Operating Instructions
Conveyor Hopper
SSK-3
Sterling Material Processing
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SSK-3
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: 12/97
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:
2
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SSK-3
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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SSK-3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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. Disassembling the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.1. Replace the sealing rings . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.2. Adjust the flap switch . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.3. Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1. Dimension sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of contents 4
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SSK-3
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-3
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.
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 6
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SSK-3
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
responsibility or according to instructions (minimum age: 16).
·
Operator
·
The “operator” of the equipment (production manager, foreman, etc.) is the
person responsible for all production sequences. The operator instructs the
operating personnel of what is to be done.
Operating instructions
·
The “plant operating instructions” describe the interaction of the equipment,
production sequences or methods. The plant operating instructions must be
compiled by the operator of the equipment.
Equipment foreman
·
When several operating personnel work on one machine, the “equipment
foreman” 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-3
1.3. For your safety
It is absolutely necessary that you observe the operating instructions for the
corresponding 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
corresponding 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).
·
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-3
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.
1828.8 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 accessible;
this facilitates maintenance and repair work.
Installation instructions 9
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SSK-3
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.
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.
Assembly
Installation instructions 10
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SSK-3
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!
F
Installation instructions 11
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SSK-3
2.3. Compressed-air supply (only with compressed-air valves)
For operating the control valves, a
compressed-air supply is neces-
sary.
Check compressed-air piping for
correct installation and assembly.
Check fittings, length and quality of
the hose connections for agree-
ment with requirements.
The operating pressure is 5-6 bar
PSI)
(72.52-87.02
overpressure).
(system
Check the compressed-air sup-
plied by the plant’s supply network.
Maintenance unit
Adjust compressed-air pressure to
5-6 bar (72.52-87.02 PSI) (system overpressure).
Compressed air must be dewatered and oiled.
Install a maintenance unit (pressure reducer with water separator and oiler) if re-
quired.
Connect the unit to the plant’s supply network by means of a hose.
Depressurize compressed-air supply lines which must be
opened.
L
Compressed air must be dewatered and oiled.
F
Adjust pressure to a max. value of 6 bar (87.02 PSI) (system
overpressure).
Installation instructions 12
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SSK-3
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
Connection plug “flap switch (KL)”
Connection plug “conveyor control”
Plug connection connection housing hopper
Installation instructions 13
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SSK-3
Installation instructions 14
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SSK-3
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
B
A
C
D
Connection housing hopper
Functional description 15
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SSK-3
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.
1828.8 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 16
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SSK-3
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 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-3
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 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:
Maintenance 18
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SSK-3
4.2. Disassembling the hopper
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.
&
Wait until the conveying procedure has stopped.
Switch off the hopper by means of the on/off switch (A) on the connection hous-
ing.
Disassemble the vacuum line on the hopper.
Close the disassembled vacuum line so that the vacuum for the active hop-
per-loaders does not break down.
A
B
Connection housing hopper
Maintenance 19
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SSK-3
Depressurize the compressed-air line to the hopper (only with compressed-air
valve).
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 20
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SSK-3
4.2.1. Replace the sealing rings
Nonreturn valve
Open the toggle-type fasteners be-
tween the hopper lid and the hop-
per loader.
Fold the hopper lid upwards.
Draw the old sealing ring off the
nozzle (A).
Install the new sealing ring. Ob-
serve the direction of installation
(B).
A
Close the hopper lid.
B
Close the toggle-type fasteners.
Install the hopper.
SSK-3
Order number sealing ring: ID 85610
&
Maintenance 21
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SSK-3
Outlet flap
Draw the old sealing ring (A) off the nozzle of the material outlet.
Install the new sealing ring (A).
Observe the direction of installation (B).
F
Install the hopper.
Order number sealing ring: ID 29258
&
180 °
A
B
Installation sealing ring
Maintenance 22
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SSK-3
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 inches) 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.
3
O
Check the adjustment:
C
B
A
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 with plug:
outlet flap with magnet:
ID 29570
ID 28647
Maintenance 23
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SSK-3
4.2.3. Cleaning the hopper
Open the toggle-type fasteners be-
tween the hopper lid and the hopper
loader.
Fold the hopper lid upwards.
A
Check the sieve within the hopper
lid (A) for material residue. For
cleaning, disassemble the sieve:
Pull the sieve out of the sealing ring.
Clean the sieve by means of com-
pressed-air.
B
C
Install the sieve.
D
Check the sieve for proper fit.
Clean the hopper loader by means
of a vacuum cleaner.
Close the hopper lid.
Close the toggle-type fasteners.
Open the toggle-type fasteners (B)
on the flap of the hopper loader.
Check the filter (D) and the filter mat
(C) in the flap for material residue.
Clean the filter by means of com-
pressed air.
SSK-3
Close the toggle-type fasteners (B) on the flap of the hopper loader.
Install the hopper.
Maintenance 24
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SSK-3
5. Spare parts list
29253
85610
97704 (Ø 50 mm)
05956 (Ø 40 mm)
17213
84555
28647
29258
Spare parts list 25
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SSK-3
97704 (Æ 50 mm)
05956 (Æ 40 mm)
26487
28628
29252
23092
28621
28634
26462
29570
23091
28626
28625
Spare parts list 26
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SSK-3
6. Technical data
6.1. Dimension sheet
Technical data 27
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