Sterling SSE-2 User Manual

Sterling Material Processing

Operating Instructions

Single Conveying Hopper Loader

SSE-2

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ii

Sterling Material Processing

5200 West Clinton Ave.

Milwaukee, WI 53223

Telephone: [phone]

Fax: [phone]

www.sterlco.com

Technical service:

Service department
Telephone: [phone]

Edition: 02/04

Bulletin #: SM4-615.2

These operating instructions are for*:

(* please fill in personally)

Serial number:

Year of manufature:

Date of Delivery:

Number of delivery:

Date of commissioning:

Location:

Group of machines:

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iii

Sterling Material Processing retains all rights to change the information in these
operating instructions at any time without notice.

We assume no liability for any errors or direct or indirect damage resulting in context
with these operating instructions.

Copying, translation or publication in any form except for personal use of purchaser
requires approval from Sterling Material Processing.

All rights reserved.

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iv

Please note that our address and phone information has changed.
Please reference this page for updated contact information.

These manuals are obsolete and are provided only for their technical information, data and capacities.
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
warnings and precautions.

Parts and Service Department

The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering
design specifications, which will maximize your equipment’s performance 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 manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to
providing excellent customer service.

For immediate assistance, please contact:

• North, Central and South America, 8am – 5pm CST [phone] for drying, conveying, heating and cooling
and automation. For size reduction: [phone].
North America, emergencies after 5pm CST [phone]

North America email: [e-mail]

• Mexico, Central & South America
Email: [e-mail]

• Europe, Middle East & Africa [phone]

Email: [e-mail]

• India [phone]

Email: [e-mail]

• Asia/Australia [phone]

Email: [e-mail]

Sales and Contracting Department

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.

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 non-union installations.

For assistance with your sales or system contracting needs please Call:

North, Central and South America [phone] or [phone] Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa [phone]
India [phone]
Asia/Australia [phone]

Facilities:

ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at
www.acscorporate.com

United States:

ACS Schaumburg – Corporate Offices

1100 E. Woodfield Road
Suite 588
Schaumburg, IL 60173
Phone: + 1 847 273 7700
Fax: + 1 847 273 7804

ACS New Berlin – Manufacturing Facility

2900 S. 160th Street
New Berlin, WI 53151
Phone : [phone]
Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: [phone]

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: [phone]

India

ACS India

Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: [phone]
Fax: + 91 20 40147576

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Table of Contents

1. General instructions......................................................................................................... 1-1

1.1. Warnings and symbols ......................................................................................................................... 1-2

1.2. Explanations and information .............................................................................................................. 1-3

1.3. Legal basis ............................................................................................................................................ 1-3

1.4. Fields of applications............................................................................................................................ 1-3

1.5. Notes on usage...................................................................................................................................... 1-3

2. Safety instructions ........................................................................................................... 2-1

2.1. For your safety...................................................................................................................................... 2-2

2.1.1. General......................................................................................................................................... 2-2

2.1.2. Assembly....................................................................................................................................... 2-3

2.1.3. Operation ..................................................................................................................................... 2-4

2.1.4. Maintenance................................................................................................................................. 2-4

2.2. For the operating safety of the equipment ........................................................................................... 2-5

3. Transport, Assembly and Storage................................................................................... 3-1

3.1. Transport and Packing.......................................................................................................................... 3-2

3.2. Assembly .............................................................................................................................................. 3-2

3.3. Storage .................................................................................................................................................. 3-2

4. Assembly instructions...................................................................................................... 4-1

4.1. Unpacking............................................................................................................................................. 4-2

4.2. Installing the Dump Valve Sensor ....................................................................................................... 4-3

4.3. Attaching the Pickup Wand.................................................................................................................. 4-4

4.4. Mounting............................................................................................................................................... 4-5

4.4.1. Mounting on the processing machine ......................................................................................... 4-6

4.4.2. Mounting onto a machine hopper ............................................................................................... 4-6

4.4.3. Mounting onto mixing hoppers with lateral inlet ....................................................................... 4-7

4.4.4. Mounting onto dosing station DT 30 .......................................................................................... 4-7

4.5. Electrical connection ............................................................................................................................ 4-8

4.6. Installation of the optional SKW proportioning valve........................................................................ 4-9

5. Functional Description .................................................................................................... 5-1

5.1. Sequence of Operation ......................................................................................................................... 5-2

5.2. Controller .............................................................................................................................................. 5-2

6. Operation ......................................................................................................................... 6-1

6.1. Switching on the unit............................................................................................................................ 6-2

6.2. Checking the Flexible Hose ................................................................................................................. 6-2

6.3. Setting the Conveying Time................................................................................................................. 6-3

6.4. Setting the Purge Time (optional)........................................................................................................ 6-4

6.5. Initial Operation.................................................................................................................................... 6-5

6.6. Switching off the unit ........................................................................................................................... 6-5

7. Troubleshooting ............................................................................................................... 7-1

7.1. Alarms................................................................................................................................................... 7-2

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8. Maintenance..................................................................................................................... 8-1

8.1. Maintenance intervals........................................................................................................................... 8-3

8.2. Servicing the Loader............................................................................................................................. 8-4

8.2.1. Changing the sealing ring of the outlet flap ............................................................................... 8-4

8.2.2. Adjusting the dump valve sensor................................................................................................. 8-5

8.2.3. Cleaning the unit.......................................................................................................................... 8-6

8.2.4. Replacing carbon brushes at the motor ...................................................................................... 8-8

9. Technical data.................................................................................................................. 9-1

10. Spare parts list ............................................................................................................... 10-1

10.1. SSE-2, 230 V, 50 Hz ........................................................................................................................ 10-3

10.2. SSE-2, 110 V, 60 Hz ........................................................................................................................ 10-4

10.3. SSE-2, 230 V, 50 Hz with active cleaning ...................................................................................... 10-5

10.4. SSE-2, 110 V, 60 Hz with active cleaning ...................................................................................... 10-5

11. Accessories ..................................................................................................................... 11-1

12. Electrical manual ........................................................................................................... 12-1

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General instructions 1-1

1. General instructions

M These instructions apply to all persons within the range of action of the

equipment.

These operating instructions are to be used by all persons assigned activities
connected with the equipment.

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1-2 General instructions

1.1. Warnings and symbols

The following warnings and symbols are used in these operating instructions:

M This symbol indicates danger to life. Fatal or serious injury is possible if the

corresponding instructions, regulations or warnings are not observed.

L This symbol indicates that serious injury is possible if the corresponding

instructions, regulations or warnings are not observed.

F This symbol indicates that extensive damage to equipment is possible if the

corresponding instructions, regulations or warnings are not observed.

& This symbol indicates information important for becoming familiar with the

equipment, i.e. technical correlations.

$ This symbol indicates that a technical term is explained at this point.

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General instructions 1-3

1.2. Explanations and information

Various terms are used in these operating instructions to ensure clarity. Therefore
please note that the terms used in the text stand for the corresponding explanations
listed below.

• Equipment: ”Equipment” can mean an individual unit, a machine or an installation.

• Operating personnel: The ”operating personnel” are persons operating the
equipment on their own responsibility or according to instructions.

• Operator: The ”operator” of the equipment (production manager, foreman, etc.) is the
person responsible for all production sequences. The operator instructs the operating
personnel of what is to be done.

• Operating instructions: The ”operating instructions” describe the interaction of the
equipment, production sequences or methods. The operating instructions must be
compiled by the operator of the equipment.

• Equipment foreman: When several operating personnel work on one machine, the
”equipment foreman” coordinates the sequences. The equipment foreman must be
appointed by the operator.

• Trained personnel: ”Trained personnel” are persons who, due to their training, are
authorized to carry out the required work.

1.3. Legal basis

See “Manufacturer’s Certificate” resp. “Certificate of Conformity”.

1.4. Fields of applications

Sterling single conveying units are designed for use in facilities that require independent
machine conveying systems. The single conveying units have been developed for
conveying thermoplastic granules. A typical area of application is for processing
machines and drying hoppers with throughputs of up to 400 lbs./hr (180 kg/h).

1.5. Notes on usage

• Experienced operators can begin directly with the chapter on “Start-up” if the unit has
been properly installed.

• If the unit has not been installed yet, observe the instructions in the chapters
“Transport, Assembly and Storage” and “Assembly Instructions”.

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Safety instructions 2-1

2. Safety instructions

M These safety instructions apply to all persons within the range of action of the

equipment, and should be used by all persons assigned activities connected
with the equipment.

Please inform all persons within the range of action of the equipment of the
direct and indirect hazards connected with the equipment.

Knowledge of the English language is prerequisite.

Ensure that all operating personnel are familiar with the operating instructions
and the function of the equipment.

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2-2 Safety instructions

2.1. For your safety

2.1.1. General

To prevent injury and/or damage to equipment, observe the following safety rules:

• Read these operating instructions carefully before operating for the first time. Contact
us should questions arise.

• These operating instructions must be kept available at all times at the place of
operation of the equipment.

• Please note that, for reasons of clarity, not all conceivable cases regarding operation
or maintenance of the equipment can be covered in these operating instructions.

• Observe all safety instructions and warnings on the equipment.

• All work on the equipment is to be carried out by persons whose qualifications are
specified in the pertaining chapters of the operating instructions.

• Wear proper working clothes while performing any work on the equipment.

• The local regulations and requirements pertaining to this equipment must be
observed.

• Disconnect electrical components from the main power supply before work is carried
out on these components

• Compile detailed operating instructions based on these operating instructions for the
sequence of procedures to be carried out on this equipment.

• Please note that sound levels exceeding 85 db(A) may in the long term damage your
health. Use appropriate ear protection to prevent hearing impairment.

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Safety instructions 2-3

2.1.2. Assembly

To prevent injury and/or damage to equipment, observe the following safety rules:

• Compare the connected loads with those of the main supply.

• Use care when using lifting gear, and observe any pertaining regulations.

• Do not modify, add other equipment or change the design of the equipment without
the approval of the manufacturer.

• Attachments not supplied by Sterling must be manufactured in accordance with
safety regulation EN 294.

• Make sure all the accessories and components are properly connected in
accordance with any relevant regulations.

• To prevent electrical shock, operate the device only if all its components are
grounded.

• Do not allow solid particles and dust to enter to the vacuum generator.

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2-4 Safety instructions

2.1.3. Operation

To prevent injury and/or damage to equipment, observe the following safety rules:

• Appoint an equipment foreman to be responsible for the equipment.

• Ensure that the operating personnel are provided detailed instruction in the operation
of the equipment.

• When the main switch is switched off for reasons pertaining to safety, it must be
secured against unauthorized activation.

• Repair work may be carried out by trained personnel only.

• Never operate the equipment when partially dismantled.

• In case of malfunction, shut down the equipment immediately. Have malfunctions
corrected immediately.

• The equipment is intended only for conveying granulated plastics and regrinds. Any
other or additional use is contrary to specifications.

• This equipment is not suitable for food processing.

• The safety instructions of the connected machines must be followed.

• Explosive gases and mixtures of gas and air must not be conveyed.

2.1.4. Maintenance

To prevent injury and/or damage to equipment, observe the following safety rules:

• Before starting maintenance work, appoint a supervisor.

• Inform the responsible personnel before maintenance work on the system is started.

• Disconnect the equipment from main supply before starting maintenance procedures
to ensure that it cannot be switched on unintentionally.

• All pipes, hoses and screwed connections should be checked regularly for leaks and
damage. Any faults that arise should be corrected immediately.

• Depressurize all compressed air piping before starting maintenance work.

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Safety instructions 2-5

2.2. For the operating safety of the equipment

Never change settings if the consequences are not precisely known.

Use only original Sterling spare parts.

Please observe the maintenance schedule.

Keep record of all maintenance and repair work.

Please note that electronic components may be damaged by static discharge.

Check all electrical connections for proper fit before the equipment operated for the first
time and at regular intervals.

The operating temperature range is 32 to +113 °F (0 °C to +45 °C).

The recommended storage temperature range is -13 to +131 °F (-25 °C and +55 °C).

Write down all data that you have entered into the control system.

Please ensure that all plugs are correctly plugged in.

The operating instructions of the connected machines must be followed.

Operate the device only if all its components are grounded.

Never adjust sensors without exact knowledge of their function.

Please note that a compressed air supply is required for the operation of the active
cleaning option.

Compressed air supply for the active cleaning option should not exceed 87 PSI (6 bar)
(active cleaning option only).

Align the suction tubes correctly.

The unit should be installed in such a way that the outlet flap swings at right angles to
the moving direction of the equipment.

The load-bearing capacity of the machine flange should be adhered to.

A level indicator is required when conveying from granulators.

The maximum conveying capacity is up to 400 lbs./hr (180 kg/hr) at 100% operating
time.

The typical conveying capacity is up to 200 lbs./hr (90 kg/hr) at 50 % operating time.

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Transport, Assembly and Storage 3-1

3. Transport, Assembly and Storage

M This chapter is intended for all operating personnel of the equipment.

Personnel using these instructions must be instructed in the regulations for
the prevention of accidents, the operating conditions and safety regulations
and their implementation.

Ensure in each case that the operating personnel are sufficiently informed.

Please inform all persons within the range of action of the equipment of the
direct and indirect hazards connected with the equipment.

Please observe all safety regulations for the operation of lifting equipment.

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3-2 Transport, Assembly and Storage

3.1. Transport and Packing

M Please ensure adequate carrying capacity of the lifting equipment.

The equipment passes rigorous testing in the factory and is packed carefully to avoid
transport damage.

Please check packing on delivery for transport damage.

The inlet and discharge flanges are sealed with plugs, so that no dirt can enter during
transport. Plugs must be removed before assembly.

Packing materials should be disposed of according to environmental laws or reused.

Only use for transport of the equipment a suitable lifting device (e. g. a fork lift truck or a
workshop crane).

Transport must be shock-proofed and free from vibrations.

3.2. Assembly

M Please ensure adequate carrying capacity of the lifting equipment.

Check the carrying capacity of the point of installation, particularly if installed
on a platform.

The place selected for installation should be as free of vibrations as possible.

The main power switch must be freely accessible.

Ground the equipment against electrostatic charging.

3.3. Storage

The control system may only be stored at temperatures from -13 to +131 °F (-25 to
+55°C).

Between delivery and machine commissioning, the equipment should be stored in a dry,
dust-free and vibration-free room.

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Assembly instructions 4-1

4. Assembly instructions

M These installation instructions are intended for persons with skills in electrical

and mechanical areas due to their training, experience and received
instructions.

Personnel using these installation instructions must be instructed in the
regulations for the prevention of accidents, the operating conditions and
safety regulations and their implementation.

Ensure in each case that the personnel are sufficiently knowledgeable about
the equipment.

The installation instructions provided in the corresponding operating
instructions apply for all connected equipment.

Please observe all safety regulations for the operation of lifting gear.

All installation work must be carried out with the equipment disconnected from
electrical power and compressed air supply.

L For installation work taking place at heights of over approx. 6 feet, use only

ladders or similar equipment and working platforms intended for this purpose.
At greater heights, the proper equipment for protection against falling must be
used.

Use only suitable lifting gear that is in proper working order and load
suspension devices with sufficient carrying capacity. Do not stand or work
under suspended loads!

Use only suitable workshop equipment.

F Install the equipment so that all parts are easily accessible; this facilitates

maintenance and repair work.

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4-2 Assembly instructions

4.1. Unpacking

The loader is insensitive to shocks and can be
mounted directly onto the processing machine,
on a machine hopper, a drying hopper or a
dosing and blending unit.

The equipment is delivered as a complete
assembly.

Use the following procedure to prepare the
machine for assembly:

1. Unpack the equipment.

2. Remove the plastic stopper (A) from the
material inlet nozzle.

3. Open the flap (B) and remove the adhesive
tape from the exit flap.

F The controller must be freely accessible.

Figure 1: SSE 2

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Assembly instructions 4-3

4.2. Installing the Dump Valve Sensor

The controller uses a dump valve sensor (A) with a
magnet (B) to determine demand. When the
dump valve is closed, indicating demand, the
magnet is pushed towards the sensor. The
presence of the magnet near the sensor indicates
demand and triggers a new conveying cycle.

When the dump valve is open, indicating that no
material is needed, the magnet is pushed up and
away from the sensor. If the sensor does not
detect the magnet, it does not trigger a new
conveying cycle.

To install the dump valve sensor, insert the
appliance plug of the dump valve sensor into the connector (Figure 3) on the lower side
of the controller.

Figure 3: Lower side of the controller
Figure 2: Dump valve and sensor