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.

© Copyright ACS, Inc.2007
All rights reserved. Effective 5/15/2007
Part No.: 882.00205.00 Revision: New Bulletin No. XX2-615

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

contact us for the information required. Prices for additional

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

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 equipment safety.

This manual contains safety warnings throughout, specific to each

function and point of operation.

2-6 Operator Responsibility

The operator’s responsibility does not end with efficient

production. The operator usually has the most daily contact with

the loader and intimately knows its capabilities and limitations.

Plant and personnel safety is sometimes forgotten in the desire to

meet incentive rates, or through a casual attitude toward machinery

formed over a period of months or years. Your employer probably

has established a set of safety rules in your workplace. Those

rules, this manual, or any other safety information will not keep

you from being injured while operating your equipment.

ONLY YOU can make safety work for you by constantly thinking

about what is safe and what is not. It is often the “just once” that

an operator reaches into a loader to remove material and it results

in serious injury.

Learn and always use safe operation. Cooperate with co-workers

to promote safe practices. Immediately report any potentially

dangerous situation to your supervisor or appropriate person.

REMEMBER:

• NEVER place your hands or any part of your body in any

dangerous location.

• NEVER operate, service, or adjust the loader without

appropriate training and first reading and understanding this
manual.

• NEVER try to pull material out of the loader with your hands

while it is running!

• Before you start the loader check the following:

• Remove all tools from the blender;

• Be sure no objects (tools, nuts, bolts, clamps, bars) are

laying in the metering or mixing area;

Page 14 Powder Hopper Loaders

• If your blender has been inoperative or unattended, check all

settings before starting the unit.

• At the beginning of your shift and 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, modify, or remove safety guards. Such
alteration is not only unsafe, but will void the warranty on your
equipment.

• When changing control settings to perform a different mode of

operation, be sure selector switches are correctly positioned.
Locking selector switches should only be adjusted by
authorized personnel and the keys removed after setting.

• Report the following occurrences IMMEDIATELY:

• unsafe operation or condition

• unusual blender action

• leakage

• improper maintenance

• NEVER stand or sit where you could slip or stumble into the

loader while working on it.

• DO NOT wear loose clothing or jewelry, which can be caught

while working on a loader. Also cover or tie back long hair.

• Clean the loader and surrounding area DAILY, and inspect the

machine for loose, missing or broken parts.

• Shut off power to the loader when it is not in use. Turn the

switch to the OFF position, or unplug it from the power
source.

2-7 Maintenance Responsibility

Safety is essential to the good health of both operator and machine.

If you are a maintenance worker, you must make safety a priority

in order to effectively repair and maintain equipment.

BEFORE REMOVING, ADJUSTING, OR REPLACING

PARTS ON A MACHINE, REMEMBER TO DO THE

FOLLOWING:

Powder Hopper Loaders Page 15

• 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.

When you need to perform maintenance or repair work on a loader

above floor level, use a solid platform or a hydraulic elevator. If

there is a permanently installed catwalk on your loader, use it. The

work platform should have secure footing and a place for tools and

parts. DO NOT climb on loaders, machines, or work from

ladders.

If you need to repair a large component, use appropriate handling

equipment. Before you use handling equipment (portable “A”

frames, electric boom trucks, fork trucks, overhead cranes) be sure

the load does not exceed the capacity of the handling equipment or

cause it to become unstable.

Carefully test the condition of lifting cables, chains, ropes, slings,

and hooks before using them to lift a load.

Be sure that all non-current carrying parts of electrical apparatus,

electrical component enclosures, and the loader frame are correctly

connected to earth ground with an electrical conductor that

complies with current codes. Install in accordance with national

and local codes, which apply.

When you have completed the repair or maintenance procedure,

check your work, remove your tools, rigging, and handling

equipment.

Do not restore power to the loader until all persons are clear of the

area. Start and run the loader until you are sure all parts are

functioning correctly.

BEFORE you turn the loader over to the operator for production,

verify all guards and safety devices are in place and functioning

properly.

Page 16 Powder Hopper Loaders

2-8 Safety

2-8-1 Description and Objectives

This section includes information 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 section is recommended to supplement these

procedures in order to provide a safer working environment.

At the completion of this section, the operator and maintenance

personnel will be able to:

• Identify and locate specific safety devices.

• Understand the proper use of the safety devices provided.

• Describe the function of the safety devices.

2-8-2 Safety Circuit Standards

Safety circuits used in industrial systems protect the operator and

maintenance personnel from dangerous energy. They also provide

a means of locking out or isolating the energy for servicing

equipment.

Various agencies have contributed to the establishment of safety

standards that apply to the design and the manufacture of

automated equipment. The Occupational Safety and Health

Administration (OSHA) and the Joint Industrial Council (JIC) are

just a few of the organizations that have joined with the plastics

industry to develop safety standards.

Powder Hopper Loaders Page 17

Every effort has been made to incorporate these standards into the

design of the Powder Hopper Loading system; however, it is the

responsibility of the personnel operating and maintaining the

equipment to familiarize themselves with the safety procedures and

the proper use of any safety devices.

2-8-3 Fail Safe Operation

If a safety device or circuit should fail, the design must be such

that the failure causes a “Safe” condition. As an example, a safety

switch must be a normally open switch. The switch must be held

closed with the device it is to protect. If the switch fails, it will go

to the open condition, tripping out the safety circuit.

At no time should the safety device fail and allow the operation

to continue. For example, if a safety switch is guarding a motor,

and the safety switch fails, the motor should not be able to run.

2-8-4 Safety Device Lock-Outs

Some safety devices disconnect electrical energy from a circuit.

The safety devices that are utilized on powder hopper loader

models are primarily concerned with the pneumatics and electrical

power disconnection, and the disabling of moving parts that may

need to be accessed during the normal operation of the machine.

Some of the safety devices utilize a manual activator. This is the

method of initiating the safety lock out. This may be in the form of

a plug, disconnect plug, lever or a handle. Within this lockable

handle, there may be a location for a padlock. Personnel servicing

the equipment should place a padlock in the lockout handle.

WARNING! Always disconnect and lockout all electrical power and pneumatic

(i.e. compressed air) sources prior to servicing or cleaning any
loader, including all units. Failure to do so may result in serious
injury.

At no time must anyone remove the lockout or reconnect the twist

plug, other than the person who installed the lockout or who

unplugged the twist plug.

Page 18 Powder Hopper Loaders

2-8-5 Lock-Outs, Plugs, and 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 approved electrical

lockout tags. These tags are available at most electrical supply

stores.

WARNING!

Disconnect both of these items to ensure optimum maintenance
personnel safety when cleaning or servicing this equipment.

Powder Hopper Loaders Page 19

Figure 1

Typical Powder Hopper Loader

Figure 2

Powder Hopper Loader Dimensions, Specifications, and Maximum Machine-Side

Throughput

Specifications

Model Hopper capacity Full-load amps Inlet size range Shipping weight

cu. ft. Liters lbs. Kg (FLA) inches

Powder
Hopper

Loader

1.6 45 50 22
11 1½”

mm

38 mm

lbs. Kg

120

Maximum Machine-Side Throughput

55

Model lbs./hr. Kg/hr.

Powder Hopper

Loader

Note: Twelve (12) -foot (3.66 m) vertical 1½” OD (approx. 38 mm)
flex hose; free-flowing powder @ 35 lbs./cu. ft. (560 Kg/cu. m)

1000 454

ACS, Inc. is committed to a continuing program of product improvement.

Specifications, appearances, and dimensions are subject to change without notice.

Page 20 Powder Hopper Loaders

3 Shipping Information

3-1 Unpacking and Inspection

You should inspect your powder hopper loader for possible
shipping damage. If the container and packing materials are in
reusable condition, save them for reshipment if necessary.

Thoroughly check the equipment for any damage that might have
occurred in transit, such as broken or loose wiring and
components, loose hardware and mounting screws, etc. In case of
breakage, damage, shortage, or incorrect shipment, refer to the
following sections.

3-2 In the Event of Shipping Damages

Important!

According to the contract terms and conditions of the Carrier,
the responsibility of the Shipper ends at the time and place of
shipment.

; Notify the transportation company’s local agent if you discover

damage.

; Hold the damaged goods and packing material for the

examining agent’s inspection. Do not return any goods to the

manufacturer before the transportation company
inspection and authorization.

; File a claim against the transportation company. Substantiate

the claim by referring to the agent’s report. A certified copy of
our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was
prepaid, write us for a receipted transportation bill.

; Advise the manufacturer regarding your wish for assistance

and to obtain an RMA (return material authorization) number.

Powder Hopper Loaders Page 21

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 inspection by postal authorities.

United Parcel Service Shipment

; Contact your local UPS office regarding damage and insurance

claims.

; Retain the container and packing.
; Notify the manufacturer at once.

3-3 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 have:

; Powder hopper loader(s) with controller(s)
; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
; Component instruction manuals

Re-inspect the container and packing material to see if you missed
any smaller items during unpacking. Determine that the item was
not inadvertently taken from the area before you checked in the
shipment. Notify the manufacturer immediately of the shortage.

Page 22 Powder Hopper Loaders

3-4 If the Shipment is Not Correct

If the shipment is not what you ordered, contact the parts and
service department immediately at [phone]. Have the

order number and item number available. Hold the items until you
receive shipping instructions.

3-5 Returns

Important!

Do not return any damaged or incorrect items
until you receive shipping instructions from the manufacturer.

Powder Hopper Loaders Page 23

4 Installation & Setup

4-1 Safety Considerations

; Connect the hopper loader to a grounded three-prong power

receptacle. If this is not possible, ground the hopper loader
motor for electrical isolation and protection from electric
shock.

; Do not use hopper loaders in explosive atmospheres.
; Do not use outdoors or in wet environments. Moisture damages

the motor and can create an electric shock hazard.

; Operate hopper loaders at the rated voltage. Operation at other

than design voltage can result in, at best, poor performance,
and can cause damage to the vacuum motor, control, and
personnel.

4-2 Necessary Tools

; Hand drill
; Pop-rivet gun
; 3/16” (about 4.8 mm) -diameter rivets

4-3 Mounting Powder Hopper Loaders

Important! You can mount your powder hopper loader directly to the

processing machine by cutting a hole in the machine bin lid
and fastening the hopper loader to it. The hopper loader
mounting flange mates with ACS equipment and uses the
same mounting holes as previous ACS models.

For new installations or mounting on other manufacturer’s
equipment, a hole location template is included in the information
packet.

Page 24 Powder Hopper Loaders

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 mounting flange

before seating the hopper loader. This provides an additional
seal.

• Use rivets to mount the hopper loader. Bolts, nuts, and

washers can loosen, fall into, and damage process equipment.

• Check across the mounting flange with a bubble level. Level

installation ensures proper material discharge valve
operation.

• Install controller boxes to a non-moving solid structure to

avoid loosening any wiring from vibration.

• Remove all rubber banding and any other packaging

materials from around the flapper dump valve before
installation for proper operation.

4-6 Attaching the Pickup Wand

Slide the flex hose onto the material inlet and pickup wand. Strip
material away from the ground wire in the hose and secure the bare
wire under the hose so it is in contact with the metal tube. Use the
hose clamps supplied to secure the flex hose.

The pickup wand can be adjusted for maximum performance.
Insert it into the material to be conveyed. Adjust the tube by
loosening the wing nut at the top and sliding the wand assembly to
maintain performance.

The material should flow freely and not surge through the hose.

4-7 Making Compressed Air Connections

Your powder hopper loader requires a clean, dry, 80 to 120 psi
(551.6 to 827.4 kPa/5.52 to 8.27 bars) compressed air supply. A

Powder Hopper Loaders Page 25

filter, regulator, and shutoff valve are recommended components
of your in-plant compressed air supply.

You may need to install an accumulator in your air supply system
to enhance blowback effectiveness if your system cannot
consistently meet these requirements. Make sure you use full-sized
1/2” diameter pipe or tubing when making connections.

4-8 Making Electrical Connections

The controller you selected is shipped pre-wired to the hopper
loader. Units are supplied with a power cord with plug wired to the
control unit, ready to plug into an appropriately grounded three­prong receptacle.

Make sure that the material demand sensor is installed with the
proper amount of clearance, and that it is free of obstructions.

If the installation has the 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 are

tight.

Page 26 Powder Hopper Loaders

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 switch activate without obstruction?
; Can the material discharge valve swing without

obstruction?

5-2 Operating Sequence

1. Blowback sequence.

2. Motor starts.

3. Flapper discharge valve seals under vacuum.

4. Material conveys.

5. Vacuum receiver fills.

6. Vacuum timer times out.

7. Motor stops.

8. Blowback sequence begins, the flapper discharge valve
opens under the weight, and material dumps.

Steps 1 through 8 repeat automatically.

If the level switch remains open, the receiver loader remains idle
until the material level in the bin drops and frees the
counterbalanced dump valve. Steps 1 through 8 in the loading
sequence as listed above then resume automatically.

Powder Hopper Loaders Page 27

Figure 4

Series One Control Panel

TM

AUTO

SERIES ONE

LOADE R

ON

OFF

A0542127

Page 28 Powder Hopper Loaders

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

ON position.

the

5-4 Changing the Conveying Sequence

DANGER! DISCONNECT POWER BEFORE

OPENING THE CONTROL BOX.

Electric current, CAPABLE OF
CAUSING INJURY OR DEATH, MAY BE

PRESENT in the controller enclosure
during these procedures.

The adjustments listed in this section
must be performed

qualified, safety-conscious technician.

ONLY by a

The Series One controller is a time-fill mode controller, and has
sixteen (16) loading sequences to select. Make sure you avoid
over-filling the receiver! Figure 2 lists loading times and number
of blowback pulses in each sequence. Use the chart as your
model; select a sequence that suits your needs.

Powder Hopper Loaders Page 29

To select a sequence:

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 Series 1 controller and prepare the
unit for operation.

Note: Figure 7 contains two (2) different programs (12 and 14

blowback pulses).

5-5 Selecting the Most Efficient Loading Sequence

By selecting the best sequence, you can reduce vacuum motor
wear, save energy, and reduce your need to maintain filters.

1. Begin with a sequence time longer than what is required for
your process.

2. Start up the hopper loader with the Series One controller.

3. Observe the flex hose and the material in which you buried
the pickup probe. Listen to the vacuum motor and the sound
that the material makes as it enters the hopper loader.

4. When the hopper loader is full, the conveying rate drops off
sharply. You can observe this condition in the clear flex hose
and the material container in which you buried the pickup
probe. When the hopper loader is full, the vacuum motor and
material sounds also change.

5. Make a note of the elapsed time from the start of conveying
to the time the hopper loader is full.

6. See Figures 7 and 8; pick the next-shorter sequence. For
example, if the hopper is full by the 90-second point of the
conveying sequence, select the 80-second conveying sequence.

Page 30 Powder Hopper Loaders

Figure 5

Conveying Sequence DIP Switch Chart, Program A0536814

6 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

15 SECONDS 10 SECONDS 20 SECONDS 25 SECONDS

BLOWBACK

PULSES OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

OPEN OPEN OPEN OPEN

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

6

BLOWBACK OFF OFF OFF OFF OFF OFF OFF OFF

PULSES OPEN OPEN OPEN OPEN

7

BLOWBACK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

PULSES

OFF OFF OFF OFF OFF OFF OFF OFF
OPEN OPEN OPEN OPEN

7

BLOWBACK 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

ON ON ON ON

30 SECONDS 35 SECONDS 40 SECONDS 45 SECONDS

ON ON ON ON ON ON ON ON

50 SECONDS

ON ON ON ON ON ON ON ON

80 SECONDS 90 SECONDS 100 SECONDS 120 SECONDS

55 SECONDS 60 SECONDS 70 SECONDS

PULSES

OFF OFF OFF OFF
OPEN OPEN OPEN OPEN

ON ON ON ON ON ON ON ON ON ON ON ON

Note: Figure 4 contains two (2) different programs (6 and 7

blowback pulses).

Powder Hopper Loaders Page 31

5-6 Shutting Down the Hopper Loader Using the

Series One Controller

 Move the power switch on the Series 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 32 Powder Hopper Loaders

6 Maintenance

6-1 Routine Maintenance

Cleaning Filters

Check the condition of the filter assembly frequently until you can
determine a filter-cleaning interval. Units conveying dusty or fine
materials need more frequent cleaning. Note that a clogged filter
can reduce the overall capacity of the loader.

Replace the filter bags if they show any signs of wear. You can
obtain replacements from the manufacturer.

To gain access to the filter, release the cover latches and lift the
hopper/lid assembly off, grasping the lip of the filter assembly and
remove.

CAUTION! Do not lift the cover assembly by the motor, piping, or

accumulator.

These components are not designed to support the

assembly.

Checking Flex Hose for Wear

Worn hoses can cause leaks and reduce conveying rates. Check the
hose regularly.

Inspect Material Discharge Valves

Look for signs of wear, improper operation, or material
obstruction. Make sure that the flapper discharge valve is secure
and free from all obstructions.

Note: Powder hopper loaders that convey very abrasive and/or

very dusty materials may require more frequent
maintenance.

Powder Hopper Loaders Page 33

6-2 Replacing Motor Brushes

Note: Make sure that you replace motor brushes before the brush

shunt touches the commutator. Replacements and spares
are available from the manufacturer.

Powder hopper loader vacuum motor brushes require periodic
replacement. Maintain a supply of motor brushes, and establish a
preventive maintenance program to reduce downtime.

Make sure that you properly seat replacement brushes to
achieve maximum service life. Unseated brushes may fail
prematurely and increase your maintenance workload.

WARNING! HAZARDOUS ELECTRICAL CURRENT PRESENT.

Secure the machine

WEAR SAFETY GLASSES BEFORE performing

this procedure!

Use a stable platform if working above floor
level.

Removing Old Motor Brushes

BEFORE servicing!

1. If you haven’t already done so, disconnect the hopper
loader from the electrical supply!

2. Disconnect motor and blowback connection receptacles at
the control enclosure.

3. Release the latches that secure the cover assembly. Lift off
the cover assembly by the edges.

Remove the motor from the cover assembly by carefully
releasing the springs. Springs are under tension, so be very
careful!

5. Remove the brush end cap, then the two brush clips from
the brush holder.

6. Remove the two brushes from the brush holder, and replace
with new brushes.

Replacement and Reassembly

1. Re-attach the brush clips and the end cap after you make
sure that the brush assembly is properly seated.

Page 34 Powder Hopper Loaders

Seating Motor Brushes

Following steps 5 and 6 above, perform the same procedure
for the opposite side.

2. Remove the armature assembly at the top portion of the
hopper loader to properly seat the replacement brushes.

3. Insert a strip of 600-grit sandpaper with the rough side
facing the brush.

4. Release the brush and rotate the commutator back and forth
by hand (See the alternative seating procedure on the facing
page) so that the brush is sanded to match the arc of the
commutator.

5. In older motors, the wear of the brushes creates a shallow
trough in the commutator. Sand the brush to conform to the
contour.

6. Remove the sandpaper, and repeat steps 5 and 6, as needed
until all brushes are replaced.

7. Reinstall the armature assembly.

Option 1

Option 2

You have two (2) options for seating motor brushes (Steps 5
to 11):

 Run the powder hopper loader at 50% to 75% voltage for about

30 minutes.

 Apply power from a variable transformer at the motor

disconnect, not at the control box.

 Connect two (2) hopper loader motors in series and run them

for about 30 minutes.

WARNING! On motors using white AMP disconnects,

make sure power is not applied to the green
ground wire; otherwise, the motor housing
becomes electrically “hot.”
Reducing line voltage may be accomplished
by using a variable transformer or by
connecting two identical motors in series.

Powder Hopper Loaders Page 35

7 Troubleshooting

Powder Hopper Loaders

Problem Possible cause Solution

Plug in power cord. Check
main disconnect.

Unit resumes operation when
the material level drops; this is
normal.
Remove obstruction; check for
free movement of flapper
assembly.
Clean and readjust for material
flow characteristics.
Secure all terminal
connections.
Reattach blowback and/or
motor connections.

Replace reed switch, adjust
magnet.

Unit resumes operation when
the material level drops; this is
normal.
Plug motor assembly into the
controller enclosure.
Replace fuse with an MDL 10
fuse.
Repair or replace motor as
needed.

Hopper loader does not
work.

Vacuum motor does not
work.

No power to control box.
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.
Fouled flapper discharge

valve.
Build-up on flapper.
Loose control wiring.

Blowback and motor
connections are not secure.
Power switch has failed. Replace switch.

Reed switch has failed.
Circuit board has failed. Replace circuit board.
The bin below the hopper

loader is filled to capacity.
Motor assembly is not properly

connected to the controller.
Fuse is blown.

Motor requires servicing.

Page 36 Powder Hopper Loaders

Powder Hopper Loaders Cont’d.

Problem Possible cause Solution

Air pressure is too low.

Air supply to blowback is
restricted.

Blowback does not work
properly.

Hopper does not
completely fill.

Power light does not work.

Hopper over-fills
repeatedly.

Blowback valve assembly is
not connected to controller.

Control wiring connections are
loose on the circuit board.

Solenoid valve or valve coil
has failed.

Material supply is low. Refill material supply.

Selected conveying sequence
is too short.

Material probe not properly
positioned in material supply.

Material probe not adjusted for
flow characteristics of material.

Obstructions in supply line.
Filter is dirty.

Filter is clogged, holding open
the flapper discharge valve.

Terminal connection is loose.
Light is burned out. Replace light.

Wire has been cut. Replace wire; replace light.
The loading sequence is too

long.

Increase air pressure to at
least 80 psi (551.6 kPa/5.52
bars).
Make sure piping is full size.
Remove all restrictions in air
supply.
Connect blowback assembly
to controller at the proper
receptacle.
Secure terminal connections of
the controller wiring on the
circuit board.
Repair or replace solenoid
valve as needed.

Select a more suitable
sequence from the 16
selections; see Section 4-4 on
Pages 29 to 30 for more
information.
Adjust material probe at
material pickup point.
Adjust material probe to
compensate for flow
characteristics; see Section
3-8 for more information.
Clear all obstructions in the
line.
Clean or replace filter as
needed.

Replace filter as needed.
Secure terminal connections

on the terminal board.

Select a more suitable
sequence from the 16
selections; see Section 4-4 for
more information.

Powder Hopper Loaders Page 37

8 Loader Options

Your loader may have been equipped with the following options:

Special Voltages

Models are also available in 230/1/50 and 230/1/60 supply
voltages.

Page 38 Powder Hopper Loaders

9 Spare Parts

9-1 Powder Hopper Loader System Component

Description

This section describes the various components of the loading
system. The loading system is made up of the following
components:

• Stainless steel vacuum receiver

• Tangential 11/2” OD (about 38.1 mm 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.

9-2-1 Overview

Component Identification and Location

This section will familiarize the reader with the components of the
powder loading system. After reading this section, the reader will
be able to identify the individual common components of the
loading system.

Powder Hopper Loaders Page 39

10 Technical Assistance

10-1 Contact Information for Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call
The ACS Customer Service Group will provide your company with genuine OEM quality parts
manufactured to engineering design specific ations, which will maximize your equipment’s performa nce
and efficiency. To assist in expediting your phone or fax order, please have the model and serial
number of your unit when you contact us. A customer replacement parts list is included in this manu al
for your convenience. ACS welcomes inquiries on all your parts needs and is dedic ated to providing
excellent customer service.

Service Department

Call toll-free 8am–5pm CST [800] 423-3183 or call
Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most of our
products. www.acscustomerservice.com

[262]

641-8610, Fax [262] 641-8653

[262]

641-8610

Sales Department

[262]

Call
Our products are sold by a worldwide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.

641-8610 Monday–Friday, 8am–5pm CST

Contract Department

[262]

Call
Let us install your system. The Contract Department offers any or all of these services: project planning;
system packages including drawings; equipment, labor, and construction materials; and union or non­union installations.

641-8610 Monday–Friday, 8am–5pm CST

10-2 Returned Material Policy

10-2-1 Credit Returns

1. Prior to the return of any material authorization must be

given by the manufacturer. A RMA number will be assigned
for the equipment to be returned.

2. Reason for requesting the return must be given.

Page 40 Powder Hopper Loaders

3. ALL returned material purchased 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 material that is not within the

manufacturer’s warranty period and/or in new and unused
condition, suitable for resale.

10-2-2 Warranty Returns

1. Prior to the return of any material, authorization must be given

by the manufacturer. A RMA number will be assigned for the
equipment to be returned.

2. Reason for requesting the return must be given.

3. All

returns are to be shipped prepaid.

4. The invoice number and date or purchase order number and

date must be supplied.

5. After inspecting the material, a replacement or credit will be

given, at the manufacturer’s discretion. If the item is found to
be defective in materials or workmanship, and it was
manufactured by ACS, purchased components are covered
under their specific warranty terms.

Powder Hopper Loaders Page 41

11 Safety Tag Information

11-1 Powder Hopper Loader Safety Tags

Pinch Point
Slide Gate and Installation

High Voltage Earth Ground
Inside Enclosure

Read Operation

Manual

Ground

PE Protected Earth

Lifting Point

11-2 Pushbutton and Keypad Tags

Button Position Function

ON

OFF

Turns power on to the loader.

Turns power off to the loader.

Page 42 Powder Hopper Loaders

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
1Ǿ 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 110 lbs/(50 KG)
Electrical Diagrams
Pneumatic Diagram

2900 S. 160
New Berlin, Wisconsin USA

[phone]

th

Street

Powder Hopper Loaders Page 43