close the tension ring (B).

Mount the cleaning unit.

Mount the hopper loader lid.

Close the tension ring (A).

Install the hopper.

SSP 5

Maintenance 27

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SSP 5

5.5. Cleaning/replacing the filter cartridges of the cleaning unit

Stop the conveying procedure.

Switch off the hopper by means of the on/off switch on the con-

nection housing.

Switch off the conveying control by means of the main switch.

Disconnect the unit from mains supply.

Depressurize all system sections of the equipment.

Clean the separator hopper each time you are changing the

materials.

Use only cleaning agents which fulfil the corresponding re-

quirements.

Only clean the separator hopper with compressed-air and/or

a brush.

The conveying capacity is diminished by a clogged filter car-

tridge.

Maintenance 28

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SSP 5

Removal

Open the tension ring (A).

Remove the hopper loader lid.

Remove the cleaning unit.

Release clamping devices of the filter car-

tridges.

Remove the filter cartridges from the inter-

mediate platform.

Clean the filter cartridges from the inside

out by means of compressed air or re-

place the filter cartridges by new ones.

Installation

Insert filter cartridges into the opening of

the intermediate platform.

SSP 5

Make sure that the sealing pad is tightly fitted between filter

cartridges and intermediate platform.

Mount clamping devices of the filter cartridges.

Mount the cleaning unit.

Mount the hopper loader lid.

Mount the tension ring.

Order number

filter cartridge, short version:

ID 83379

Maintenance 29

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SSP 5

6. Technical data

Basic Version

• Conveying hopper made of stainless steel

• Integrated high performance filter

• Automatic filter cleaning

• Integrated controller for cleaning

Performance

• Hopper loader capacity

SSP 5: approx. 5 l (0.28 cf.)

with extension module: max. 15 l (0.53 cf.)

• Typical conveying capacity

SSP 5: up to 250 kg/hr (550 lbs/hr)

with extension module: 400 kg/hr (880 lbs/hr)

Optional Features

• Extension module

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

Technical data 30

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SSP 5

Dimension Sheet

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

Technical data 31

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SSP 5

7. 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.

Spare parts list 32

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SSP 5

Spare parts list 33

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SSP 5

Pos.

Order no.

26487

85460

85462

97556

86851

98754

83081

83379

85533

28420

85610

35796

26299

85533

28420

28839

26462

23098

23093

Designation

Pneumatic valve

Vent valve

Compressed-air container

Solenoid valve

Tension ring

Sealing (1 m)

Controller SSP (24 V)

Filter cartridge, short version (4x)

Tension ring

Sealing

Sealing ring

Filter support

Filter bag

Tension ring

Sealing

Flap switch

Cover

Sealing ring

Outlet flap with magnet

Spare parts list 34

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SSP 5

8. Accessories

o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Accessories 35

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