Sterling SGFE User Manual

Ope ra ting In struc tions

Con vey or Hopper
with blo wer-filter unit SGFE

816-4MS

Ster ling Ma te rial Pro cess ing

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Please reference this page for updated contact information.

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Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance
and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied
upon. Please contact the ACS Group for more current information about these manuals and their
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design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone
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New Berlin, WI 53151
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Dist. Pune 410501, India
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Fax: + 91 20 40147576

Ster ling Ma te rial Pro cess ing

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Mil wau kee, WI 53223

Tele phone: [phone]

Fax: [phone]

www.sterlco.com

Technical service:

Ser vi ce de part ment
Tele phone: [phone]

Edition: 10/01

SGFE

The se ope ra ting in struc tions are for:*

(* Plea se fill in per so nal ly)

Se ri al num ber:

Built in:

Date of de li very:

Num ber of de li very:

Date of com mis sio ning:

Lo ca ti on:

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Group of ma chi nes:

2

SGFE

Ster ling Ma te rial Pro cess ing re tains all rights to chan ge the in for ma ti on in the se
ope ra ting in struc tions at any time wit hout no ti ce.

We as su me no lia bi li ty for any er rors or di rect or in di rect da ma ge re sul ting in con ­text with the se ope ra ting in struc tions.

Co py ing, trans la ti on or pub li ca ti on in any form ex cept for per so nal use of pur cha -

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ser re qui res ap pro val from Ster ling Ma te rial Pro cess ing.

All rights re ser ved.

3

SGFE

Tab le of con tents

1. Sa fe ty in struc tions ..........................................1-1

1.1. Ge ne ral.............................................1-1

1.2. For your sa fe ty.......................................1-2

1.3. For the ope ra ting sa fe ty of the equip ment .................1-5

2. Con cer ning the se Ope ra ting In struc tions .......................2-1

2.1. Ge ne ral In for ma ti on ...................................2-1

2.2. War ning Mes sa ges and Sym bols ........................2-2

2.3. Ex pla na tions and De fi ni tions ............................2-3

2.4. No tes on Usa ge ......................................2-4

3. Start-up ....................................................3-1

3.1. Ge ne ral.............................................3-1

3.2. Con trol sys tem .......................................3-2

3.2.1. Ope ra ti on ...................................3-2

3.2.2. Key as signment ..............................3-3

3.3. Swit ching on the con trol sys tem .........................3-3

3.4. Set ting the ba sic pa ra me ters ...........................3-4

3.5. Star ting the con vey ing pro ce du re ........................3-7

3.6. The first con vey ing ope ra tions ..........................3-7

3.7. Vie wing Alarm Mes sa ges ..............................3-8

3.8. Swit ching off the unit ..................................3-9

4. Main ten an ce ................................................4-1

4.1. Ge ne ral.............................................4-1

4.2. Main ten an ce sche du le.................................4-3

4.3. Chec king the di rec ti on of ro ta ti on of the va cu um ge ne ra tor ...4-5

4.4. Te sting the con duit sys tem .............................4-6

4.5. Ad ju sting the suc ti on tube ..............................4-7

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4.6. Clea ning/re pla cing the fil ter car trid ge .....................4-8

4.7. Ser vi cing the ac ces so ries ..............................4-9

4

SGFE

5. As sem bly in struc tions .......................................5-1

5.1. Trans port ...........................................5-2

5.2. In stal la ti on ..........................................5-2

5.3. Ma te ri al feed ........................................5-2

5.4. Suc ti on pipe .........................................5-3

5.5. Pi pe work............................................5-4

5.6. Va cu um ge ne ra tor ....................................5-5

5.6.1. Ro ta ry lobe va cu um pump GDK .................5-6

5.7. In stal ling the ac ces so ries ..............................5-6

5.8. Elec tri cal con nec ti on ..................................5-7

6. Functio nal des crip ti on .......................................6-1

6.1. Ge ne ral.............................................6-1

7. Tech ni cal data ..............................................7-1

8. Spa re parts list..............................................8-1

9. Ac ces so ries ................................................9-1

o con vey or hop per SSE 15 / SSE 30

o con vey or hop per _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

o side vane va cu um pump GSV

o ro ta ry va lue pump GDS

o ro ta ry lobe va cu um pump GDK

o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

10. Elec tri cal ma nu al ..........................................10-1

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o Con nec ti on dia gram no.: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

o Cur rent ly not avai la ble; will be de li ver ed at a la ter date!

5

1. Sa fe ty in struc tions

1.1. General

The se sa fe ty in struc tions ap ply to all per sons wit hin the ran ge of

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ac ti on of the equip ment.

Plea se in form all per sons wit hin the ran ge of ac ti on of the equip ­ment of the di rect and in di rect ha zards con nec ted with the
equip ment.

The se ope ra ting in struc tions are to be used by all per sons as ­sig ned ac ti vi ties con nec ted with the equip ment.

Knowled ge of the En glish langua ge is pre re qui si te.

General

En su re in each case that the ope ra ting per son nel are fa mi li ar
with the ope ra ting in struc tions and the functi on of the equip ­ment.

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Sa fe ty in struc tions 1-1

For your sa fe ty

1.2. For your sa fe ty

General

The ope ra ting per son nel of this equip ment must be at least 16 ye ars old.

Plea se read the se ope ra ting in struc tions ca re ful ly be fo re ta king into ope ra ti on for
the first time. Con tact us should que stions ari se. This avoids in ju ry and da ma ge
to equip ment!

The se ope ra ting in struc tions must be kept avai la ble at all ti mes at the pla ce of
ope ra ti on of the equip ment. Im pro per ope ra ti on re sults in dan ger of ac ci dents!

Plea se note that, for rea sons of cla ri ty, not all con cei va ble ca ses re gar ding ope ­ra ti on or main ten an ce of the equip ment can be co ver ed in the se ope ra ting in ­struc tions.

Plea se ob ser ve all sa fe ty in struc tions and war nings on the equip ment. This
avoids in ju ry and da ma ge to equip ment!

All work on the equip ment is to be car ried out by per sons who se qua li fi ca tions are
spe ci fied in the per tai ning chap ters of the ope ra ting in struc tions. Im pro per ope ra ­ti on re sults in dan ger of ac ci dents!

The pro per wor king clot hes are to be worn du ring any work on the equip ment.
This avoids in ju ry!

The lo cal re gu la tions and re qui re ments per tai ning to this equip ment must be ob ­ser ved.

Dis con nect elec tri cal com po nents from the mains supp ly be fo re work is car ried
out on the se com po nents Cau ti on: Dan ger to life through elec tri cal shock!

Com pi le de tai led ope ra ting in struc tions ba sed on the se Ope ra ting in struc tions
for the se quen ce of pro ce du res to be car ried out on this equip ment. Im pro per
ope ra ti on re sults in dan ger of ac ci dents!

Plea se note that sound le vels ex cee ding 85 db(A) may in the long term da ma ge
your he alth. Use the ap pro pria te ear muffs. This avoids im pair ment of hea ring!

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Sa fe ty in struc tions 1-2

For your sa fe ty

Assembly

Com pa re the con nec ted lo ads with tho se of the mains supp ly. Dan ger of in ju ry
through elec tri cal shock!

When using lif ting gear, plea se ob ser ve the per tai ning re gu la tions. Cau ti on: Dan ­ger of ac ci dents!

Do not mo di fy, add ot her equip ment or chan ge the de sign of the equip ment wit ­hout the ap pro val of the ma nu fac tu rer. Cau ti on: Dan ger of ac ci dents!

At tach ments not supp lied by Ster ling must be ma nu fac tur ed in ac cor dan ce with
sa fe ty re gu la ti on EN 294. Dan ger of ac ci dents!

The equip ment may only be ope ra ted when all the as so cia ted com po nents are
pro per ly con nec ted up and in ac cor dan ce with the re le vant re gu la tions. This
avoids in ju ry and da ma ge to equip ment!

Ope ra te the de vi ce only if all its com po nents are groun ded. Dan ger: ac ci dent
through elec tri cal shock!

So lid par ti cles and dust must be se pa ra ted be fo re en try to the va cu um ge ne ra tor.
This avoids da ma ge to equip ment!

If PVC ho ses are used for con vey ing, they must be groun ded. This avoids in ju ry
and da ma ge to equip ment!

An acous tic co ver should be in stal led when va cu um ge ne ra tors are lo ca ted in
work rooms. This avoids im pair ment of hea ring!

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Sa fe ty in struc tions 1-3

For your sa fe ty

Operation

Ap point an equip ment fo re man to be re spon si ble for the equip ment.

En su re that the ope ra ting per son nel are pro vi ded de tai led in struc ti on in the ope ­ra ti on of the equip ment. Im pro per ope ra ti on re sults in dan ger of ac ci dents!

When the main switch is swit ched off for rea sons per tai ning to sa fe ty, it must be
se cu red against un aut ho ri zed ac ti vat ion. Cau ti on: Dan ger of ac ci dents!

Re pair work may be car ried out by trai ned per son nel only.
Cau ti on: Dan ger of ac ci dents!

Ne ver ope ra te the equip ment when parti al ly dis mant led!
Dan ger! Limbs may be caught in ma chi ne ry! Elec tric shock!

In case of mal functi on, shut down the equip ment im me di ate ly. Have mal functions
cor rec ted im me di ate ly. Dan ger of ac ci dents!

The equip ment is in ten ded only for con vey ing gra nu la ted plas tics and re grinds.
Any ot her or ad di tio nal use is con tra ry to spe ci fi ca tions.

This equip ment is not suit ab le for food pro ces sing.

The sa fe ty in struc tions of the con nec ted ma chi nes must be fol lo wed.

Ex plo si ve ga ses and mix tu res of gas and air must not be con vey ed. Dan ger of ex ­plo si on! Avoids in ju ry or da ma ge to equip ment!

Maintenance

Be fo re star ting main ten an ce work, ap point a su per vi sor.

In form the re spon si ble per son nel be fo re main ten an ce work on the sys tem is
start ed. Cau ti on: Dan ger of ac ci dents!

Dis con nect the equip ment from mains supp ly be fo re star ting main ten an ce pro ce ­du res to en su re that it can not be swit ched on un in ten tio nal ly.
Cau ti on: Dan ger of ac ci dents!

All pi pes, ho ses and scre wed con nec tions should be che cked re gu lar ly for le aks
and da ma ge. Any faults which ari se should be cor rec ted im me di ate ly.
Dan ger of ac ci dents!

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De pres su ri se all com pres sed air pi ping be fo re star ting main ten an ce work.
Dan ger of ac ci dents!

Sa fe ty in struc tions 1-4

For the ope ra ting sa fe ty of the equip ment

1.3. For the ope ra ting sa fe ty of the equip ment

Ne ver chan ge set tings if the con se quen ces are not pre ci se ly known.

Use only ori gi nal Ster ling spa re parts.

Plea se ob ser ve the main ten an ce sche du le.

Keep re cord of all main ten an ce and re pair work.

Plea se note that elec tro nic com po nents may be da ma ged by sta tic disch ar ge.

Check all elec tri cal con nec tions for pro per fit be fo re the equip ment is ta ken into
ope ra ti on for the first time and at re gu lar in ter vals.

Please en sure that the per mit ted op er a tion tem per a ture lies be tween 0 °C and
+45 °C (32°F and 113°F).

Please en sure that the per mit ted stor age tem per a ture lies be tween -25 °C and
+55 °C (-13°F and 131°F).

Note down all set ting data.

Af ter con nec ti on to the elec tri ci ty supp ly has been made, check the ro ta tio nal di ­rec ti on of the va cu um ge ne ra tors (note the di rec ti on in di ca ted by the ar row).

Plea se en su re that all plugs are cor rect ly plug ged in.

The ope ra ting in struc tions of the con nec ted ma chi nes must be fol lo wed.

All com po nents must be suf fi cient ly groun ded.

Plea se note that a com pres sed air supp ly is re qui red for the ope ra ti on of the unit.

Ne ver set a hig her ope ra ting pres su re than 6 bar (87.02 PSI) for the unit (sys tem
over pres su re).

Align the suc ti on tu bes cor rect ly.

Please note that the max i mum per mit ted am bi ent and air tem per a ture on en try to
the vac uum gen er a tor is 40 °C (104°F).

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Sa fe ty in struc tions 1-5

2. Con cer ning the se Ope ra ting In struc tions

2.1. Ge ne ral In for ma ti on

The se ope ra ting in struc tions are ad dres sed to all users of the

»

de vi ce.

The se ope ra ting in struc tions must be used by every per son
char ged with work on the unit.

Ge ne ral In for ma ti on

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Con cer ning the se Ope ra ting In struc tions 2-1

War ning Mes sa ges and Sym bols

2.2. War ning Mes sa ges and Sym bols

The fol lo wing war ning mes sa ges and sym bols are used in the se ope ra ting in ­struc tions:

This sym bol in di ca tes dan ger to life! Fa tal or se ri ous in ju ry is

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pos si ble if the cor re spon ding in struc tions, re gu la tions or war ­nings are not ob ser ved.

L

F

&

$

This sym bol in di ca tes that se ri ous in ju ry is pos si ble if the cor ­re spon ding in struc tions, re gu la tions or war nings are not ob ­ser ved.

This sym bol in di ca tes that ex ten si ve da ma ge to equip ment
is pos si ble if the cor re spon ding in struc tions, re gu la tions or
war nings are not ob ser ved.

This sym bol in di ca tes in for ma ti on im por tant for be co ming fa ­mi li ar with the equip ment, i.e. tech ni cal cor re la tions.

This sym bol in di ca tes that a tech ni cal term is ex plai ned at
this point.

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Con cer ning the se Ope ra ting In struc tions 2-2

Ex pla na tions and De fi ni tions

2.3. Ex pla na tions and De fi ni tions

In this ope ra ting ma nu al, cer tain terms are used re pea ted ly for bet ter cla ri ty.
The re fo re plea se keep in mind that the se terms stand for the ex pla na tions gi ven
here.

Unit

·

“Unit” may de sig na te eit her a sing le de vi ce, a ma chi ne or a plant.

User

·

The user is the per son who uses the unit on his or her own re spon si bi li ty or on the
re spon si bi li ty of so meo ne else.

Ope ra tor

·

The ope ra tor of a unit (pro duc ti on ma na ger, fo re man etc.) is the per son re spon si ­ble for the sum of the pro ces ses. The ope ra tor in structs the users to do so me ­thing.

Ope ra ting ma nu al

·

The ope ra ting ma nu al des cri bes the cor re la tions bet ween se ve ral units, pro ces ­ses or ma nu fac tu ring pro ce du res. The ope ra ting ma nu al must be pre pa red by
the ope ra tor of the units.

Co-ordinator

·

If se ve ral users work on one unit, the “co-ordinator” co-ordinates the pro ces ses.
The co-ordinator must be de sig na ted by the ope ra tor.

Trai ned per son nel

·

Trai ned per son nel are peo ple who are qua li fied by their trai ning to car ry out the
re spec ti ve work in a pro fes sio nal man ner.

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Con cer ning the se Ope ra ting In struc tions 2-3

No tes on Usa ge

2.4. No tes on Usa ge

Ex pe rien ced ope ra tors can be gin di rect ly with the chap ter on “Start-up” if the unit

·

has been pro per ly in stal led.

If the unit has not been in stal led yet, ob ser ve the in struc tions in the chap ter on

·

“As sem bly In struc tions”.

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Con cer ning the se Ope ra ting In struc tions 2-4

3. Start-up

3.1. Ge ne ral

Ge ne ral

This chap ter is di rec ted at the ope ra tor of the equip ment.

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F

This chap ter as su mes ge ne ral skills in dea ling with con vey ing
units and SPS con trol units.

This chap ter as su mes that the functio nal des crip ti on has been
read and un ders tood.

It should be en su red in each and every case that the ope ra tors
have the re le vant skills.

Ex plo si ve ga ses and mix tu res of gas and air must not be con ­vey ed by the va cu um ge ne ra tor. So lid par ti cles and dust must
be se pa ra ted be fo re en try to the va cu um ge ne ra tor.

Check the com pres sed air supp ly if pneu ma tic val ves are
pre sent (5-6 bar (72.52-87.02 PSI) sys tem over pres su re).

Check whet her the plas tic stop pers have been re mo ved from
the suc ti on pipe of the va cu um ge ne ra tor.

Check that the on/off swit ch is in po si ti on ”OFF".

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Start-up 3-1

Con trol system

A BA B

ESC

OK

I: 1 2 3 4 5 6
Mo 08:33

Q: 1 2 3 4 RUN

EE

DD

C C

ESC

OK

B01 : T
T = 01.00s

Ta= 00.00s

3.2. Con trol system

The fa ci li ty’s con trol sys tem is fac to ry-programmed. Ne ver the less, you have to
set spe ci fic va lu es (ba sic pa ra me ters) which are de pen dent on the pro ces sed
ma te ri al, for ins tan ce.

The set va lu es are sa ved and re main sa ved even af ter swit ching off or af ter a po ­wer fail. All en tries are sa ved and can also be vie wed at a la ter point in time. All
mes sa ges are dis play ed in plain text.

A = Lamp “ope ra ti on”

B = Lamp “alarm”

C = Main switch

D = Key “Re set”

E = Con trol unit

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3.2.1. Ope ra ti on

The con trol sys tem is ope ra ted via the
keys “ESC”, “OK” and the ar row keys (A).

Mes sa ges are dis play ed on a four-line
dis play.

In the first dis play line the pa ra me ter de ­sig na ti on is dis play ed.
In the se cond dis play line the set va lue of
the pa ra me ter is di play ed.
In the last dis play line the ac tu al va lue of
the pa ra me ter is dis play ed.

Switch box

A

Start-up 3-2

3.2.2. Key as signment

ESC

OK

Ar row keys
to se lect a va lue

to scroll the menu pa ges
to chan ge a va lue

Pus hing the key “OK”
to se lect a menu, to chan ge va lu es (the cur sor bar jumps to
the first di git of the va lue);
to con firm va lue en tries (with va lue ac cep tan ce).

Swit ching on the con trol sys tem

Pus hing the key “OK”
to lea ve va lue en tries (wit hout va lue ac cep tan ce);
to lea ve the menu “ba sic pa ra me ters”.

3.3. Swit ching on the con trol sys tem

Con nect the con trol sys tem to mains supp ly by the de vi ce plug.

Check that the on/off switch is in po si ti on ”OFF".

F

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Start-up 3-3

3.4. Set ting the ba sic pa ra me ters

ESC

OK

Set Clock
> Set Param

ESC

OK

B01 : T
T = 01.00s

Ta= 00.00s

ESC

OK

I: 1 2 3 4 5 6
Mo 08:33

Q: 1 2 3 4 RUN

OK

OK

ESC

OK

Se lect the menu “ba sic pa ra me ter”.

Se lect “Set Pa ram”.

Set ting the ba sic pa ra me ters

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Sig nal ti mes flap (B01)

(stan dard set ting: 1 se cond).

Chan ges only af ter con sul ta ti on with
the Sterling Service.

Start-up 3-4

Con vey ing time (B05)

ESC

OK

B09 : PAR
LIM = ###

Cnt = ###

ESC

OK

B14 : PAR
LIM = ###

Cnt = ###

ESC

OK

B05 : PAR
LIM = ###

Cnt = ###

OK

OK

OK

En ter the de si red con vey ing time in se ­conds.

Line clea ring (B09)
En ter the de si red line cle ar time in se ­conds.

Set ting the ba sic pa ra me ters

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En ter “0” if no line clea ring val ve is moun ted.

F

Emp ty ing time (B14)

En ter the de si red emp ty ing time in se ­conds.

Start-up 3-5

Blo wer run on time (B17)

ESC

OK

B22 : PAR
Par = ###

Cnt = ###

ESC

OK

B17 : PAR
LIM = ###

Cnt = ###

ESC

ESC

OK

I: 1 2 3 4 5 6
Mo 08:33

Q: 1 2 3 4 RUN

OK

OK

En ter the blo wer run on time in se conds .

Er ror tolerance (B22)

En ter the er ror to le ran ce.

Set ting the ba sic pa ra me ters

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&

Set ting “0”: functi on not ac ti ve
Set ting “1 -###”: an alarm is gi ven when the er ror to le ran ce

rea ches this va lue.

Start-up 3-6

3.5. Star ting the con vey ing pro ce du re

Set the on/off switch in po si ti on ”ON”.

Star ting the con vey ing pro ce du re

&

3.6. The first con vey ing ope ra tions

F

If the hop per loa der re ports a lack of ma te ri al, the con vey ing
is start ed.

Check the ro ta tio nal di rec ti on of the va cu um ge ne ra tors.

Check the line sys tem.

Ad ju sting the suc ti on tube.

Ma te ri al co ming from the hop per loa der du ring the first con ­vey ing may not be used.

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Start-up 3-7

3.7. Vie wing Alarm Mes sa ges

Vie wing Alarm Mes sa ges

&

An alarm is gi ven by stea dy light of the “alarm” lamp.

Pres sing the “Reset” key era ses the stea dy light of the
“alarm” lamp (the “alarm” lamp goes off). The fai lu re is not re ­pai red.

Fai lu res must be re pai red im me di ate ly.

F

Pos si ble events:

- Fault hop per
In the ope ra ting mode “pro be con vey ing”, the le vel of ma te ri al has not rea -

ched the pro be wit hin the set con vey ing time.
Pos si ble cau ses: lack of ma te ri al, fal se con vey ing time set ting or de fec ti ve pro be.
In the ope ra ting mode “time-controlled con vey an ce”, no sig nal chan ge of the
flap switch has oc cur red wit hin the set emp ty ing time.
Pos si ble cau ses: lack of ma te ri al, fal se emp ty ing time set ting or de fec ti ve flap.

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Start-up 3-8

3.8. Swit ching off the unit

Set the on/off switch in po si ti on ”OFF”.

Swit ching off the unit

&

Dis con nect the unit from mains supp ly by the de vi ce plug.

If the unit is swit ched off du ring a con vey ing pro ce du re this
ope ra ti on will be fi nis hed.

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Start-up 3-9

4. Main ten an ce

Ver si on: 64.10-0198GB05WA 02/01

4.1. Ge ne ral

This chap ter is in ten ded for per sons with skills in elec tri cal and

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me cha ni cal are as due to their trai ning, ex pe rien ce and re cei ved
in struc tions.

Per son nel using the in struc tions in this chap ter must be in struc ­ted of the re gu la tions for the pre ven ti on of ac ci dents, the ope ra ­ting con di tions and sa fe ty re gu la tions and their im ple men ta ti on.

En su re in each case that the per son nel are in form ed.

For main ten an ce work ta king pla ce at heights of over
approx.1829 mm. (6 ft.), use only lad ders or si mi lar equip ment
and wor king plat forms in ten ded for this pur po se. At grea ter
heights, the pro per equip ment for pro tec ti on against fal ling must
be worn.

Ge ne ral

Use only suit ab le lif ting gear which is in pro per wor king or der
and load sus pen si on de vi ces with suf fi cient car ry ing ca pa ci ty.
Do not stand or work un der sus pen ded lo ads!

En su re that the elec tric mo tors/switch ca bi nets are suf fi cient ly
pro tec ted against moi stu re.

Use only suit ab le work shop equip ment.

Be fo re star ting main ten an ce work, ap point a su per vi sor.

In form the re spon si ble per son nel be fo re main ten an ce work on
the sys tem is start ed.

Ne ver ope ra te the equip ment when parti al ly dis mant led.

All main ten an ce and re pair work not des cri bed in this chap ter
may only be car ried out by Ster ling ser vi ce per son nel or aut ho ri ­zed per son nel (ap poin ted by Sterling).

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Main ten an ce 4-1

Ge ne ral

L

F

Dis con nect the equip ment from mains supp ly be fo re star ting
main ten an ce pro ce du res to en su re that it can not be swit ­ched on un in ten tio nal ly.

De pres su ri ze all com pres sed air pi ping of the equip ment be ­fo re star ting main ten an ce work.

Plea se ob ser ve the main ten an ce in ter vals.

Be fo re star ting main ten an ce work, cle an the equip ment of
oil, fuel or lu bri cants.

En su re that ma te ri als and in ci den tals re qui red for ope ra ti on
as well as spa re parts are dis po sed of pro per ly and in an en ­vi ron men tal ly sound man ner.

Use only ori gi nal Ster ling spa re parts.

Keep re cord of all main ten an ce and re pair pro ce du res.

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Main ten an ce 4-2

Main ten an ce sche du le

4.2. Main ten an ce sche du le

In iti al ope ra ti on: Check the ro ta tio nal di rec ti on of the va cu um

ge ne ra tors
Check the line sys tem
Ad just the suc ti on tube

Dai ly: Check war ning signs on equip ment for le gi bi li ty

and com ple te ness

Check the oil le vel in the oi ler
Emp ty the wa ter se pa ra tor
Check ope ra ting pres su re of the plant’s supp ly
net work (5-6 bar (72.52-87.02 PSI) sys tem over
pres sure)

Check the oil le vel in ro ta ry val ve pumps
Fol low the ma nu fac tu rer’s ope ra ting in struc tions

Wee kly/month ly: Cle an the fil ter car trid ge

(ac cor ding to the ac cu mu la ti on of dust)

Check that the main switch on the equip ment
is functio ning

Every six months: Re pla ce the fil ter car trid ge

(ac cor ding to the ac cu mu la ti on of dust)

Check the set tings on the le vel pro bes (if pre sent)

Check that all elec tri cal and me cha ni cal
con nec tions fit se cu re ly

Chan ge oil and oil fil ters on the ro ta ry val ve pumps
Fol low the ma nu fac tu rer’s ope ra ting in struc tions

Lu bri ca te the bea rings with high mel ting-point
grea se on the ro ta ry lobe va cu um pumps
Fol low the ma nu fac tu rer’s ope ra ting in struc tions

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Main ten an ce 4-3

Main ten an ce sche du le

Af ter the first 100
hours of ope ra ti on: Chan ge the oil on the ro ta ry val ve pumps
Fol low the ma nu fac tu rer’s ope ra ting in struc tions

Af ter 500 hours
of ope ra ti on: Check oil le vel and con di ti on of the oil in the gear

box of the ro ta ry lobe va cu um pumps
Fol low the ma nu fac tu rer’s ope ra ting in struc tions

Af ter 20,000 hours
of ope ra ti on: Re mo ve old grea se from anti-fric ti on bea ring

of side vane va cu um pump and ap ply fresh grea se
Fol low the ma nu fac tu rer’s ope ra ting in struc tions

The gi ven main ten an ce in ter vals are aver age va lu es.

F

Check whet her in your in di vi du al case the main ten an ce in ­ter vals must be shor te ned.

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Main ten an ce 4-4

Chec king the di rec ti on of ro ta ti on of the va cu um ge ne ra tor

4.3. Chec king the di rec ti on of ro ta ti on of the va cu um ge ne ra tor

Start a con vey ing pro ce du re.

Wait un til the va cu um ge ne ra tor be gins to ope ra te.

Ob ser ve the ro ta tio nal di rec ti on ar row on the va cu um ge ne ra tor hou sing.

Stop the con vey ing pro ce du re.

Wait un til the blo wer has come to a stand still.

Switch off the unit.

If the va cu um ge ne ra tor ro ta tes in the wrong di rec ti on, cor rect the di rec ti on by
chan ging the po les of two pha ses.

Elec tri cal con nec tions should only be car ried out by trai ned

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staff.

Ob ser ve the re gu la tions of your lo cal Elec tri ci ty Board.

The wrong di rec ti on of ro ta ti on may lead to ma jor de fects or
may in ter fe re with the functi on of the va cu um ge ne ra tor.

F

A pro per con vey an ce is not pos si ble.

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Main ten an ce 4-5

Te sting the con duit sys tem

4.4. Te sting the con duit sys tem

De tach the fle xi ble line from the con nec ted ma te ri al take-up as sem bly.

Clo se the open end of the line with your hand.

Start a con vey ing pro ce du re.

Wait un til the va cu um ge ne ra tor be gins to ope ra te; af ter this, the hand should be ­co me sen si bly at ta ched by suc ti on wit hin a few se conds.

If no va cu um can be felt, the line sys tem has a leak.

Stop the con vey ing pro ce du re.

Wait un til the blo wer has come to a stand still.

Switch off the unit.

Check the line sys tem and seal the lea ka ge.

Re-con nect the con vey ing line.

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Main ten an ce 4-6

Ad ju sting the suc ti on tube

4.5. Ad ju sting the suc ti on tube

To gua ran tee a trou ble-free ope ra ting run, the suc ti on tube must be ex act ly ad ­jus ted.

1. The suc ti on tube should be pla ced in the ba sic set ting

In the ba sic set ting, the in ner pipe of the suc ti on tube sticks out of the ou ter pipe

ap prox. 120-160 mm ..................................with Ø 40 mm

. (4.72-6.30 in) with (1.67 in)

approx. 150-180 mm.................................. with Ø 50 mm

.......(5.91-7.19 in) with (1.97 in)

approx. 180-200 mm.................................. with Ø 65 mm

.......(7.19-7.97 in) with (2.66 in)

2. Start the con vey ing pro cess.

3. Ob ser ve the fle xi ble line on the suc ti on tube.

The fle xi ble line must not be des cri bing any pul sa ting mo ve ments.

4. Ob ser ve the fle xi ble line on the se pa ra tor.

The supp ly hose may only move when con vey ing is ta king pla ce.

If conditions (points 3 + 4) are not fulfilled:

Pull the in ner pipe furt her out of the ou ter pipe un til the jer ky con vey ing stops.

If the conditions (points 3 + 4) are fulfilled:

Push the in ner pipe slowly into the ou ter pipe, un til a pul sa ting of the fle xi ble line
or a jer ky con vey ing starts.

Pull the in ner pipe back anot her bit, un til the li nes have stop ped pul sing.

Se lect the ad just ment bet ween the two pi pes in such a way that that the re is al ­ways suf fi cient air flow in the ma te ri al line.

If the con vey ing is pro cee ding sa tis fac to ri ly, tighten the wing screw on the suc ti on
tube.

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Main ten an ce 4-7

4.6. Clea ning/re pla cing the fil ter car trid ge

Stop the con vey ing pro ce du re.

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Switch off the con vey ing sys tem at the main switch.

In ter rupt the mains supp ly.

Set all com pres sed-air li nes at zero pres su re.

&

Loo sen the screw con nec ti on on the fil ter
hou sing (A).

Re mo ve the hou sing lid (A).

Loo sen the screw con nec ti on on the fil ter
car trid ge.

The con vey ing ca pa ci ty is di mi nis hed by a clog ged fil ter car ­trid ge.

Re mo ve the fil ter car trid ge.

Re pla ce the fil ter car trid ge.

Resp.

Use com pres sed air to blow through the
fil ter car trid ge from the in si de to the out si ­de.

Cle an the fil ter hou sing. Use lint-free clea ­ning rags.

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Main ten an ce 4-8

Re-in stall the new/clea ned fil ter car trid ge.

Mount the hou sing lid.

Ser vi cing the ac ces so ries

&

4.7. Ser vi cing the ac ces so ries

Pur cha se or der num ber

fil ter car trid ge: ID 85612

The ope ra ting in struc tions must be fol lo wed.

F

816-4MS

Main ten an ce 4-9

5. As sem bly in struc tions

The se in stal la ti on in struc tions are in ten ded for per sons with

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skills in elec tri cal and me cha ni cal are as due to their trai ning, ex ­pe rien ce and re cei ved in struc tions.

Per son nel using the se in stal la ti on in struc tions must be in struc ­ted in the re gu la tions for the pre ven ti on of ac ci dents, the ope ra ­ting con di tions and sa fe ty re gu la tions and their im ple men ta ti on.

En su re in each case that the per son nel are in form ed.

The in stal la ti on in struc tions pro vi ded in the cor re spon ding ope ­ra ting in struc tions ap ply for all con nec ted equip ment.

Ob ser ve sa fe ty re gu la tions with re gard to lif ting gear hand ling

All in stal la ti on work must be car ried out with the equip ment dis ­con nec ted from elec tri cal po wer and com pres sed air supp ly.

L

816-4MS

For in stal la ti on work ta king pla ce at heights of over approx.
1829 mm. (6 ft.), use only lad ders or si mi lar equip ment and
wor king plat forms in ten ded for this pur po se. At grea ter
heights, the pro per equip ment for pro tec ti on against fal ling
must be worn.

Use only suit ab le lif ting gear which is in pro per wor king or der
and load sus pen si on de vi ces with suf fi cient car ry ing ca pa ci ­ty. Do not stand or work un der sus pen ded lo ads!

Use suit ab le work shop equip ment.

F

As sem bly in struc tions 5-1

Trans port

In stall the equip ment such that all parts are ea si ly ac ces si ­ble; this fa ci li ta tes main ten an ce and re pair work.

5.1. Trans port

For trans port, only the ap pro pria te lif ting gear should be used (eg fork lift or work ­shop cra ne).

Plea se en su re the ade qua te car ry ing ca pa ci ty of the lif ting gear.

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Plea se ob ser ve all sa fe ty re gu la tions for the ope ra ti on of lif ting
gear.

5.2. In stal la ti on

The lo ca ti on of the con trol unit should be cho sen so that a cle ar view of the se pa ­ra tors is gua ran teed from the con trol unit. Thus any mal functions which ari se can
be cor rec ted more ea si ly.

The main switch on the con trol unit must be free ly ac ces si ble at

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all ti mes.

5.3. Ma te ri al feed

Suc ti on pi pes type MV may be til ted by ap prox. 45 de grees in eit her di rec ti on to
the ver ti cal. Ad di tio nal fas te ning is not re qui red.

When con vey ing from the bot tom of sto ra ge con tai ners (si los), a suc ti on box with
1-3 suc ti on pi pes is re qui red.

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The con nec ti on of the suc ti on pi pes must be car ried out with a pie ce of fle xi ble
line to pro vi de suf fi cient mo ve ment.

As sem bly in struc tions 5-2

Suc ti on pipe

Plea se ob ser ve that the length of the hose should not ex ceed 3 m (9.84 ft.) Push
the free pipe end into the fle xi ble line to a depth of ap prox. 4-5 cm (1.67-1.97 in.)
Con nect both parts by me ans of a hose clamp.

5.4. Suc ti on pipe

The suc ti on pipe con sists of an in ner (A) and an ou ter pipe (B) which can be off set
against each ot her.

Push the free pipe end into the flex i ble line to a depth of approx. 4-5 cm (1.67-1.97
in.)

Con nect both parts by me ans of a hose clamp.

Please ob serve that the length of the hose should not ex ceed 3 m (9.84 ft.)

Plea se check that the ou ter pipe is not co ver ed as it pro vi des for un hin de red ac ­cess of am bient air.

When con vey ing from si los, ma te ri al hop pers and sto ra ge
con tai ners, a suc ti on box with 1-3 suc ti on pi pes is re qui red.

F

B A

MV

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As sem bly in struc tions 5-3

Pi pe work

5.5. Pi pe work

When all the po si tions and ar ran ge ment for ma te ri al feed, hop per loa der and blo ­wer are de ter min ed, start as sem bling the pi pe work.

Ri gid pi pes should al ways be laid next to each ot her and the re should be the fol lo ­wing mi ni mum dis tan ces in bet ween:

40 mm (1.67 in.) pipe dia me ter...........75 mm (2.95 in.) cen ter dis tan ce

50 mm (1.97 in.) pipe dia me ter .......... 85 mm (3.35 in.) cen ter dis tan ce

65 mm (2.66 in.) pipe dia me ter ......... 150 mm (5.91 in.) cen ter dis tan ce

Lay ing the pipe can be done on wall bra ckets, ener gy supp ly brid ges or in ducts in
the floor. Com bi na tions are also pos si ble. De vi ces ac cor ding to the lo cal en vi ron ­ment have to be pro vi ded to al low for scre wing of the pi pes if they are laid on. The
dis tan ce bet ween the in di vi du al supp orts should not be more than 3 to 4 m
(9.84-13.12 ft) with smooth pi pes. El bows have to be fas te ned twi ce. Also it is ab ­so lu te ly ne ces sa ry to pro vi de sup port for con vey ing bran ches if the re are any.

Line lay ing is nor mal ly start ed with the suc ti on line, par ting from the blo wer. In iti ­al ly, a pie ce of fle xi ble line of ap prox. 1 m (3.38 ft.) should be pro vi ded to avoid the
trans fer of os cil la tions. Fle xi ble li nes have to be pus hed onto ri gid li nes and con ­nec ti on pie ces at a depth of at least 5 cm (1.97 in.) Use hose clamps for fas te ning.
Pi pes are con nec ted by me ans of wide band clamps and rub ber muffs. Plea se
check that the pi pes are free from gaps and that the clamp is tight. El bows have to
be in stal led (also in the suc ti on line) on joints from the ver ti cal to the ho ri zon tal
and whe re the di rec ti on chan ges. Mi nor di rec tio nal chan ges can be over co me by
ben ding straight li nes. A mi ni mum ben ding ra di us of 500 mm (19.79 in.) should al ­ways be ob ser ved (ener gy loss!).

When as sem bling con vey ing bran ches the mi ni mum dis tan ce bet ween ma chi ne
thro at cen ter and disch ar ge of con vey ing branch must be at least 1.5 m (4.92 ft.)
to avoid too small a ben ding ra di us. When ar ran ging the fle xi ble con nec ti on line
mo ve ments of the pro ces sing ma chi ne du ring ope ra ti on or du ring mould chan ge
have to be ta ken into con si de ra ti on! As sem bly of the con vey ing line is start ed at
ma te ri al ta keup . For line lay ing the same in struc tions gi ven for suc ti on line ap ply.

If PVC ho ses are used for con vey ing, they must be groun ded: draw out the cop per
lead on both ends of the hose and jam it bet ween hose and tube. For fas te ning,
use threa ded clamps.

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As sem bly in struc tions 5-4

5.6. Va cu um ge ne ra tor

Ex plo si ve ga ses and mix tu res of gas and air must not be con -

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vey ed.

So lid par ti cles and dust must be se pa ra ted be fo re en try to the
va cu um ge ne ra tor.

For all work on the equip ment, hea ring pro tec ti on should be
worn.
Avoids im pair ment of hea ring!

The ma nu fac tu rer’s ope ra ting in struc tions should be fol lo wed.

Va cu um ge ne ra tor

L

F

&

An acous tic co ver should be in stal led when va cu um ge ne ra ­tors are lo ca ted in work rooms.

When in stal ling an acous tic co ver, care should be ta ken that
the ven ti la ti on of the ele tric mo tors is not im pe ded.

Ex am ples for the ex pec ted noi se le vel:
side vane va cu um pump GSV

2.2 kW: ap prox. 72 dB (A)

4.0 kW: ap prox. 75 dB (A)
ro ta ry va lue pump GDS

7.5 kW: ap prox. 75 dB (A)

11.0 kW: ap prox. 77 dB (A)
ro ta ry lobe va cu um pump GDK

4.0 kW: ap prox. 78 dB(A)

816-4MS

As sem bly in struc tions 5-5

In stal ling the ac ces so ries

The va cu um ge ne ra tor should be in stal led near the equip ment, to avoid loss of
per for man ce through lea ka ge and fric ti on.

Only fle xi ble con nec tions should be used to join up the pi pes.

The con trol unit should be in stal led in cle ar view of the va cu um ge ne ra tor.

To keep noi se to a mi ni num, we re com mend in stal la ti on in an en clo sed spa ce.

5.6.1. Ro ta ry lobe va cu um pump GDK

The fan is equip ped with a se pa ra te elec tric mo tor which must

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5.7. In stal ling the ac ces so ries

be con nec ted to 24 V.

The ope ra ting in struc tions must be fol lo wed.

F

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As sem bly in struc tions 5-6

5.8. Elec tri cal con nec ti on

The re gu la tions of the lo cal Elec tri ci ty Board must be ob ser ved.

Elec tri cal con nec ti on

»

Be fo re con nec ti on to the elec tri ci ty supp ly, it should be en su red
that the supp ly vol ta ge and the po wer fre quen cy are in ac cor ­dan ce with the data on the name pla te of the ma chi ne.

The elec tri cal con nec ti on may only be car ried out by Ster ling
ser vi ce staff or trai ned per son nel aut ho ri sed by Sterling.

It is not per mit ted for ot her per sons to un der ta ke the elec tri cal
con nec ti on.

Check that the on/off switch is in po si ti on ”OFF".

F

The ope ra ting vol ta ge is 480/3/60
Spe ci al vol ta ges on re quest.

De pen ding on the mo del, the con nec ted load is up to 11.0 kW.

816-4MS

As sem bly in struc tions 5-7

6. Functio nal des crip ti on

6.1. Ge ne ral

This functio nal des crip ti on is in ten ded for all ope ra ting per son -

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nel of the equip ment.

Pre re qui si te for this functio nal des crip ti on is ge ne ral knowled ge
of con vey ing units and SPS con trol units.

En su re in each case that the ope ra ting per son nel are suf fi cient ­ly in form ed.

Ge ne ral

816-4MS

Functio nal des crip ti on 6-1

Ge ne ral

The unit works on the pneu ma tic con vey ing prin ci ple. Ac cor ding to this, a va cu um
ge ne ra tor (A) crea tes a va cu um, which ex tends through the pipe ducts and hose
as sem blies (B), through the se pa ra tors (C) un til it rea ches the ma te ri al take-up
as sem bly (D).
The ma te ri al which has been con vey ed is than se pa ra ted from the air in si de the
se pa ra tor.
De pen ding on con vey or con trol sys tem (E) and hop per loa ders time con vey ing
mode or pro be con vey ing mode with con vey ing time used as mo ni to ring time is
pos si ble.
A fil ter car trid ge (F) in front of the va cu um ge ne ra tor pu ri fies the aspi ra ted air.

&

If the hop per loa der re ports a lack of ma te ri al, the con vey ing is start ed.

Fol lo wing the con vey ing pro cess, if line clea ning ti mes are set, line clea ning ta ­kes pla ce. The line clea ning val ves in ter rupt the flow of ma te ri al and al low air to
flow into the con nec ting pipe. In this way the con nec ting pipe is clea red of ma te ri ­al.

Con vey ing is not pos si ble wit hout mo ve ment of air in the ma ­te ri al line.

816-4MS

Functio nal des crip ti on 6-2

SGFE

7. Tech ni cal data

Ver si on: 64.10-0198GB05TD 02/01

Me thod of fil ling: ..........time con vey ing mode or pro be con vey ing mode

..........................with con vey ing time used as mo ni to ring time

Va cu um ge ne ra tor (de pen ding on the mo del)

Side vane va cu um pump GSV: ............................1.5-4.4 kW

Noi se le vel: .................................... ap prox. 75-78 dB(A)

Ro ta ry val ve pump GDS: ................................4.0-11.0 kW

Noi se le vel: ....................................ap prox. 73-75 dB(A)

Ro ta ry lobe va cu um pump GDK: ..............................4.0 kW

Noi se le vel: .......................................ap prox. 78 dB(A)

Ope ra ting vol ta ge (stan dard): ........................400 V/3 AC/50 Hz

(ot her vol ta ges pos si ble)

Per mis si ble sto ra ge tem pe ra tu re: ........................-25 to +55 °C

.................................................(-13° to +131° F)

Per mis si ble ope ra ting tem pe ra tu re: ........................0 to +45 °C

..................................................(32° to +113°F)

+

816-4MS

Tech ni cal data 7-1

Di men si on sheet SGFE

SGFE

All di men sions are in mm. (in.) Sub ject to al te ra ti on.

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Tech ni cal data 7-2

Di men si on sheet GDK 4 kW

All di men sions are in mm. (in.) Sub ject to al te ra ti on.

SGFE

Di men si on sheet GSV

816-4MS

All di men sions are in mm. (in.) Sub ject to al te ra ti on.

Tech ni cal data 7-3

Di men si on sheet GDS

SGFE

816-4MS

All di men sions are in mm. (in.) Sub ject to al te ra ti on.

Tech ni cal data 7-4

8. Spa re parts list

This spa re parts list is in ten ded to be used only by trai ned per -

»

son nel.

Ot her per sons are not per mit ted to mo di fy or re pair the equip ­ment.

SGFE

816-4MS

Spa re parts list 8-1

SGFE

Pos. ID-No. De sig na ti on

1 93102 pres su re li mi ter val ve (1.5 and 2.2 kW)

93100 pres su re li mi ter val ve (4.0 kW)

2 86308 side vane va cu um pump GSV 4.0 kW

88235 side vane va cu um pump GSV 2.2 kW
83564 side vane va cu um pump GSV 1.5 kW

Optional

84724 ro ta ry lobe va cu um pump GDK 4.0 kW
98148 ma no me ter

92156 ro ta ry val ve pump GDS 5,5 kW
93650 ro ta ry val ve pump GDS 7,5 kW
89430 ro ta ry val ve pump GDS 11,0 kW
98148 ma no me ter

3 85612 fil ter car trid ge

85486 lock nut

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4 83411 con trol unit LOGO

Spa re parts list 8-2

9. Ac ces so ries

¨ con vey or hop per CSE 15 / CSE 30

¨ con vey or hop per _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

¨ side vane va cu um pump GSV

¨ ro ta ry va lue pump GDS

¨ ro ta ry lobe va cu um pump GDK

¨ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

¨ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

¨ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

SGFE

816-4MS

Ac ces so ries 9-1

10. Elec tri cal ma nu al

This elec tri cal ma nu al is in ten ded to be used only by Ster ling

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¨ Con nec ti on dia gram no.: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

¨ Cur rent ly not avai la ble; will be de li ver ed at a la ter date!

ser vi ce per son nel and trai ned per son nel aut ho ri zed by Ster ling.

Other per sons are not per mit ted to mo di fy or re pair the equip ­ment.

SGFE

816-4MS

Elec tri cal ma nu al 10-1