Sterling Powder Hopper Loaders, 238, 882 User Manual

Powder Hopper Loaders

Part Number: 882.00238.00

Bulletin Number: CV1-605.2

Effective: 4/15/08

Write down your Powder ________________ ________________ Hopper Loader(s) 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 sea level, using 60 Hz power. Altitude is an important consideration when specifying hopper loaders. ACS can advise you on proper selection and sizing of systems for your operating environment.

ACS is committed to a continuing program of product improvement.

Specifications, appearance, and dimensions described in this manual

are subject to change without notice.

Page 2 Powder Hopper Loaders

Safety Considerations

Powder hopper loaders are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes.

To avoid possible personnel injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices:

; Follow all SAFETY CODES. ; Wear SAFETY GLASSES and WORK GLOVES. ; Disconnect and/or lock out power before servicing or

maintaining the powder hopper loader.

; Use care when LOADING, UNLOADING, RIGGING, or

MOVING this equipment.

; Operate this equipment within design specifications. ; OPEN, TAG, and LOCK ALL DISCONNECTS before

working on equipment. You should remove the fuses and carry

them with you.

; Make sure the hopper loader and components are properly

GROUNDED before you switch on power.

; Do not jump or bypass any electrical safety control. ; Do not restore power until you remove all tools, test

equipment, etc., and the powder hopper loader and related

equipment are fully reassembled.

; Only PROPERLY TRAINED personnel familiar with the

information in this manual should work on this equipment.

Powder Hopper Loaders Page 3

Annex B Information

The following design information is provided for your reference:

1. No modifications are allowed to this equipment that could alter the CE compliance

2. Ambient temperature: 40 degrees Celsius – Maximum (104 degrees Fahrenheit)

3. Humidity range: 50% relative humidity

4. Altitude: Sea level

5. Environment: Clean, dust-free and non-explosive

6. Radiation: None

7. Vibration: Minimal, i.e. machine mounting

8. Special installation requirements: Clean, dry compressed air 1 cfm @ 60 psi (1.7 m³/hr @ 4.14 bar)

9. Allowable voltage fluctuation: +/- 10%

10. Allowable frequency fluctuation: Continuous +/- 1% Intermittent +/- 2%

11. N/A

12. Nominal supply voltage: 120/1/60 or 220/1/50/60 (V erify on serial number tag)

13. Earth ground type: TN (system has one point directly earthed through a protective

conductor)

14. Power supply should include a neutral power connection.

15. Over-current protection is supplied in the loader, but additional protection should be supplied by

the user.

16. The plug on the power cord serves as the electrical disconnect device.

17. Unit is not equipped with three-phase motors.

18. N/A

19. Loader is not equipped with local lighting.

20. Functional identification

21. Loader is equipped with a CE mark

22. Loader is supplied with an operating manual in the language of the destination country.

23. Cable support may be required for power cord, depending on final installation.

24. No one is required to be in the interior of the electrical enclosure during the normal operation of the

unit. Only skilled electricians should be inside the enclosure for maintenance.

25. Doors can be opened with a screwdriver, but no keys are required.

26. Two-hand control is not required or provided.

27. All loaders should be moved around and set in a place with a lift truck or equivalent.

28. There are no frequent repetitive cycles that require manual control⎯repetitive functions are

automatic while the loader is operating.

29. An inspection report detailing the functional test is included with the loader.

30. The machine is not equipped with cableless controls.

31. Color-coded (harmonized) power cord is sufficient for proper installation.

Page 4 Powder Hopper Loaders

Table of Contents

1 General Information .................................................7

1-1 Introduction.....................................................................................7

1-2 Equipment Function........................................................................7

1-3 Accessories.......................................................................................7

1-4 Customer Service............................................................................ 8

1-5 Necessary Documents.................................................................... 8

1-6 System Capabilities........................................................................... 8

1-7 Models Covered in this Manual.......................................................9

1-8 Standard Features ........................................................................ 10

2 Safety.......................................................................11

2-1 Work Rules....................................................................................... 11

2-2 Tools and Equipment Needed .........................................................11

2-3 Mechanical Installation ..................................................................... 12

2-4 Safety Considerations....................................................................... 12

2-5 General Responsibility......................................................................13

2-6 Operator Responsibility ..................................................................... 14

2-7 Maintenance Responsibility.............................................................. 15

2-8 Safety 17

3 Shipping Information .............................................21

3-1 Unpacking and Inspection.............................................................21

3-2 In the Event of Shipping Damages................................................21

3-3 If the Shipment is Not Complete....................................................22

3-4 If the Shipment is Not Correct....................................................... 23

3-5 Returns ......................................................................................... 23

4 Installation & Setup................................................24

4-1 Safety Considerations................................................................... 24

4-2 Necessary Tools ........................................................................... 24

4-3 Mounting Powder Hopper Loaders................................................ 24

4-5 Mounting Tips................................................................................ 25

4-6 Attaching the Pickup Wand........................................................... 25

4-7 Making Compressed Air Connections........................................... 25

4-8 Making Electrical Connections...................................................... 26

5 Operation.................................................................27

5-1 Pre-Startup Checklist....................................................................27

5-2 Operating Sequence.....................................................................27

5-3 Starting the Loader........................................................................ 29

5-4 Changing the Conveying Sequence.............................................. 29

Powder Hopper Loaders Page 5

The adjustments listed in this section must be performed ONLY by a

qualified, safety-conscious technician. ...............................29

5-5 Selecting the Most Efficient Loading Sequence............................ 30

5-6 Shutting Down the Hopper Loader Using the Series One Controller32

6 Maintenance............................................................33

6-1 Routine Maintenance....................................................................33

6-2 Replacing Motor Brushes.............................................................. 34

7 Troubleshooting .....................................................36

8 Loader Options.......................................................38

9 Spare Parts..............................................................39

9-1 Powder Hopper Loader System Component Description.............. 39

10 Technical Assistance.............................................40

10-1 Contact Information for Technical Assistance............................... 40

10-2 Returned Material Policy................................................................. 40

11 Safety Tag Information...........................................42

11-1 Powder Hopper Loader Safety Tags...............................................42

11-2 Pushbutton and Keypad Tags ........................................................ 42

11-3 Loader Identification (Serial Number) Tag..................................... 43

Page 6 Powder Hopper Loaders

1 General Information

1-1 Introduction

Powder hopper loaders economically and efficiently 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 significant operational advantages.

They’re engineered construction permits easier cleaning and

maintenance, and they can be quickly and easily reconfigured to

accommodate future production requirements. Simple electrical

and compressed air connections are all that’s needed for operation;

central vacuum systems are not necessary.

Powder hopper loaders use an integral-mount three-stage

centrifugal motor with a quick-disconnect power cord. The

receiver-mounted junction box is pre-wired to the field-mounted

control box. The powder hopper loaderfeatures a high-flow

blowback valve to enhance cleaning its acrylic/mesh flat filter,

providing excellent filtration of conveying air. Powder hopper

loaders also feature a counter-weighed flapper assembly.

1-2 Equipment Function

Powder hopper loaders are efficient conveyers of free-flowing

powder, pelletized or granular materials. They are typically used

to convey material 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 connections are

all that’s needed for operation; a central vacuum system is not

necessary.

1-3 Accessories

ACS offers a variety of standard options for the powder loaders.

All accessories are designed and manufactured by ACS, Inc. to

ensure proper results for your application.

Powder Hopper Loaders Page 7

1-4 Customer Service

The intent of this manual is to familiarize the operator and

maintenance personnel with this equipment and help your

organization get the maximum service from your equipment. If

you have any questions regarding installation, service, repair,

custom equipment, or applications, please do not hesitate to

equipment, accessories, or repair parts will be furnished promptly

upon request.

NOTICE: If you desire to use a loader for an application other than that for

which it was purchased, please contact your sales representative or

our factory to verify compatibility of the equipment with the new

process. Misapplication of the equipment could result in injury to

the operator or damage to the equipment.

1-5 Necessary Documents

The items listed here are required for installation, operation, and

maintenance of powder hopper loaders. Additional copies are

available from the manufacturer.

• This product manual.

• Product manuals for accessories and options selected by the

customer, where installed.

1-6 System Capabilities

Loading systems are as varied as the applications that they service.

This equipment is intended to load the materials(s) specified at the

time of purchase at specific rates.

Page 8 Powder Hopper Loaders

1-7 Models Covered in this Manual

Models are designated by capacity. Powder hopper loaders are

available in 1.6 cu. ft. (45.3 liters) capacities and hold

approximately 50 lbs. of material.

Powder Hopper

Loaders

models cu. ft. liters lbs. kg

50(E) 1.6 45 50 22

Note: (E) Denotes “CE” models, including 220/1/50 operation and CE mark.

Capacity

Powder Hopper Loaders Page 9

1-8 Standard Features

Powder Hopper Loaders

• Stainless steel vacuum receiver

• Tangential 11/2” (38mm) OD material inlet

• High flow blowback valve with electrical quick disconnect

and accumulator

• Twin bag filter assembly with glazed polyester filter bags

• Receiver-mounted junction box with 8 feet (2.6 m) of cable

to a field-mounted control box

• Material demand/level sensor

• High-performance centrifugal motor with electrical quick

disconnect

• Sound enclosure

• 9-foot (2.7 m) power cord

• Dual tube aluminum pickup wand with ten (10) feet (3 m) of

grounded flexible vinyl hose and two (2) hose clamps

• Counter-weighted flapper assembly.

Page 10 Powder Hopper Loaders

2 Safety

2-1 Work Rules

Install, operate, and maintain this equipment according to

applicable work and safety codes for your location. This includes

OSHA, CE, NEC, CSA, SPI, and many other local, national, and

international regulations. Obey these specific work rules:

 Read and follow the instructions in this manual before

installing, operating, or maintaining any equipment. Additional copies are available from the manufacturer.

 Only qualified persons should work on, or with, this equipment.

 Work only with approved tools and devices.

 Disconnect and lock out power while working on this

equipment.

2-2 Tools and Equipment Needed

You’ll need the following:

• Hand tools

• Fork lift or overhead lift

• Wire, conduit, and fittings for wiring runs (if receptacle is not

already in place)

• Mounting bolts with lock nuts and washers, or pop rivets

• Compressed air tubing and fittings

Powder Hopper Loaders Page 11

2-3 Mechanical Installation

Loaders are typically mounted on the machine supply hopper. Be

sure it is securely attached and additional bracing is used if

necessary. The sections on the following pages explain general

installation rules.

Read manual thoroughly before installing loader.

Use approved safety straps or chains to lift the loader at the marked lifting points.

2-4 Safety Considerations

The terms NOTICE, CAUTION, WARNING, and DANGER have specific meanings in this manual. See Section 11 for a

complete list of specific safety warning information.

A NOTICE is used to indicate a statement of company policy directly or indirectly related to the safety of personnel or protection of property.

A CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

A WARNING indicates a potentially hazardous situation which, if not avoided could result in death or serious injury.

A DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This word will be limited to the most serious situation(s).

Page 12 Powder Hopper Loaders

The term IMPORTANT emphasizes areas where equipment damage could result, or provides additional information to make a step or procedure easier to understand. Disregarding information marked IMPORTANT would not be likely to cause personal injury.

REPORTING A SAFETY DEFECT

NOTE: If you believe that your equipment has a defect which could

cause injury, you should immediately discontinue its use and inform the manufacturer at our address listed in this manual.

The principle factors which can result in injury are:

• Failure to follow proper operating and clean-out

procedures, i.e. lockout/tagout.

• Failure to maintain a clean and safe working environment.

2-5 General Responsibility

NO MATTER WHO YOU ARE…

Safety is important. Owners, operators, and maintenance

personnel must realize that every day, safety is a vital aspect of

their jobs.

If your main concern is loss of productivity, remember this:

Production is always affected in a negative way following an

accident. The following are some of the reasons, which can affect

your production:

• Loss of a skilled operator (temporarily or permanently)

• Breakdown of shop morale

• Costly damage to equipment

• Down-time

An effective safety program is responsible and economically

sound.

Organize a safety committee or group, and hold regular meetings.

Promote this group from the management level. Through this

group, the safety program can be continually reviewed,

maintained, and improved. Keep minutes or a record of the

meetings.

Powder Hopper Loaders Page 13

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Sterling Powder Hopper Loaders, 238, 882 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual