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Sterling 238 manual

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Table of contents for the manual

  • Page 1

    Powder Hopper Loaders Part Number: 882.00238.0 0 Bulletin Number: CV1-605.2 Effective: 4/15/08[...]

  • Page 2

    Page 2 Powder Hopper Loaders Write down your Powder ________________ ________________ Hopper Loader(s) serial ________________ ________________ numbers here for ________________ ________________ future reference _______________ _ ________________ _________ _______ ________________ ________________ ________________ ________________ ________________ [...]

  • Page 3

    Powder Hopper Loaders Page 3 Safety Considerations Powder hopper loaders are designed to provide safe and reliable operation when installed and operate d within design specifications, following national and lo cal safety codes. To avoid possible personnel injury or equipment damage when installing, operating, or maintain ing this equipment, use goo[...]

  • Page 4

    Page 4 Powder Hopper Loaders Annex B Information The following design information is pro v ided for your refere nce: 1. No modifications are allowed to this equ ipment that could alter the CE com plian ce 2. Ambient temperature: 40 degrees Celsius – Maximum (10 4 de grees Fahrenheit) 3. Humidity range: 50% relative humidity 4. Altitude: Sea level[...]

  • Page 5

    Powder Hopper Loaders Page 5 Table of Contents 1 General Information ................................................. 7 1-1 Introducti on ..................................................................................... 7 1-2 Equipment F unction ........................................................................ 7 1-3 Acce ssories .......[...]

  • Page 6

    Page 6 Powder Hopper Loaders The adjustments listed in this section must be performed ONLY by a qualified, safety-con scious tech nician. ............................... 29 5-5 Selecting the Most Effi cient Loading Sequence ............................ 30 5-6 Shutting Down the Hopper Loader Usi ng the Series One Controller32 6 Maintenance .........[...]

  • Page 7

    Powder Hopper Loaders Page 7 1 General Information 1-1 Introduction Powder hopper loaders economically and efficiently load free- flowing pellets or granular materi als from supply containers into machine bins or other receivers. They are a modular, stainless steel component design using signifi cant operational advantages. They’re engineered con[...]

  • Page 8

    Page 8 Powder Hopper Loaders 1-4 Customer Service The intent of this m anual is to familiarize the ope rator and maintenance personnel with this equipm ent and help your organization get the maximum service from your equipm ent. If you have any questions regarding installation, service, repair, custom equipment, or applica tions, please do not hesi[...]

  • Page 9

    Powder Hopper Loaders Page 9 1-7 Models Covered in this Manual Models are designated by capaci ty. Powder hopper loaders are available in 1.6 cu. ft. (45.3 liters) capacities and hold approximately 50 lbs. of material. Powder Hopper Loaders Capacity models cu. ft. liters lbs. kg 50(E) 1.6 45 50 22 Note: (E) Denotes “CE” models, incl uding 220/1[...]

  • Page 10

    Page 10 Powder Hopper Loaders 1-8 Standard Features Powder Hopper Loaders • Stainless steel vacuum receiver • Tangential 1 1 / 2 ” (38mm ) OD material inlet • High flow blowback valve with electrical quick disconnect and accumulator • Twin bag filter assembly with glaz ed polyester filter bags • Receiver-mounted junction box with 8 feet[...]

  • Page 11

    Powder Hopper Loaders Page 11 2 Safety 2-1 Work Rules Install, operate, and m aintain this equipment according to applicable work and safety code s for your location. This includes OSHA, CE, NEC, CSA, SPI, and ma ny other local, national, and international regulations. Obey these specific work rules:  Read and follow the instructions in this man[...]

  • Page 12

    Page 12 Powder Hopper Loaders 2-3 Mechanical Installation Loaders are typically mounted on the machine supply hopper. Be sure it is securely attach ed a nd additional bracing is used if necessary. The sections on the following pages explain general installation rules. Read manual thoroughl y before installing loader. Use approved safety straps or c[...]

  • Page 13

    Powder Hopper Loaders Page 13 The term IMPORTANT em phasizes areas where equipment damage could result, or provides additiona l information to make a step or procedure easier to unde rstand. Disregarding information mark ed IMPORTANT would not be likely to cause personal injury. REPORTING A SAFETY DEFECT NOTE: If you believe that your equipment has[...]

  • Page 14

    Page 14 Powder Hopper Loaders Hold daily equipment inspections in addition to regular maintenance checks. You will keep your equipment safe for production and exhibit your commitment to safety. Please read and use this manual as a guide to equipm ent safety. This manual contains safety warnings throughout, specific to each function and point of ope[...]

  • Page 15

    Powder Hopper Loaders Page 15 • If your blender has been inope rative or unattended, check all settings before starting the unit. • At the beginning of your shift a nd after breaks, verify that the controls and other auxiliary equipment are functioning properly. • Keep all safety guards in place and in good repair. NEVER attempt to bypass, mo[...]

  • Page 16

    Page 16 Powder Hopper Loaders • BLEED all air pressure from system components (refer to the Maintenance Section of this manual.) • TURN OFF all air and electric supplies and all accessory equipment at the machine. • DISCONNECT AND LOCK OUT electrical and pneumatic power, and attach warning tags to the disconnect switch and air shutoff valve. [...]

  • Page 17

    Powder Hopper Loaders Page 17 2-8 Safety 2-8-1 Description and Objectives This section includes inform ation on safety devices and procedures that are inherent to the Powder Hopper Loading system. This manual is not intended to supersede or alter safety standards established by the user of this equipment. Instead, the material contained in this sec[...]

  • Page 18

    Page 18 Powder Hopper Loaders Every effort has been made to incorporate these s tandards into the design of the Powder Hopper Load ing system; however, it is the responsibility of the personnel operating and maintaining the equipment to familiarize them selves with the safety procedures and the proper use of any safety devices. 2-8-3 Fail Safe Oper[...]

  • Page 19

    Powder Hopper Loaders Page 19 2-8-5 Lock-Out s, Plugs, a nd Other Safety Devices The Powder Hopper Loading system utilizes several types of safety devices. The Line Cord Plug This line cord plug allows the operator or maintenance personnel to unplug the loading system from its power source and tag it out. This plug may be tagged with any number of [...]

  • Page 20

    Page 20 Powder Hopper Loaders Figure 1 Typical Powder Hopper Loader Figure 2 Powder Hopper Loader Dimensions, Specif ications, and Maximum Machine-Side Throughput Specifications Model Hopper capacity Full-load amps Inlet size range Shipping w eight cu. ft. Liters lbs. Kg (FLA) inches mm lbs. Kg Powder Hopper Loader 1.6 45 50 22 11 1½” 38 mm 120 [...]

  • Page 21

    Powder Hopper Loaders Page 21 3 Shipping Information 3-1 Unpacking and Inspection You should inspect your powder hopper loader for possible shipping damage. If the containe r and packing materials are in reusable condition, save them for reshipment if necessary. Thoroughly check the equipment for any damage that m ight have occurred in transit, suc[...]

  • Page 22

    Page 22 Powder Hopper Loaders Parcel Post Shipment ; Notify the manufacturer at once in writing, giving details of the loss or damage. This information is required for filing a claim with our insurance company. ; Hold the damaged goods with the container and packing materials for possible inspec tion by postal authorities. United Parcel Service Shi[...]

  • Page 23

    Powder Hopper Loaders Page 23 3-4 If the Shipment is Not Correct If the shipment is not what you ordered, contact the parts and service department immediately at (262) 641-8610. Have the order number and item num ber available. Hold the items until you receive shipping instructions . 3-5 Returns Important! Do not return any damaged or incorrect ite[...]

  • Page 24

    Page 24 Powder Hopper Loaders 4 Installation & Setup 4-1 Safety Considerations ; Connect the hopper loader to a grounded three-prong power receptacle. If this is not possible, gro und the hopper loader motor for electrical isola tion and protection from electric shock. ; Do not use hopper loaders in explosive atmospheres. ; Do not use outdoors [...]

  • Page 25

    Powder Hopper Loaders Page 25 Important! The manufacturer is not responsible for equipment damage from excessive processing machine movement or vibration. 4-5 Mounting Tips • Run a bead of silicone sealant around the m ounting flange before seating the hopper loader . This provides an additional seal. • Use rivets to mount the hopper lo ader. B[...]

  • Page 26

    Page 26 Powder Hopper Loaders filter, regulator, and shutoff va lve are recommended com ponents of your in-plant compressed air supply. You may need to install an accumulator in your air supply system to enhance blowback effectiv eness if your system cannot consistently meet these requireme nts. Make sure you use full-sized 1/2” diameter pipe or [...]

  • Page 27

    Powder Hopper Loaders Page 27 5 Operation 5-1 Pre-Startup Checklist ; Are all electrical connections correct, secure, and to code? ; Is the compressed air connection secure and safe? ; Is the receiver level and mounted securely? ; Are the flex hose and pick-up wand secure? ; Is the flexible hose properly grounded? ; Can the material level sw itch a[...]

  • Page 28

    Page 28 Powder Hopper Loaders Figure 4 Series One Control Panel A0542127 OFF SERIES ONE LO A DE R AU T O TM ON[...]

  • Page 29

    Powder Hopper Loaders Page 29 5-3 Starting the 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. 5-4 Changing the Conveying Sequence DANGER! DISCONNECT POWER BEFORE OPENING THE CONT[...]

  • Page 30

    Page 30 Powder Hopper Loaders To select a sequence: 1. Turn off and disconnect power to the unit. 2. Re move 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 Series 1 controll[...]

  • Page 31

    Powder Hopper Loaders Page 31 Figure 5 Conveying Sequence DIP Swit ch Chart, Program A0536814 6 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 BLOWBACK ON ON ON ON PULSES OFF O FF OFF OFF OFF OFF OFF OFF OF F OFF OFF 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 OFF OFF OFF OFF OFF PULSES OPEN OPEN OPEN OPE[...]

  • Page 32

    Page 32 Powder Hopper Loaders 5-6 Shutting Down the Hopper Loader Using the Series One Controller  Move the power switch on the Se ries One graphic panel to the OFF position. For maintenance or for a long-term shutdown, unplug the unit from the power source and shut off the compressed air supply.[...]

  • Page 33

    Powder Hopper Loaders Page 33 6 Maintenance 6-1 Routine Maintenance Cleaning Filters Check the condition of the filter assembly f requently until you can determine a filter-clean ing interval. Units conveying dusty or fine materials need more frequent cl eaning. Note that a clogged filter can reduce the overall capacity of the loader. Replace the f[...]

  • Page 34

    Page 34 Powder Hopper Loaders 6-2 Replacing Motor Brushes Note: Make sure that you repl ace motor brushes before the brush shunt touches the commutator. Replacements and spares are available from the manufacturer. Powder hopper loader vacuum mo tor brushes require periodic replacement. Maintain a supply of motor brushes, and establish a preventive [...]

  • Page 35

    Powder Hopper Loaders Page 35 Following steps 5 and 6 above, perform the same procedure for the opposite side. 2. Re move the armature assem bly at the top portion of the hopper loader to properly seat the replacement brushes. 3. Insert a strip of 600-grit sa ndpaper with the rough side facing the brush. 4. Release the brush and rotate the commutat[...]

  • Page 36

    Page 36 Powder Hopper Loaders 7 Troubleshooting Powder Hopper Loaders 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 fuse. The bin below the hopper loader is filled to capacity. Unit resumes operation when the material le[...]

  • Page 37

    Powder Hopper Loaders Page 37 Powder Hopper Loaders 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. Remove all restrictions in air supply. Blowback valve assembly is not connected to controller. Con[...]

  • Page 38

    Page 38 Powder Hopper Loaders 8 Loader Options Your loader may have been equi pped with the following options: Special V oltages Models are also available in 230/1/50 and 230/1/60 supply voltages.[...]

  • Page 39

    Powder Hopper Loaders Page 39 9 Spare Parts 9-1 Powder Hopper Loader System Component Description This section describes the vari ous components of the loading system. The loading system is m ade up of the following components: • Stainless steel vacuum receiver • Tangential 1 1 / 2 ” OD (about 38.1 mm OD) m aterial inlet • High flow blowbac[...]

  • Page 40

    Page 40 Powder Hopper Loaders 10 Technical Assistance 10-1 Contact Information for Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3183 or call [262] 641 -8610, Fax [262] 641-8653 The ACS Customer Service Group will provide your compan y with genuine OEM quality p arts manufactured to engi neering desi gn specificati[...]

  • Page 41

    Powder Hopper Loaders Page 41 3. ALL returned material p urcha sed from the manufacturer returned is subject to 15 % ($75.00 minimum) restocking charge. 4. ALL returns are to be shipped prepaid. 5. The invoice number and date or purchase order number and date must be supplied. 6. No credit will be issued for mate rial that is not within the manufac[...]

  • Page 42

    Page 42 Powder Hopper Loaders 11 Safety Tag Information 11-1 Powder Hopper Loader Safety Tags Pinch Point Read Operation Slide Gate and Installation Manual High Voltage Earth Ground Inside Enclosure PE Protected Earth G r o u n d Lifting Point 11-2 Pushbutton and Keypad Tags Button Position F u n c t i o n Turns power on to the loader. ON Turns pow[...]

  • Page 43

    Powder Hopper Loaders Page 43 11-3 Loader Identification (Serial Number) Tag (Located on back of mixing chamber) Series Powder Hopper Loader Model Number 50E Max Capacity 227 KG/HR 220V Serial Number 060701 1 Ǿ Date of Manufacture 06/2002 A Over-current Protection Device (s) A Total Frequency 50/60Hz Compressed air supply 4.14 bar (60 psi) Mass 11[...]