Sterling Webcam SM3 615a User Manual

Operating Instructions

Conveyor Hopper

SSK 5-DURO

Sterling Material Processing

SSK 5-DURO

Sterling Material Processing

5200 West Clinton Ave.

Milwaukee, WI 53223

Telephone: (414) 354-0970

Fax: (414) 354-6421

www.sterlco.com

Technical service:

Service department

Telephone: (800) 423-3183

Edition: 10/01

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:

SSK 5-DURO

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 purcha-

ser requires approval from Sterling Material Processing.

SSK 5-DURO

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) . . . . . . . . . . . . . . . . 11

2.4. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3. Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2. Servicing the hopper loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2.1. Replace the sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2.2. Adjust the flap switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.2.3. Replacing the filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.2.4. Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6. Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SSK 5-DURO

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 equipment of the

direct and indirect hazards connected with the equipment.

These operating instructions are to be used by all persons assigned activi-

ties connected with the equipment.

Knowledge of the English language is prerequisite.

Ensure in each case that the operating personnel are familiar with the operat-

ing instructions and the function of the equipment.

Observe the safety instructions of the connected conveying system.

Safety instructions 5

SSK 5-DURO

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 warnings are not observed.

This symbol indicates that serious injury is possible if the corresponding

instructions, regulations or warnings are not observed.

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 familiar with

the equipment, i.e. technical correlations.

This symbol indicates that a technical term is explained at this point.

Safety instructions 6

SSK 5-DURO

1.2. Explanations and information

Various terms and designations are used frequently in these operating instructions to ensure clar-

ity. 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 ac-

cording to instructions (minimum age: 16).

Operator

The “operator” of the equipment (production manager, foreman, etc.) is the person responsible for

allproductionsequences. Theoperatorinstructstheoperatingpersonnelofwhatistobedone.

Operating instructions

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

quences 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

SSK 5-DURO

1.3. For your safety

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

veying 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 con-

veying 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 8

SSK 5-DURO

2. Installation instructions

These installation instructions are intended for persons with skills in electri-

cal and mechanical areas due to their training, experience and received in-

structions.

Personnel using these installation instructions must be instructed in the reg-

ulations for the prevention of accidents, the operating conditions and safety

regulations and their implementation.

Ensure in each case that the personnel are informed.

The installation instructions provided in the corresponding operating instruc-

tions 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. 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 capacity. Do not stand or

work under suspended loads!

Use suitable workshop equipment.

Install the equipment such that all parts are easily accessible; this facili-

tates maintenance and repair work.

Installation instructions 9

SSK 5-DURO

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 device to be conveyed

on and the material used. Fastening onto fixed machine throats is provided by means of strap re-

tainers. However, additional support of the hopper loader is necessary if the devices are not suffi-

ciently capable of bearing the load.

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

tion 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 performance 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 sepa-

rately, if necessary!

Assembly

Installation instructions 10

SSK 5-DURO

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

For operating the control valves, a com-

pressed-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

PSI)

(72.52- 87.02

overpressure).

(system

Connect the unit to the plant’s supply net-

work by means of a hose.

Maintenance unit

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 11

SSK 5-DURO

2.4. Electrical connection

The electrical connection may only be carried out by trained personnel.

Other persons are not permitted to carry out the electrical connection.

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 12

SSK 5-DURO

AV = cleaning valve

KS = flap switch

SV = diaphragm valve

1 = flap switch (KS)

2 = cleaning valve (AV)

3 = diaphragm valve (SV)

4 = KS

5 = AV

6 = SV

Installation instructions 13

SSK 5-DURO

3. Functional description

The conveyor hopper is used for the automatic conveyance of thermoset duroplast material as

well as thermoplastic powder.

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

The hopper works with a filter cartridge. The shut-off valve of the vacuum line is operated with

compressed air (compressed-air valve). The automatic filter cleaning is achieved by intense

vibration.

Functional description 14

SSK 5-DURO

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 instructed of the reg-

ulations for the prevention of accidents, the operating conditions and safety

regulations and their implementation.

Ensure in each case that the personnel are informed accordingly.

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 sus-

pension 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).

Disconnect the equipment from mains supply before starting mainte-

nance procedures to ensure that it cannot be switched on unintentionally.

Depressurize all compressed air piping of the equipment before starting

maintenance work.

Maintenance 15

SSK 5-DURO

Please observe the maintenance intervals.

Before starting maintenance work, clean the equipment of oil, fuel or lubri-

cants.

Ensure that materials and incidentals required for operation as well as

spare parts are disposed of properly and in an environmentally sound

manner.

Use only original Sterling spare parts.

Keep record of all maintenance and repair procedures.

Maintenance 16

SSK 5-DURO

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 (if available)

check the sealing rings on the locking flaps

Yearly:

replace the sealing rings on the locking flaps

replace filter cartridge (depending on amount of dust)

The given maintenance intervals are average values.

Check whether in your individual case the maintenance intervals must be

shortened.

4.2. Servicing the hopper loader

Individual hoppers can also be maintained during operation. However,

Sterling recommends that you switch off the conveying plant for all types

of work on the hopper.

Wait until the conveying procedure has stopped.

Disassemble the vacuum line on the hopper.

Close the disassembled vacuum line so that the vacuum for the active hopper-loaders does not

break down.

Depressurize the compressed-air line to the hopper (only with compressed-air valve).

Disassemble the material line on the lateral inlet of the hopper.

Disassemble the hopper.

Maintenance 17

SSK 5-DURO

4.2.1. Replace the sealing rings

Nonreturn valve

Loosen the tightening strap at the hopper lid.

Remove the hopper lid .

Draw the old sealing ring off the nozzle (A).

Install the new sealing ring. Observe the direc-

tion of installation (B).

Mount the hopper lid.

Mount the tightening strap.

Install the hopper.

SSK 5-DURO

Order number sealing ring: ID 85610

Maintenance 18

SSK 5-DURO

Outlet flap

Draw the old sealing ring off the nozzle of

the material outlet.

Install the new sealing ring.

Outlet flap

Observe the direction of installation.

Install the hopper.

Order number sealing ring: ID 23098

Maintenance 19

SSK 5-DURO

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 1 and 4 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. 35-40 mm

(1.48-1.67 in.) away from the sealing sur-

face.

- 40

Displace the flap switch (B) until the con-

tact 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.

Flap switch

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 20

SSK 5-DURO

4.2.3. Replacing the filter cartridge

Loosen the tightening strap (A).

Remove the hopper lid (B).

Remove the locking pin from the threaded

rod (C).

Loosen the 2 flat nuts (D) and remove the

safety plate (E).

Remove the washer (F).

Pull the filter cartridge (G) from the threa-

ded rod.

Use compressed air to blow through the

filter cartridge from inside out or replace

the old filter cartridge.

Put the new filter cartridge/cleaned filter

cartridge (G) onto the threaded rod.

SSK 5-DURO

Mount the washer (F) and a flat nut (D).

Put back the safety plate (E).

Mount the second flat nut (D).

Put a new locking pin in the threaded rod (C).

Mount the hopper lid (B).

Mount the tightening strap (A).

Install the hopper.

Order numbers

filter cartridge:

locking pin:

ID 85612

ID 96093

Maintenance 21

SSK 5-DURO

4.2.4. Cleaning the hopper

Loosen the tightening strap.

Remove the hopper lid.

Clean the hopper loader by means of a

vacuum cleaner.

Mount the hopper lid.

Mount the tightening strap.

Open the toggle-type fasteners (A) on the

flap of the hopper loader.

Check the filter cloth (B) and the wire cloth

by means of compressed air.

Close the toggle-type fasteners (A) on the

flap of the hopper loader.

Install the hopper.

SSK 5-DURO

Maintenance 22

SSK 5-DURO

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

Spare parts list 23

SSK 5-DURO

V 66412 SSK 5-DURO, complete

78, 79

Spare parts list 24

SSK 5-DURO

Pos.

Order no.

26487

26491

23066

09646

85489

02128

85612

03141

96093

13021

85610

85533

26451

28420

Designation

compressed-air valve, complete

diaphragm valve, complete

cylinder with valve

sealing ring

sieve

Wear Code

hose

filter cartridge

vibrator

locking pin

sealing

tension ring

fastener

sealing ring

Spare parts list 25

SSK 5-DURO

78, 79

Pos.

Order no.

85533

26451

28420

23091

28626

28625

28839

26462

23098

23093

Designation

tension ring

fastener

Wear Code

sealing ring

wire cloth

filter cloth

sealing

flap switch with plug and cable

cover

sealing ring

outlet flap with magnet

Spare parts list 26

SSK 5-DURO

6. Technical data

Dimension Sheet

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

Technical data 27

SSK 5-DURO

Electrical manual

This electrical manual is intended to be used only by Sterling service person-

nel and trained personnel authorized by Sterling.

Other persons are not permitted to modify or repair the equipment.

Technical data 28

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