Sterling SSIL manual

Operation, Installation & Service Manual SSL and SSIL Series Sight Glass Hopper Loaders Important! Read Carefully Before Attempting to Install or Operate Equipment Part No. 882.00149.00 Revision C Bulletin No. CV1-600[...]

2 Write down your hopper ________________ ________________ loader serial numbers ________________ ________________ here for future reference ________________ ________________ _________ _______ ________________ Performance figures stated in this manual are based on a standard atmosphere of 59°F (15°C) at 29.92” Hg (1,014 millibars) at s ea level[...]

3 Shipping Information Unpacking and Inspection You should inspect your SSL/CSL or SSIL/CSIL ho pper loader for possible shipping damage. If the container and packing materials are in re usable condition, save them for reshipment if necessary. Thoroughly check the equipment for any dam age th at might have occurred in transit, such as broken or loo[...]

4 If the Shipment is Not Complete Check the packing list. The apparent shortage may be intentional. Back-ordered items are noted on the packing list. You should h ave: ; SSL/CSL Series or SSIL/CSIL Series hopper loader(s) with controller(s) ; Bill of lading ; Packing list ; Operating and Installation packet ; Electrical schematic and panel layout d[...]

5 T able of Content s CHAPTER 1: SAFETY ................................................................ 7 CHAPTER 2: FUNCTIONAL DESCRIPTION .............................. 8 2-1 Introduction............................................................................................................... ... 8 2-2 Necessary Documents ..................[...]

6 5-12 Shutting Down the Hopper Loader using the Series One Plus Controller ................. 43 CHAPTER 6: SERIES ONE PLUS SPI COMMUNICATIONS .. 44 6-1 SPI Network Functions .............................................................................................. 44 6-2 Setting Up the SPI Function .............................................[...]

7 Chapter 1: Safety SSL/CSL Series hopper loaders and SSIL/CSIL Series sight glass hopper loaders are designed to provide safe and reliable operation when insta lled and operated within design specifications, following national and local safety codes. To avoid possible personnel injur y or equipm ent damage when installing, operating, or maintainin[...]

8 Chapter 2: Functional Description 2-1 Introduction SS/CS Series hopper loaders economically and effici ently load free-flowing pellets or granular materials from supply containers into machine bins or other receivers. They are a modular, stainless steel component design using significan t operational advantages. Their engineered construction perm[...]

9 2-3 Equipment Function SS/CS Series hopper loaders are efficient conveye rs of free-flowing pelletized or granular materials from supply containers into machine bins or other receivers. You can customize operation by adjusting operating parameters accessible through a menu system built into the control. Simple electrical and compressed air c onne[...]

10 • Removable inlets on 0.2, 0.4, 0. 8, and 1.6 cu. ft. (5.6, 11.3, 22 and 45 liter) models only • Glazed polyester reinforced flat filter • Hopper-mounted junction box with 12 f eet (3.6 m) of cable to a field-mounted 115/1/60 control b ox • Material demand/level sensor • Series One Plus models include a proximity level sensor for volum[...]

11 • Hopper-mounted junction box with 12 f eet (3.6 m) of cable to a field-mounted 115/1/60 control b ox • Removable inlets on 0.2 and 0.4 cu. ft. ( 5.6 and 11.3 liter) models • Accumulator blowback is standa rd on 0.2 and 0.4 (5.6 and 11.3 liter) models only • Series One Plus models (option upgrade) include a proxim ity level sensor for vo[...]

12 Remote Proportioning Valve The remote proportioning valve (SPV/CPV) option le ts you economically and efficiently proportion two (2) different free-flowing granulated materials in a material conveying system. The most common application is mixing virgin and regrind materials in a plastic processing operation. SPV/CPV installation options incl ud[...]

13 Figure 1: Typical SSL/CSL Series Hopper Loader • 10” Clearance Cutout with (6) ¼” bolt holes equally spaced on an 11” circle. We are committed to a continuing program of product improvement. Specifications, appearances, and dimensions are subject to change without notice. SSL/CSL03 Hopper Loader A[...]

14 F igure 3: SSL/CSL Series Dimensions, Specificat ions, and Maximum Machine-Side Throughput American Standards Capacity Dimensions in inches cu. ft. A B C D E F 0.1 7.0 17 3 / 8” 6 3 / 8” 12” 1 3 / 4” 6 3 / 8” 0.2 21 1 / 8” 5 1 / 2” 12” 4” 9 1 / 8” 0.4 27 1 / 8” 11 1 / 2” 12” 4” 9 1 / 8” 0.8 30 ¼” 10 ½” 12” 4[...]

15 Figure 4: Typical SSIL/CSIL Series Sight Glass Hopper Loader We are committed to a continuing program of produ ct improvement. Specifications, appearances, and dimensions are subjec t to change without notice. SSIL/CSIL03 Sight Glass Hopper Loader SRIL01.DWG A B C D E HOPSRIL.DWG I H E G J SSIL 06 Model[...]

16 Figure 5: SSIL/CSIL Series Dimensions, Specifications, and Maximum Machine-Side Throughpu t American Standards Capacity Dimensions in inches cu. ft. A B C D E -sq. G -sq. H -sq. I -sq. c J 0.1 27 5 / 8 ” 17” 6 3 / 8 ” 1 3 / 4 ” 4” 2” 1 1 / 4 ” 2 1 / 2 ” 2” 0.2 35 1 / 4 ” 19 1 / 2 ” 9 1 / 8 ” 3” 7” 3 1 / 2 ” 2 3 / 4 [...]

17 Chapter 3: Inst allation 3-1 Work Rules Install, operate, and maintain this equipment acco rding to all applicable work and safety codes. This includes, but is not limited to: OSHA, NEC, CSA, and any other local, national, and international regulations. Obey these specific work rules: ; Read and follow these instructions when installing, operati[...]

18 For new installations or mounting on othe r manufacturer’s equipment, a hole loc ation template is included in the information packet. Important! We are not responsible for equipment damage from excessive processing machine vibrations. 3-5 Mounting Tips • Run a bead of silicone sealant around the mounting flange before seating the hopper loa[...]

19 Make sure that the material demand sensor is installed with the proper am ount of clearance, and that it is free of obstructions. If the installation has the SSL/CSL or SSIL/CSIL Series hopper loader wired directly to a power main, you must install a fused disconnect with lockout to allow safe operation and maintenance. Make sure all connections[...]

20 provides volume-fill control. When the hopper lo ader is full, the LED on the proximity switch should light and trigger the dum p sequence. If the switch does not reliably sense the material you are conveying, adjust switch sensitivity. Turn the potentiometer (or pot ) clockwise to increase sensitivity, counterclockwise to decrease sensitivity.[...]

21 Chapter 4: Series One Controller Operation 4-1 Pre-Startup Checklist ; Are all electrical connections correct, secure, and to code? ; Is the compressed air connection secure and safe? ; Is the hopper level and mounted securely? ; Are the flex hose and pick-up wand secure? ; Can the material level switch activate without obstruction? ; Can the ma[...]

22 Figure 6: Series One Graphic Panel A0542127 OFF SERIES ONE MPBEFS BVUP TM ON[...]

23 4-3 Starting the Hopper Loader 1. Insert the pickup probe into the material supply. 2. Turn on compressed air to the unit. 3. Plug in power to the control enclosure. 4. Move the power switch on the Series One graphic panel to the ON position. 4-4 Changing the Conveying Sequence ! DANGER DISCONNECT POWER BEFORE OPENING THE CONTROL BOX. Electric c[...]

24 To select a sequence (see Figures 7 and 8 on the following pages): 1. Turn off and disconnect power to the unit. 2. Remove the controller box cover. 3. Move the DIP switches on the DIP switch array labeled SW1 to one of the sixteen (16) available configurations as shown in Figure 8. 4. Replace the controller box cover. 5. Reconnect power to the [...]

25 12 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 BLOWBACK ON ON ON ON PULSES OFF OFF OFF OFF OFF OF F OFF OFF OF F OFF OF F OFF OPEN OPEN OPEN OPEN 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 12 ON ON ON ON ON ON ON ON BLOWBACK OFF OFF OFF OF F OF F OFF OFF OF F PULSES OPEN OPEN OPEN OPEN 14 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 BLOWBACK ON ON ON ON ON ON ON ON PULSES OFF OFF [...]

26 6 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 BLOWBACK ON ON ON ON PULSES OFF OFF OFF OFF OFF OF F OFF OFF OF F OFF OF F OFF OPEN OPEN OPEN OPEN 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 6 ON ON ON ON ON ON ON ON BLOWBACK OFF OFF OFF OF F OF F OFF OFF OF F PULSES OPEN OPEN OPEN OPEN 7 BLOWBACK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 PULSES ON ON ON ON ON ON ON ON OFF OFF OFF[...]

27 Chapter 5: Series One Plus Controller Operation The Series One Plus controller is an optional controller that includes the following features: • Sensor-driven volume fill cycle to assure full load discharge for each cycle • Operator programming of blowback pulses to optimize efficiency • Accurate fill cycle counts up to 9,999 on the batch [...]

28 Figure 9: Series One Plus Graphic Panel MENU TITLE (FACTORY SETTING) TO DESIRED MENU SCROLL THROUGH MENUS 1-8 MENU UPDATING (WHILE STOPPED) SAVE NEW SETTING ADJUST MENU'S SETTING DISPLAY MEN U'S CURRENT SETTINGS S S ADJUST % OF MA T'L "B" SA VE NEW SETTING PROPORTION ING ADJ USTMEN TS UNTIL % OF MA T'L "B"[...]

29 5-2 Operating Sequence 1. Blowback sequence. 2. Motor starts. 3. The flapper discharge valve seals under vacuum. 4. Material conveys. 5. Hopper loader hopper fills. 6. Vacuum time r times out. 7. Motor stops. 8. Blowback sequence begins, the flapper discharge valve opens under the weight, and material dum ps. Steps 1 through 8 repeat automatical[...]

30 SCROLL SCROLL Key Press the SCROLL SCROLL key to display: • available menus when the controller is in Standby mode. • operations screens such as batch counter and SPV settings when the controller is operating. S START/STOP START/STOP/SELECT/SET Key Press the S START/STOP START/STOP/SELECT/SET key to: • start the hopper loader • stop the [...]

31 BLOWBACK BLOWBACK Indicator The BLOWBACK indicator lights when the air solenoid is open. MA TERIAL "B" MATERIAL “B” Indicator The MATERIAL “B” indicator lights when the Material B port is open. 5-4 Starting Up the Hopper Loader for the First Time Using the Series One Plus Controller Non-Proportioning Models 1. Insert the pickup[...]

32 Note: You can adjust the maximum vacuum time from 0 to 360 seconds. See Section 5-11, Menu 1. When the proximity sensor trips or sixty (60) seconds elapses, the vacuum motor shuts off for three (3) seconds to relieve vacuum in the hopper and to allow the material to dump. The BLOWBACK LED flashes and the screen display s ---- as a four (4) -puls[...]

33 Note: Press and hold the CLEAR UP key and DOWN key together simultaneously while applying power to restore all factor y defaults. As the controller powers up, the screen displays in succession: • PLUS for three seconds • the software version number n.nn • the standby mode display. 4. Press the SCROLL SCROLL key repeatedly until the screen [...]

34 Note: You can adjust the maximum vacuum time from 0 to 360 seconds. See Section 5-11, Menu 1. The MATERIAL “A” and MATERIAL “B” LEDs alternate on and off as set in Steps 4 to 6 above. This indicates the proportioning valve cycle. Example: If the percent of Material B was set at 50% in Step 4, the MATERIAL “A” and MATERIAL “B” LED[...]

35 Install your SS/CS Series hopper loader, apply power, press the S START/STOP START/STOP key and operation begins. The hopper loader loads itsel f until full, then dumps and repeats, pausing only when the machine bin below it is full. The screen displays the vacuum timer while the vacuum motor is on. If the hopper loader is a PP proportioning mod[...]

36 Adjusting Proportioning On the Fly During Operation 1. While the hopper loader is operating, press the SCROLL SCROLL key until the screen displays the percent of Material B as P. nn . 2. Press the UP key or the DOWN key to change the value as needed. 3. When the percentage of Material B y ou want displays, press the S START/STOP START/STOP/ SELE[...]

37 To return to the vacuum timer screen:  Press the SCROLL SCROLL key again. The screen reverts to the vacuum timer display. Resetting the Batch Counter To reset the batch counter to zero ( 0 ) :  Press and hold both the CLEAR UP key and DOWN key together simultaneously any time the batch counter is displayed. The batch counter resets to zero[...]

38 5-10 Navigating Series One Plus Controller Menus You’ll always enter the menu system when the screen displays AEC on the controller screen. This screen displays at startup before you press the S START/ STOP START/STOP/SELECT/SET key to start the hopper loader, and displays again when you press the S START/STOP START/STOP/SELECT/ SET key to sto[...]

39  Press the S START/STOP START/STOP/SELECT/SET key. The new setting is stored in the battery-backed RAM me mory. If you decide that you don’t want to modify the current setting of a parameter:  Press the SCROLL SCROLL key to abort the change. The change is aborted and the AEC screen displays again. To return all parameters to factory defa[...]

40 timer as needed, and be sure to disable the alarm (Menu 5 set to zero [ 0 ]) to prevent tripping the No-Convey alarm Er.1 . Menu 2 Number of Blowback Pulses 0 to 16 Pulses, Default = 4 Pulses The Number of Blowback Pulses menu lets you: • control the number of blowback pulses discharged from the compressed air solenoid during the hopper dump s[...]

41 Figure 10: Proportioning Cycle[...]

42 Menu 5 Error After n Cycles 0 to 8 Cycles, Default = 3 Cycles The Error After n Cycles menu lets you: • control the number of unsuccessful loading cycle attempts (maximum vacuum timer times out and proximity sensor does not sense a full hopper) before the Er. 1 error message displays • increase to prevent alarms while you refill the material[...]

43 Note: When operating in this mode, the Er. 2 error message displays at startup or after material changes. To clear the error code and silence the alarm, if installed, press the Clear key combination by pressing and holding both the CLEAR UP key and DOWN key together simultaneously. • enable a customer-supplied auxiliary proximity switch ( 1 ) [...]

44 Chapter 6: Series One Plus SPI Communications 6-1 SPI Network Functions The Series One Plus controller equipped with the SPI communications opti on lets you operate the controller on a network con-forming to Version 3. 01 or later of the SPI proto col specification. When installed on an SPI network, SS/CS Se ries hopper loaders, as well as other[...]

45 Menu 8 SPI Enable/Disable & Loopback Test Range = 0 to 1, Default = 0 When the expanded service menus are enabled, an additional parameter becomes available on this menu. Set this parameter to 1 to enable SPI communications. Set it to 2 to perform an internal self test. Disconnect all communication cables be fore performing the internal self[...]

46 6-3 Operating under SPI Control If you enabled the SPI function by setting the Menu 8 set value to 1 , and you press the SCROLL SCROLL key, the screen display s SPI instead of displaying vacuum time. All control is now through th e SPI network, and your SS/CS Series hopper loader now operates as instru cted by the IMM control. Press the S START/[...]

47 Chapter 7: Maintenance 7-1 Routine Maintenance Cleaning Filters Check the condition of the filter frequently until you can determ ine a filter-cleaning interval. Units conveying dusty or fine materials need mo re frequent cleaning. Note that a clogged filter can cause the discharge flapper valve to stay open, critically reducing overall sy stem [...]

48 7-2 Replacing Motor Brushes Note: Make sure that you replace motor brushes before the brush shunt touches the commutator. Replace ments and spares are available from the manufacturer. SS/CS Series hopper loader vacuum motor brush es require periodic replacement. Maintain a supply of motor brushes, and establish a preven tive maintenance program [...]

49 Replacement and Reassembly 1. Re-attach the brush clips and the end cap after you make sure that the brush assembly is properly seated. Following steps 5 and 6 above, perform the sam e procedure for the opposite side. 2. Remove the armature assembly at the top porti on of the hopper loader to properly seat the replacement brushes. 3. Insert a st[...]

50 Seating Motor Brushes You have two (2) options for seating motor brushes (Steps 5 to 11): Option 1  Run the SS/CS Series hopper loader at 50% to 75% voltage for abo ut 30 minutes.  Apply power from a variable transformer at the motor disconnect, not at the control box. Option 2  Connect two (2) SS/CS Series hopper loader motors in serie[...]

51 -Notes-[...]

52 Figure 12: Typical SSL/CSL 03 Series Hopper Loader - Exploded View[...]

53 Figure 13: SSL/CSL 03 Series Hopper Loader Parts List Refer to Figure 12 on the previous page for parts location . Item Quantity Part no. Description 1 1 A0556521 FLG, M T, ADPT 2 1 A0553741 CONE, WELD , 6” ID, SSTL 3 1 A0556534 FLTR, FLAT, CLOTH, 6” OD 4 1 A0556513 CVR, WELD, 6” ID, SSTL 5 1 A0541543 GSKT, SILC , SGLS 6 SEE VOLTAGE OPTION[...]

54 Figure 13: SSL/CSL 03 Series Hopper Loader Parts List (Continued) 230 VAC Options 34 .16 A0535193 TBG, HTSHRNK, 0.75ID, 0.81OD, 48”L 6 1 A05421 90 MTR, 230, 2-STG, LAMB, 116125-01 36 1 A0544851 ASSY, CNTRL, SER, 1.230 37 1 A0555792 SPLC, BUTT, PANDUIT, #PSN16-M 28 1 A0556608 VLV, SOL, 3/8”, #JSF8201G1, 240/60 39 1 A0559414 ASSY, CORD, BL ACK[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 55 Figure 15: Typical SLC Series Hopper Loader Parts List, Version 2 Refer to Figure 14 on the previous page for parts location. Item Quantity Part no. Description 1 1 A0563504 CONE, WELD, 9” DIA., SSR/SSL/CSL06 1 A0563505 CONE, WELD, 9” DIA., SSR/SSL/CSL11 1 A0535506 CONE, WELD, 14” DIA[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 56 GASKET SELECTION Figure 16: Typical SSIL/CSIL Series Sight Glass Hopper Loader - Exploded View Item Quantity Part no. Description 52A 1 W00012559 GSKT, THRT, EPT, BLACK, 4”, STD TEMP 52B 1 W00018024 GSKT, THRT, SILICONE, ORANGE, 4”, HI-TEMP 52C 1 W00016136 GSKT, THRT, NEOPRENE, WHI TE, [...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 57 Figure 17: SSIL/CSIL Series Sight Glass Hopper Loader Parts List Refer to Figure 16 on the previous page for parts location. Item Model no. Quantit y Part no. Description SSIL/CSIL03 1 A05537 17 PLATE, MACH, TOP, ALU, SRI/IL03 1. SSIL/CSIL06/11 1 A055 3725 PLATE, MACH, TO P, ALU, S RI/IL06/[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 58 Figure 18: Typical SSIL/CSIL 03 Series Sight Glass Hopper Loader – Expl oded View[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 59 Figure 19: SSIL 03 Series Sight Glass Loader Parts List Refer to Figure 18 on the previous page for parts location. ITEM QTY PA RT NO. P A RT DESCRIPTION 1 1 A05565 31 FLTR, F LAT, WIRE, 8” OD 2 1 A0556820 GSKT, U-CHNL, NPRN, .38 X .20 X .06 W 3 2 A05568 22 SCR, CAP, HE X, SCC, HD, 10-32 [...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 60 Chapter 8: T roubleshooting SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Standard Series One Controllers Problem Possible cause Solution No power to control box. Plug in power cord. Check main disconnect. Power switch is off. Turn ON control box. Fuse is blown. Replace the MDL 10 f[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 61 SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Standard Series One Controllers Cont’d. Problem Possible cause Solution Air pressure is too low. Increase air pressure to at least 80 psi (551.6 kPa/5.52 bars). Make sure piping is full size. Air supply to blowback is restricted. Remov[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 62 SSL/CSL, SLC, and SSIL/CSIL Series Hopper Loaders with Optional Series One Plus Controllers Problem Possible cause Solution No power to control box. Plug in power cord; check main disconnect. Power switch is off. Turn ON control box. External fuse 1FU is blown Replace fuse 1FU. Internal fus[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 63 SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Optional Series One Plus Controllers Cont’d. Problem Possible cause Solution The blowback valve is unplugged. Plug in the blowback valve cable. The number of blowback pulses on Menu 2 is set to zero. Restore Menu 2 to an appropriate va[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 64 SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Optional Series One Plus Controllers Cont’d. Problem Possible cause Solution Low material supply. Replenish material supply. Material supply obstructed. Clear all obstructions. Proximity sensor misadjusted. Increase sensitivity of prox[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 65 SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Optional Series One Plus Controllers Cont’d. Problem Possible cause Solution The customer-supplied auxiliary proximity switch is tripped because of a low material level in the machine bin. Correct the material supply problem. The scree[...]

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders 66 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [ 630 ] 595-1060, Fax [630] 475-700 5 The ACS Customer Service Group will provide your compa ny with genuine OEM qualit y parts manufactured to engineeri ng design specifications, wh ich will maxim [...]