Sterling SSL, SSIL User Manual 2

Download

Operation, Installation & Service Manual

SSL and SSIL Series

Sight Glass Hopper Loaders

Important! Read Carefully Before Attempting to Install or Operate Equipment

Part No. 882.00149.00 Revision C Bulletin No. CV1-600

Write down your hopper ________________ ________________

loader 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.

Shipping Information

Unpacking and Inspection

You should inspect your SSL/CSL or SSIL/CSIL 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.

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.

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.

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:

; SSL/CSL Series or SSIL/CSIL Series 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.

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the manufacturer immediately. For shipments in the United States and Canada, call 1 (630) 475-7143; for all other countries, call 001 (630) 475-7143. Include the order number and item. Hold the items until you receive shipping instructions.

Returns

Important!

Do not return any damaged or incorrect items

until you receive shipping instructions from the manufacturer.

Table of Contents

CHAPTER 1: SAFETY ................................................................ 7

CHAPTER 2: FUNCTIONAL DESCRIPTION.............................. 8

2-1 Introduction.................................................................................................................. 8

2-2 Necessary Documents ................................................................................................8

2-3 Equipment Function .................................................................................................... 9

2-4 Models Covered in this Manual ................................................................................... 9

2-5 Standard Operational Features ................................................................................... 9

2-6 Available Options ...................................................................................................... 11

CHAPTER 3: INSTALLATION .................................................. 17

3-1 Work Rules................................................................................................................17

3-2 Safety Considerations ...............................................................................................17

3-3 Necessary Tools........................................................................................................ 17

3-4 Mounting SSL/CSL and SSIL/CSIL Hopper Loaders ................................................17

3-5 Mounting Tips............................................................................................................18

3-6 Attaching the Pickup Wand .......................................................................................18

3-7 Making Compressed Air Connections ....................................................................... 18

3-8 Making Electrical Connections .................................................................................. 18

3-9 Installing the Remote Control Box.............................................................................19

3-10 Adjusting the Proximity Switch ..................................................................................19

CHAPTER 4: SERIES ONE CONTROLLER OPERATION ...... 21

4-1 Pre-Startup Checklist ................................................................................................ 21

4-2 Operating Sequence ................................................................................................. 21

4-3 Starting the Hopper Loader ....................................................................................... 23

4-4 Changing the Conveying Sequence..........................................................................23

4-5 Selecting the Most Efficient Loading Sequence ........................................................ 24

4-6 Shutting Down the Hopper Loader Using the Series One Controller ........................26

CHAPTER 5: SERIES ONE PLUS CONTROLLER OPERATION

.................................................................................... 27

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

5-2 Operating Sequence ................................................................................................. 29

5-3 Series One Plus Controls and Displays ....................................................................29

5-4 Starting Up the Hopper Loader for the First Time Using the

Series One Plus Controller...........................................................................31

5-5 Operating a Hopper Loader at Factory Defaults .......................................................34

5-6 Operating the Proportioning Feature.........................................................................35

5-7 Using the Batch Counter ...........................................................................................36

5-8 Operating in Single-Shot Mode .................................................................................37

5-9 Customizing Series One Plus Controller Operations ................................................37

5-10 Navigating Series One Plus Controller Menus .......................................................... 38

5-11 Series One Plus Operating Parameter Menus .......................................................... 39

5-12 Shutting Down the Hopper Loader using the Series One Plus Controller.................43

CHAPTER 6: SERIES ONE PLUS SPI COMMUNICATIONS .. 44

6-1 SPI Network Functions..............................................................................................44

6-2 Setting Up the SPI Function ...................................................................................... 44

6-3 Operating under SPI Control ..................................................................................... 46

CHAPTER 7: MAINTENANCE .................................................. 47

7-1 Routine Maintenance ................................................................................................ 47

7-2 Replacing Motor Brushes .......................................................................................... 48

CHAPTER 8: TROUBLESHOOTING ........................................ 59

Chapter 1: Safety

SSL/CSL Series hopper loaders and SSIL/CSIL Series sight glass 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

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 hopper loader and related equipment are fully reassembled.

; Only PROPERLY TRAINED personnel familiar with the

information in this manual should work on this equipment.

Chapter 2: Functional Description

2-1 Introduction

SS/CS Series 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. Their 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.

SSL/CSL Series hopper loaders use an integral-mount three-stage centrifugal motor with a quick-disconnect plug power cord. The hopper-mounted junction box is pre-wired to the fieldmounted 115/1/60 control box. The SSL/CSL Series features a high-flow blowback valve to enhance cleaning its acrylic/mesh flat filter, providing excellent filtration of conveying air.

SSIL/CSIL Series sight glass hopper loaders have the features of the SSL/CSL Series hopper loader, but include a high-visibility Pyrex™ sight glass for easy monitoring of material load/ discharge cycles. The sight glass assembly is equipped with an adjustable proximity sensor to ensure full material discharge on each cycle. Like the SSL/CSL Series hopper loader, SSIL/CSIL Series hopper loaders feature a quick-release design; no tools are needed to remove the hopper cover or the sight glass.

2-2 Necessary Documents

The items listed here are required for installation, operation, and maintenance of SS/CS Series hopper loaders. Additional copies are available from the manufacturer.

• This product manual.

• Product manuals for accessories and options selected by the

customer, where installed.

2-3 Equipment Function

SS/CS Series hopper loaders are efficient conveyers of free-flowing pelletized or granular materials 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.

2-4 Models Covered in this Manual

SS/CS Series models are designated by volume and if the unit has the sight glass feature, designated with IL. SSL/CSL06 models are hopper loaders with 0.2 cu. ft. (5.6 liter) capacity; SSIL/CSIL11 models are sight glass hopper loaders with a sight glass capacity of 0.09 cu. ft. (2.55 liters) and a hopper capacity of 0.4 cu. ft. (11.3 liters); see Figures 2 and 4 for more information on capacities.

SS/CS Series models are available in 0.1, 0.2, 0.4, 0.8 and 1.6 cu. ft. (2.8, 5.6, 11.3, 22 and 45 liter) capacities, with or without the 0.09 cu. ft. (2.55 liter) sight glass feature.

Capacity SSL/CSL

Series

SSL/CSL 03 0.1 2.8 3.5 1.5 SSL/CSL 06 0.2 5.6 7.0 3.1 SSL/CSL 11 0.4 11.3 14.0 6.3 SSL/CSL 23 0.8 22 28 12.7 SSL/CSL 45 1.6 45 56 25.4

Series SSIL/CSIL 03 0.1 2.8 3.5 1.5 0.02 (0.57) 0.68 (0.31) SSIL/CSIL 06 0.2 5.6 7.0 3.1 0.09 (2.55) 3.25 (1.48) SSIL/CSIL 11 0.4 11.3 14.0 6.3 0.09 (2.55) 3.25 (1.48)

Cu. ft. Liters Lbs. Kg

Capacity Sight Glass Capacity SSIL/CSIL

Cu. ft. Liters Lbs. Kg Cu. ft (l) Lbs. (Kg)

2-5 Standard Operational Features

SSL/CSL Series Hopper Loaders

• Brushed stainless steel construction with stainless steel product

contact surfaces

•

/8” (about 9.5 mm) high flow blowback valve with electrical quick

disconnect and accumulator

• 1

/2” OD (about 38.1 mm OD) material inlet

• Removable inlets on 0.2, 0.4, 0.8, and 1.6 cu. ft. (5.6, 11.3, 22 and

45 liter) models only

• Glazed polyester reinforced flat filter

• Hopper-mounted junction box with 12 feet (3.6 m) of cable to a

field-mounted 115/1/60 control box

• Material demand/level sensor

• Series One Plus models include a proximity level sensor for volume

filling, built-in proportioning, and a batch counter; SPV/CPV available separately

• High-performance centrifugal motor with electrical quick

disconnect

• 9-foot (2.7 m) power cord

• Aluminum pickup wand with ten (10) feet (3 m) of flexible vinyl

hose and two (2) hose clamps

• SSL/CSL06, SSL/CSL11, SSL/CSL23 and SSL/CSL45 include a

counter-weighted type flapper and accumulator blowback for improved filter cleaning.

SSIL/CSIL Series Sight Glass Hopper Loaders

• Pyrex™ 0.02 cu. ft. (0.57 liter) or 0.09 cu. ft. (2.55 liter) sight

glass. (The SSIL/CSIL 03 uses the smaller sight glass and the SSIL/CSIL 06 and SSIL/CSIL 11 use the larger size).

• Brushed stainless steel construction, with stainless steel product

contact surfaces

• High-performance centrifugal motor

•

/8” (about 9.5 mm) high flow blowback valve with electrical quick

disconnect and accumulator

• Glazed polyester reinforced flat filter

• Aluminum pickup wand with ten (10) feet (3 m) of flexible vinyl

hose and two (2) hose clamps

• Minimum inventory on molding machine

• 9-foot (2.7 m) power cord

• 4” (101.6 mm) square flange on 0.1 cu. ft. (2.8 liter) model

• 7” (177.8 mm) square flange on 0.2 and 0.4 cu. ft. (5.6 and 11.3

liter) models

/2” OD (about 38.1 mm OD) material inlet

• 1

• Hopper capacities of 0.1, 0.2, and 0.4 cu. ft. (2.8, 5.6, and 11.3

liters); side outlet

Note: The Series One Plus controller option upgrade is required

2-6 Available Options

Special Voltages

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

Series One Plus Controller

The Series One Plus controller is a sensor-driven volume-fill cycle controller with available proportioning outputs. It permits operator programming of blowback pulses for optimum operating efficiency. It keeps an accurate count of up to 9,999 batches, even in the event of a power failure, and the controller includes a No Fill alarm to notify the operator of an empty gaylord or lack of material flow.

• Hopper-mounted junction box with 12 feet (3.6 m) of cable to a

field-mounted 115/1/60 control box

• Removable inlets on 0.2 and 0.4 cu. ft. (5.6 and 11.3 liter) models

• Accumulator blowback is standard on 0.2 and 0.4 (5.6 and 11.3

liter) models only

• Series One Plus models (option upgrade) include a proximity level

sensor for volume filling, built-in proportioning, control capacity, and a no-convey alarm

for remote proportioning valve (SPV/CPV) operation;

SPV/CPV is sold separately.

Remote Proportioning Valve

The remote proportioning valve (SPV/CPV) option lets you economically and efficiently proportion two (2) different free-flowing granulated materials in a material conveying system. The most common application is mixing virgin and regrind materials in a plastic processing operation. SPV/CPV installation options include a wall-mount bracket and floor stand.

Figure 1: Typical SSL/CSL Series Hopper Loader

• 10” Clearance Cutout with (6) ¼” bolt

holes equally spaced on an 11” circle.

SSL/CSL03 Hopper Loader

We are committed to a continuing program of product improvement.

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

Figure 3:

SSL/CSL Series Dimensions, Specifications, and Maximum Machine-Side Throughput

American Standards

Capacity Dimensions in inches

cu. ft. A B C D E F

0.1

0.2

0.4

0.8 30 ¼” 10 ½” 12” 4”

1.6

7.0

5.75

173/8” 63/8”

211/8” 51/2”

271/8” 111/2”

36 ½” 17 ¾” 12” 4”

12”

12” 4” 91

13/4” 63/8”

/8”

141/8”

14 1/8”

Metric Standards

Capacity Dimensions in cm

liters A B C D E F

2.8 17.8 44.1 16.2 30.5 4.4 16.2

5.6 53.7 14.0 30.5 10.1 23.2

11.3 68.9 29.2 30.5 10.1 23.2

22 77 27 12 10.1 36

c 5/16”/0.313” (8.0 mm) -diameter holes; two (2) places equally spaced. d 5/16”/0.313” (8.0 mm) -diameter holes; four (4) places equally spaced. e 1/4”/0.250” (6.3 mm) -diameter holes; six (6) places equally spaced;

J is standard mounting hole pattern.

14.6

93 45 12 10.1 36

SSL/CSL Series Specifications

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

no. cu. ft. liters lbs. Kg (FLA) inches

SSL/CSL03 0.1 2.8 3.5 1.5 11 1½” SSL/CSL06 0.2 5.6 7.0 3.1 11 1½” SSL/CSL11 0.4 11.3 14.0 6.3 11 1½” SSL/CSL23 0.8 22 28 12.7 10 1 ½” SSL/CSL45 1.6 45 56 25.4 10 1 ½”

38 mm 38 mm 38 mm 38 mm 38 mm

lbs. Kg

47 65 67 75 80

22 30 31 34 36

SSL/CSL Series Maximum Machine-Side Throughput

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

Model Non-Proportioning c Proportioning

number lbs./hr. Kg/hr. lbs./hr. Kg/hr.

SSL/CSL03 150 68 SSL/CSL06 500 227 400 182 SSL/CSL11 1,000 454 800 364 SSL/CSL23 1,500 680 1,200 544 SSL/CSL45 1,700 771 1,350 612

c Maximum throughput beside-the-press loading; includes 12-foot (3.6 m) vertical lift. We are committed to a continuing program of product improvement. Specifications, appearances, and dimensions are subject to change without notice.

Not available

Figure 4: Typical SSIL/CSIL Series Sight Glass Hopper Loader

SSIL 06 Model

SSIL/CSIL03 Sight Glass

Hopper Loader

SRIL01.DWG

HOPSRIL.DWG

We are committed to a continuing program of product improvement.

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

Figure 5:

SSIL/CSIL Series Dimensions, Specifications, and Maximum Machine-Side Throughput

American Standards

Capacity Dimensions in inches

cu. ft. A B C D E -sq. G -sq. H -sq. I -sq. c J

0.1

/8”

17” 6

/8” 13/4” 4” 2” 11/4” 21/2” 2”

0.2 351/4” 191/2” 91/8” 3” 7” 31/2” 23/4” 51/2” 3”

0.4 411/4” 253/4” 91/8” 3” 7” 31/2” 23/4” 51/2” 3”

Metric Standards

Capacity Dimensions in cm

liters A B C D E -sq. G -sq. H -sq. I -sq. c J

2.8 74.0 41.9 16.2 4.4 10.2 5.1 3.2 6.3 5.1

5.6 89.5 49.5 23.2 7.6 17.8 8.9 7.0 14.0 7.6

11.3 104.8 65.4 23.2 7.6 17.8 8.9 7.0 14.0 7.6

c 0.281” (7.1 mm) -diameter holes; four (4) places equally spaced.

SSIL/CSIL Series Specifications

Selection load Inlet/outlet Square mounting Shipping

Hopper capacity Sight glass capacity Model amps range flange dimensions weight

cu. ft.

0.1

0.2

0.4

liters

2.8

5.6

11.3

lbs.

3.5

7.0

14.0

1.5

3.1

6.3

cu. ft.

0.02

0.09

liters

0.57

2.55

lbs.

0.68

3.25

0.31

1.48

no. FLA inches

SSIL/ CSIL03 SSIL/ CSIL06 SSIL/ CSIL11

Full- Specifications

inches

4”

7”

101.6

177.8

11 1½”

38 mm

lbs.

SSIL/CSIL Series Maximum Machine-Side Throughput

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

Model Non-Proportioning c Proportioning

number lbs./hr. Kg/hr. lbs./hr. Kg/hr.

SSIL/CSIL03 150 68

Not available

SSIL/CSIL06 500 227 400 182 SSIL/CSIL11 1,000 454 800 364

c Maximum throughput beside-the-press loading; includes 12-foot (3.6 m) vertical lift.

We are committed to a continuing program of product improvement.

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

Chapter 3: Installation

3-1 Work Rules

Install, operate, and maintain this equipment according to all applicable work and safety codes. This includes, but is not limited to: OSHA, NEC, CSA, and any other local, national, and international regulations. Obey these specific work rules:

; Read and follow these instructions when installing, operating and

maintaining this equipment. If the instructions become lost or unreadable, obtain a new copy from the manufacturer.

; Only qualified persons should work on or with this equipment.

; Work only with approved tools and devices.

; Disconnect and lock out electric power before maintaining or

servicing a hopper loader. If the unit is installed with a power cord that can be unplugged, unplug it. If the unit is permanently wired to a power main, have a fused power disconnect, capable of being locked in the OFF position, installed.

3-2 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.

3-3 Necessary Tools

; Hand drill

; Pop-rivet gun

/16” (about 4.8 mm) -diameter rivets

;

3-4 Mounting SSL/CSL and SSIL/CSIL Hopper Loaders

You can mount your SSL/CSL or SSIL/CSIL 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 the equipment and uses the same mounting holes as previous models.

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

We are not responsible for equipment damage

from excessive processing machine vibrations.

3-5 Mounting Tips

Important!

• 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.

3-6 Attaching the Pickup Wand

Slide the flex hose onto the material inlet and pickup wand. Use the hose clamps supplied to secure the flex hose. The flex hose should not cover the aeration holes on the pickup wand.

The pickup wand needs no adjustment for most applications. Insert it into the material to be conveyed and it will work.

Some applications require a more defined air-to-material ratio. Cover one or more of the holes at the top of the pickup wand.

3-7 Making Compressed Air Connections

Your SSL/CSL or SSIL/CSIL 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 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

/8”-diameter pipe or tubing when making connections.

3-8 Making Electrical Connections

The controller you selected is shipped pre-wired to the SSL/CSL or SSIL/CSIL Series hopper loader. Units are supplied with a power cord with plug wired to the control unit, ready to plug into an appropriately grounded three-prong 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 SSL/CSL or SSIL/CSIL Series 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.

3-9 Installing the Remote Control Box

Optional-Series One Plus Controller Only

The remote option permits mounting a control up to 9 feet (2.75 m) from the primary control box. Both controls remain operational.

! WARNING

HAZARDOUS ELECTRICAL CURRENT PRESENT.

To avoid burn or electrocution hazard, disconnect electrical power before installing this option!

1. Install the SSL/CSL or SSIL/CSIL Series hopper loader.

2. Select a location for the remote box and mount it securely.

3. Plug the cable supplied into the 25-pin receptacle on the hopper loader controller. Route the cable to the remote box so it doesn’t interfere with processing operations. Observe all applicable electrical codes.

4. Connect the cable to the receptacle on the remote control enclosure.

Both controls are now fully operational.

• Main power supervision is available on the hopper-mounted

control only.

3-10 Adjusting the Proximity Switch

SSIL/CSIL Series Sight Glass Loaders with Series One Plus Controllers Only

The proximity switch, mounted through the side of the hopper loader tank, senses when the hopper loader is full. It is factory-set to sense most conveyed materials accurately, and

provides volume-fill control. When the hopper loader is full, the LED on the proximity switch should light and trigger the dump sequence.

If the switch does not reliably sense the material you are conveying, adjust switch sensitivity. Turn the potentiometer (or pot) clockwise to increase sensitivity, counterclockwise to decrease sensitivity.

Chapter 4: Series One Controller Operation

4-1 Pre-Startup Checklist

; Are all electrical connections correct, secure, and to code?

; Is the compressed air connection secure and safe?

; Is the hopper level and mounted securely?

; Are the flex hose and pick-up wand secure?

; Can the material level switch activate without obstruction?

; Can the material discharge valve swing without obstruction?

4-2 Operating Sequence

1. Blowback sequence.

2. Motor starts.

3. Flapper discharge valve seals under vacuum.

4. Material conveys.

5. Hopper loader hopper 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 hopper 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 resumes automatically.

Figure 6: Series One Graphic Panel

BVUP

MPBEFS

SERIES ONE

OFF

A0542127

4-3 Starting the Hopper Loader

1. Insert the pickup probe into the material supply.

2. Turn on compressed air to the unit.

3. Plug in power to the control enclosure.

4. Move the power switch on the Series One graphic panel to the

ON position.

4-4 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

safety-conscious technician.

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 hopper! Figures 7 and 8 list loading times and number of blowback pulses in each sequence. Use the chart as your model; select a sequence that suits your needs.

ONLY by a qualified,

To select a sequence (see Figures 7 and 8 on the following pages):

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.

4-5 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.

Figure 7: Conveying Dip Switch Chart, Program A0541578 SSL/CSL 03 and SSIL/CSIL03 Models

12 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

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

BLOWBACK OFF OFF OFF OFF OFF OFF OFF OFF

PULSES OPEN OPEN OPEN OPEN

14 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

BLOWBACK

PULSES OFF OFF OFF OFF OFF OFF OFF OFF

OPEN OPEN OPEN OPEN

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

PULSES

OFF OFF OFF OFF

OPEN OPEN OPEN OPEN

1.5 SECONDS 3.0 SECONDS 6.0 SECONDS

ON ON ON ON

9 SECONDS

ON ON ON ON ON ON ON ON

20 SECONDS

ON ON ON ON ON ON ON ON

40 SECONDS 45 SECONDS 50 SECONDS

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

12 SECONDS 15 SECONDS 18 SECONDS

25 SECONDS 30 SECONDS 35 SECONDS

4.0 SECONDS

55 SECONDS

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

Figure 8: Conveying Dip Switch Chart, Program A0536814 SSL/CSL 06, 11, 23 and 45 and SSIL/CSIL 06 and 11 Models

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

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

BLOWBACK OFF OFF OFF OFF OFF OFF OFF OFF

PULSES OPEN OPEN OPEN OPEN

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

PULSES

15 SECONDS 10 SECONDS 20 SECONDS 25 SECONDS

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

55 SECONDS 60 SECONDS 70 SECONDS

OFF OFF OFF OFF OFF OFF OFF OFF

OPEN OPEN OPEN OPEN

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

PULSES

OFF OFF OFF OFF

OPEN OPEN OPEN OPEN

80 SECONDS 90 SECONDS 100 SECONDS 120 SECONDS

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

Note: Figure 9 contains two (2) different programs (6 and 7

blowback pulses).

4-6 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.

-Notes-

Chapter 5: Series One Plus Controller Operation

The Series One Plus controller is an optional controller that includes the following features:

• Sensor-driven volume fill cycle to assure full load discharge for

each cycle

• Operator programming of blowback pulses to optimize efficiency

• Accurate fill cycle counts up to 9,999 on the batch counter to assist

in estimating material usage

• No Fill alarm with automatic shutdown notifies the operator of an

empty material source or lack of material flow; saves motor brushes and reduces maintenance

• Proportioning capability

5-1 Pre-Startup Checklist

; Are all electrical connections correct, secure, and to code?

; Is the compressed air connection secure and safe?

; Is the hopper level and mounted securely?

; Are the flex hose and pick-up wand secure?

; Can the material discharge valve swing without obstruction?

Figure 9: Series One Plus Graphic Panel

CLEAR

VACUUM

BVUP

MPBEFS

SERIES ONE PLUS

ADJUSTMENTS MADE WHILE RUNNING

SCROLL START/STOP

MATERIAL "A"

MATERIAL "B"BLOWBACK

MENU ADJUSTMENTS AND INSTRUCTIONS:

PROPORTIONING ADJUSTMENTS

UNTIL % OF MAT'L "B" DISPLAYED

ADJUST % OF MAT'L "B"

SAVE NEW SETTING

BATCH COUNTER RESET

UNTIL 4-DIGIT BATCH CNTR IS

DISPLAYED

RESETS BATCH COUNTER TO 0000

CLEAR ERROR

CLEAR AN

MENU TITLE (FACTORY SETTING)

[ ]

# OF BLOWBACK PULSES : 0-16 (3) PULSES

[ ]

% OF MAT'L "B" : 0-100% (0%) MAT'L "B"

[ ]

PROPORTIONING CYCLE TIME : 0-60 (0) SEC.

[ ]

ER.1 "NO CONVEY" : 1-8 CYCLES (3) 0=NEVER

[ ]

EXTERNAL CONTROL

AUXILARY PROX SWITCH

[ ]

SPI NETWORK OPERATION

A0541568

0-360 (60) SEC.MAXIMUM LOAD TIME :

SEE O & I MANUAL

MENU UPDATING (WHILE STOPPED)

SCROLL THROUGH MENUS 1-8 TO DESIRED MENU

DISPLAY MENU'S CURRENT SETTINGS

ADJUST MENU'S SETTING

SAVE NEW SETTING

5-2 Operating Sequence

1. Blowback sequence.

2. Motor starts.

3. The flapper discharge valve seals under vacuum.

4. Material conveys.

5. Hopper loader hopper 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 hopper loader remains idle until the material level in the bin drops and frees the discharge valve. Steps 1 through 8 in the loading sequence listed here resume automatically.

5-3 Series One Plus Controls and Displays

Series One Plus Controller Keys

UP Key

Press the

DOWN Key

Press the

UP key to increment up parameter values.

DOWN key to decrement down parameter values.

CLEAR

UP Key and DOWN Key—Press Together

CLEAR

Press the

UP key and DOWN key together simultaneously while turning on power to

reset to factory default values.

SCROLL

SCROLL Key

SCROLL

Press the

SCROLL key to display:

• available menus when the controller is in Standby mode.

• operations screens such as batch counter and SPV settings when the

controller is operating.

START/STOP

START/STOP/SELECT/SET Key

Press the

START/STOP

START/STOP/SELECT/SET key to:

• start the hopper loader

• stop the hopper loader

• select parameters from menu screens

• set parameters

Series One Plus Controller Indicators

LED Screen

The red LED screen is a four-character alphanumeric display. It displays system statuses, menus, and variable values for operating the hopper loader.

VACUUM

The VACUUM indicator lights when the unit is in Vacuum mode.

VACUUM Indicator

MATERIAL "A"

The MATERIAL “A” indicator lights when the Material A port is open.

MATERIAL “A” Indicator

BLOWBACK

The BLOWBACK indicator lights when the air solenoid is open.

BLOWBACK Indicator

MATERIAL "B"

The MATERIAL “B” indicator lights when the Material B port is open.

MATERIAL “B” Indicator

5-4 Starting Up the Hopper Loader for the First Time Using the Series One Plus Controller

Non-Proportioning Models

1. Insert the pickup wand into the material supply.

2. Turn on the compressed air to the hopper loader.

3. Apply power to the controller.

Note: Press and hold the

simultaneously while applying power to restore all factory defaults.

As the controller powers up, the screen displays in succession:

•

PLUS

for three seconds

CLEAR

UP key and DOWN key together

• the software version number

• the standby mode display.

4. Press the hopper loader.

The vacuum motor conveys material until the proximity sensor indicates the hopper loader is full or the factory-pre-set default maximum vacuum time of sixty seconds passes, whichever comes first. The VACUUM and MATERIAL “A” LEDs light and the LED display shows the elapsed conveying time.

START/STOP

START/STOP/SELECT/SET key to start the

n.nn

Note: You can adjust the maximum vacuum time from 0 to 360

seconds. See Section 5-11, Menu 1.

When the proximity sensor trips or sixty (60) seconds elapses, the vacuum motor shuts off for three (3) seconds to relieve vacuum in the hopper and to allow the material to dump.

The BLOWBACK LED flashes and the screen displays

----

as a four (4) -pulse blowback cycle occurs.

Note: You can adjust number of blowback pulses from 0 to 16 pulses.

See Section 5-11, Menu 2.

The conveying cycle repeats automatically until the Bin Full switch senses that the material receiver (machine hopper) is full. The hopper loader stops in Standby mode and the screen displays

FULL

until the machine bin level drops and automatic operation

resumes.

Notes: • If the Series One Plus screen displays the

Er. 1

No Convey error code and shuts down after three (3) conveying cycles, but you do not have a material supply problem, then you need to lengthen the maximum vacuum time to fill the hopper sufficiently to trigger the proximity sensor. See Section 5-11, Menu 1.

• The maximum number of consecutive unsuccessful

conveying cycles before an alarm condition occurs is adjustable from 0 to 8 cycles. See Section 5-11, Menu 5.

First Time Startup for Proportioning Models

1. Insert the pickup wand into the material supply.

2. Turn on the compressed air to the hopper loader.

3. Apply power to the controller.

Note: Press and hold the

CLEAR

UP key and DOWN key together

simultaneously while applying power to restore all factory defaults.

As the controller powers up, the screen displays in succession:

•

PLUS

for three seconds

• the software version number

n.nn

• the standby mode display.

SCROLL

4. Press the

SCROLL key repeatedly until the screen displays 3,

the percentage of Material B menu.

5. Press the

START/STOP

START/STOP/SELECT/SET key to select this

menu.

6. Press the

press the

UP key to increase the percentage of material B;

DOWN key to decrease the % of material B.

7. When the screen displays the percentage of Material B you want,

START/STOP

press the value.

8. Press the

START/STOP/SELECT/SET key to set that

START/STOP

START/STOP/SELECT/SET key to start the

hopper loader.

The Vacuum LED lights and the vacuum motor conveys material until the proximity sensor indicates the hopper loader is full or sixty seconds passes, whichever comes first.

The LED display shows the elapsed conveying time.

Note: You can adjust the maximum vacuum time from 0 to 360

seconds. See Section 5-11, Menu 1.

The MATERIAL “A” and MATERIAL “B” LEDs alternate on and off as set in Steps 4 to 6 above. This indicates the proportioning valve cycle.

Example: If the percent of Material B was set at 50% in Step 4, the

MATERIAL “A” and MATERIAL “B” LEDs alternate ON for ten second periods; this equals 50% of the factory-default thirty (30) -second proportioning cycle.

Note: The proportioning SPV total cycle time is adjustable; see Section

5-11, Menu 4 for more information. This time is not the same as total vacuum time. To see the relationship between these two time parameters, see Figure 10, Proportioning Cycle.

When the proximity sensor trips or sixty (60) seconds elapses, the vacuum motor shuts off for three (3) seconds to relieve vacuum in the hopper and to allow the material to dump.

The BLOWBACK LED flashes and the screen displays

----

as a four-(4) -pulse blowback cycle occurs.

Note: You can adjust number of blowback pulses from 0 to 16 pulses.

See Section 5-11, Menu 2.

The conveying cycle repeats automatically until the Bin Full switch senses that the material receiver (machine hopper) is full. The hopper loader stops in Standby mode and the screen displays

FULL

until the machine bin level drops and automatic operation

resumes.

5-5 Operating a Hopper Loader at Factory Defaults

Series One Plus Controller Models

The Series One Plus controller factory-set defaults are suitable for most conveying requirements.

Install your SS/CS Series hopper loader, apply power, press the operation begins. The hopper loader loads itself until full, then dumps and repeats, pausing only when the machine bin below it is full.

The screen displays the vacuum timer while the vacuum motor is on. If the hopper loader is a PP proportioning model, follow the instructions in Section 5-6 below.

Stop your hopper loader at any time by pressing the

5-6 Operating the Proportioning Feature

Series One Plus Models Only

The proportioning feature allows layering of two materials in the machine bin below the hopper loader. Install the hopper loader and put both the material pickup wands in the material supply gaylords and follow the instructions that follow.

Adjusting Proportioning While the Hopper Loader is in Standby Mode

START/STOP

START/STOP key.

START/STOP key and

1. When the standby mode displays, press the

until the Proportioning Menu displays as

2. Press the

START/STOP

START/STOP/SELECT/SET key to access

SCROLL

SCROLL key

Menu 3.

The current percentage of Material B displays.

3. Press the

UP key or the DOWN key to change the setting

as needed.

4. When the percentage of Material B you want displays, press the

START/STOP

START/STOP/ SELECT/SET key to set it.

- or -

Press the

SCROLL

SCROLL key to leave the menu unchanged.

Adjusting Proportioning On the Fly During Operation

1. While the hopper loader is operating, press the until the screen displays the percent of Material B as

SCROLL

SCROLL key

P. nn

2. Press the

3. When the percentage of Material B you want displays, press the

Note: “On-the-fly” adjustments range between 1% and 99%. To set the

5-7 Using the Batch Counter

The Series One Plus controller features a batch counter you can view during operation. The batch counter provides a rough approximation of total material throughput.

Viewing the Batch Counter

While the hopper loader is operating and while the screen displays the vacuum timer display:

UP key or the DOWN key to change the value

as needed.

START/STOP

START/STOP/ SELECT/SET key to set it.

- or -

Press the

SCROLL

SCROLL key to leave the menu unchanged.

The screen then displays the Vacuum Timer menu.

percentage of Material B from 0% to 100%, stop the Series One Plus controller and reset proportioning while the unit is in Standby mode, as described in the previous section.

 Press the

batch counter.

The screen remains on the batch count display until you press the SCROLL key again.

SCROLL

SCROLL key until the screen displays the four-digit

SCROLL

To return to the vacuum timer screen:

 Press the

SCROLL

SCROLL key again.

The screen reverts to the vacuum timer display.

Resetting the Batch Counter

(

To reset the batch counter to zero

 Press and hold both the

simultaneously any time the batch counter is displayed.

The batch counter resets to zero ( vacuum timer display.

5-8 Operating in Single-Shot Mode

1. Disconnect the Bin Full reed switch sensor and, in its place, wire

a normally closed proximity switch.

2. Install a proximity switch in the machine bin at the highest level you want the material to reach.

CLEAR

UP key and DOWN key together

) and the screen reverts to the

• The Series One Plus controller fills the machine bin until

material covers the proximity switch.

FULL

• The screen displays

until the material level drops

below the proximity switch.

The hopper loader then resumes operation automatically.

5-9 Customizing Series One Plus Controller Operations

The full-feature control gives you complete control over the loading process. You can gain access to adjustable parameters by using the Series One Plus menu system as shown in Figure

9. You can then fine-tune hopper loader operation at this point to fit the exact requirements of your process as required.

5-10 Navigating Series One Plus Controller Menus

You’ll always enter the menu system when the screen displays

START/STOP

This screen displays at startup before you press the

START/STOP/SELECT/SET key

to start the hopper loader, and displays again when you press the

AEC

on the controller screen.

START/STOP

START/STOP/SELECT/ SET key to stop the hopper loader.

To enter the menu system:

 When the screen displays

AEC

, press the

SCROLL

SCROLL key to enter

the menu system.

The screen displays

, for Menu 1.

 Press and hold the

menus.

SCROLL

SCROLL key to scroll through the eight (8)

If you scroll past a menu you want:

 Press and hold both the

DOWN key and the

together simultaneously to scroll backwards through the menus.

SCROLL

SCROLL key

When the menu you want displays:

START/STOP

 Press the

START/STOP/SELECT/SET key to gain access to

the menu.

The screen changes to display the current setting of the menu you selected.

To adjust the current menu parameter:

 Press the UP key or the DOWN key until the screen displays

the parameter value you want.

 Press the

START/STOP

START/STOP/SELECT/SET key.

The new setting is stored in the battery-backed RAM memory.

If you decide that you don’t want to modify the current setting of a parameter:

SCROLL

 Press the

SCROLL key to abort the change.

The change is aborted and the

AEC

To return all parameters to factory default values:

 Turn off the Series One Plus using the green power switch.

 Press and hold both the

CLEAR

UP key and DOWN key together

simultaneously as you turn on the Series One Plus green power switch.

All menu parameters are restored to factory default values.

5-11 Series One Plus Operating Parameter Menus

Menu 1 Maximum Vacuum Cycle Time

0 to 360 Seconds, Default = 60 Seconds

For volume-fill operation, the Maximum Vacuum Cycle Time menu lets you set the maximum vacuum motor time during a conveying sequence. If the level sensor in the hopper

loader does not detect a full loader when the time you set elapses, the vacuum motor stops and the loader dumps. Increase this time setting if it takes longer than sixty (60) seconds to fill the loader.

screen displays again.

Note: To optimize operation, set the timer in this menu to approximately

ten (10) seconds longer than the time it takes to fill the loader under your current conveying conditions.

To determine how long it takes to fill the loader, watch the timer

count up during operation. When the display changes to - - - (dashes), the loader is full. Add ten (10) seconds to the value displayed right before the display changes to

- - - - (dashes).

For time-fill operation, more frequent loading cycles, or less material conveyed per cycle, you can set this parameter so the vacuum motor stops and the loader dumps before it is full. Set the

timer as needed, and be sure to disable the alarm (Menu 5 set to zero [0 ]) to prevent tripping

Er.1

the No-Convey alarm

Menu 2 Number of Blowback Pulses

0 to 16 Pulses, Default = 4 Pulses

The Number of Blowback Pulses menu lets you:

• control the number of blowback pulses discharged from the

compressed air solenoid during the hopper dump sequence

• increase the number of pulses if the material conveyed exhibits

bridging problems or otherwise dumps slowly

• decrease the number of pulses to optimize the cycle time and

increase throughput when conveying free-flowing material

Menu 3 Percentage of Material B

0 to 100 Percent, Default = 0 Percent

PP Models Only

The Percentage of Material B menu lets you increase or decrease the percentage of Material B in the proportioning cycle.

Menu 4 SPV Total Cycle Time

0 to 60 Seconds, Default = 30 Seconds

PP Models Only The SPV Total Cycle Time menu lets you:

• control the duration of a complete proportioning cycle—this time is

not the same as the vacuum time; the vacuum and proportioning timers operate concurrently as shown in Figure 10.

• decrease the SPV total cycle time to increase the layering of the

two materials in the hopper loader as it fills

• increase the SPV total cycle time to reduce the layering of the two

materials in the hopper loader as it fills

Example: If the percent of Material B (Menu 3 ) is set at 20% and the SPV

total cycle time (Menu conveys for twenty percent (20%) of 40 seconds, or eight (8) seconds. Material A conveys for the remaining 32 seconds.

) is set at 40 seconds, Material B

Figure 10: Proportioning Cycle

Menu 5 Error After n Cycles

0 to 8 Cycles, Default = 3 Cycles

The Error After n Cycles menu lets you:

• control the number of unsuccessful loading cycle attempts

(maximum vacuum timer times out and proximity sensor does not

Er. 1

sense a full hopper) before the

error message displays

• increase to prevent alarms while you refill the material supply on

high throughput processes

• decrease to get earlier warning of material supply problems

• disable (

) if you are using a short maximum vacuum time for

less-than-full dumps

Menu 6 External Activation

Enable/Disable, Default = Disable (

The External Activation menu lets you:

• enable or disable recognition of the external system control contact

)

• disable for stand-alone operation

• enable if the hopper loader is in a central system and the external

enable contact is in use

Menu 7 Auxiliary Proximity Switch

Enable/Low Bin Op/Ignore, Default = Ignore (

The Auxiliary Proximity Switch menu lets you:

• enable a customer-supplied auxiliary proximity switch (2 )

This proximity switch is typically mounted low in the machine bin below the hopper loader, and is wired into the hopper loader as shown in Figure (14). When enabled, if the proximity switch senses

an empty machine bin, the screen displays the and an optional alarm activates. The hopper loader does not stop.

)

Er. 2

error message

Note: When operating in this mode, the

startup or after material changes. To clear the error code and silence the alarm, if installed, press the Clear key combination by

Er. 2

error message displays at

pressing and holding both the together simultaneously.

CLEAR

UP key and DOWN key

• enable a customer-supplied auxiliary proximity switch (1 )

This proximity switch is typically mounted low in the machine bin below the hopper loader, and is wired into the hopper loader as shown in Figure (14). When enabled in this mode, the hopper loader fills the machine bin below it, then stops operation.

Operation does not resume until the auxiliary proximity switch senses that the material level has dropped below the proximity switch. The hopper loader then refills the machine bin.

• disable a customer-supplied proximity switch (

Set this parameter to

if you aren’t using an auxiliary proximity

switch or if you won’t be disabling an installed auxiliary proximity switch.

Menu 8 SPI Communication Enable

Enable/Disable, Default = Disable (0 )

The SPI Communication Enable menu lets you:

• enable the SPI communication function (1 ) if the hopper loader

has the SPI communication option installed and is on an SPI network

• disable the SPI communication function (

) if the SPI option is

installed, but the hopper loader is not currently on an SPI network

5-12 Shutting Down the Hopper Loader using the Series One Plus Controller

START/STOP

START/STOP/SELECT/SET key to stop the hopper

 Press the

loader.

For maintenance or for a long-term shutdown, unplug the unit from the power source and shut off the compressed air supply.

Chapter 6: Series One Plus SPI Communications

6-1 SPI Network Functions

The Series One Plus controller equipped with the SPI communications option lets you operate the controller on a network con-forming to Version 3.01 or later of the SPI protocol specification.

When installed on an SPI network, SS/CS Series hopper loaders, as well as other auxiliary processing machines, can be controlled by an injection molding machine (IMM) or an operator at the IMM controls. Two (2) SPI interchangeable communication ports are provided for easy connection into any daisy chain-type SPI network.

Series One Plus controllers with the SPI option support all required parameters of an SPI network, and some of the “non-required” parameters, too. The supported parameters are:

• Echo (system use only)

• Version

• Status, process

 Processing flag

 Low material alarm (with auxiliary proximity switch

installed)

 High vacuum alarm (central system units only)

 No Convey alarm

• Mode, material

 Machine on/off

 Alarm acknowledgment

• Set point, Material A load time

• Set point, Material B load time

• Blanket poll (system use only)

Remember to properly terminate the first and last units on an SPI network. If the Series One Plus controller is the first or last unit in the daisy chain,

terminate the transmission line by placing the jumper on JMP1 as shown here.

6-2 Setting Up the SPI Function

You’ll need to set several Series One Plus controller parameters before network communication can occur. These parameters are set in expanded service menus.

To gain access to expanded service menus, disconnect and unplug the SS/CS Series hopper loader, open the control box, and place a jumper across the SERVICE pins. Close the box and re-apply power. You now have six (6) additional menus available; three (3) of these menus are related to SPI operation.

Jumper ON Jumper OFF

Menu 8 SPI Enable/Disable & Loopback Test

Range = 0 to 1, Default = 0

When the expanded service menus are enabled, an additional parameter becomes available on

this menu. Set this parameter to

to enable SPI communications. Set it to 2 to perform an

internal self test. Disconnect all communication cables before performing the internal self-

test; no loopback cable is needed.

Note: To exit the self-test, you’ll need to perform a complete reset:

reapply power to the control while pressing both the

CLEAR

key and DOWN key together simultaneously. All parameters reset to the factory defaults so make a note of the parameter settings you want to retain.

If the Series One Plus screen alternates displays of the numbers

and

170

, a self test is successful. This condition continues

until you do a complete reset. During the test, the number continuously transmits out the port. When the controller receives

, it echoes a

170

Menu 9 SPI Address

Range = 32 to 254, Default = 32

Each auxiliary device on an SPI network must be assigned a unique address to identify it to the IMM controlling the network. Do not assign the same address to any two auxiliary machines on the network, or line contention will occur.

Menu 10 SPI Baud Rate

Range = 300 to 19,200 bps, Default = 4,800 bps

The baud rate in bits per second (bps) is the data transmission rate. All units on the network must be set at the same baud rate. In general, this rate should be set to the fastest common

speed available to the controllers on the network where satisfactory communication occurs.

6-3 Operating under SPI Control

If you enabled the SPI function by setting the Menu 8 set value

, and you press the

SCROLL

SCROLL key, the screen displays

SPI

instead of displaying

vacuum time. All control is now through the SPI network, and your SS/CS Series hopper loader now operates as instructed by the IMM control.

Press the

START/STOP

START/STOP/SELECT/SET key to view vacuum time, blowback pulse

settings, proportioning percentage, and batch count. SPI is still in control, so return the display

SPI

before leaving the machine unattended.

You can stop the Series One Plus controller in the normal manner by pressing the

START/STOP

START/STOP/SELECT/SET key, but it may restart at any time if so instructed by the

CLEAR

IMM control. To avoid this condition, press both the

together simultaneously while the screen displays

To re-enable, set Menu

set value to 1.

SPI

. This disables SPI communication.

UP key and DOWN key

Figure 11

Typical SPI Network Wiring Diagram

Chapter 7: Maintenance

7-1 Routine Maintenance

Cleaning Filters

Check the condition of the filter 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 cause the discharge flapper valve to stay open, critically reducing overall system effectiveness. The discharge flapper valve requires proper venting; a clogged filter prevents proper flapper valve operation.

Replace the filter if it shows any signs of wear. You can obtain replacements and spares 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 cover.

! 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 hose reduces 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:

SS/CS Series hopper loaders that convey very abrasive and/or very dusty materials may require more frequent maintenance.

7-2 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.

SS/CS Series 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

BEFORE servicing!

WEAR SAFETY GLASSES

BEFORE performing this

procedure!

Use a stable platform if working above floor level.

Removing Old Motor Brushes

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.

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.

Seating Motor Brushes

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

Option 1

 Run the SS/CS Series 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.

Option 2

 Connect two (2) SS/CS Series 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.

-Notes-

Figure 12: Typical SSL/CSL 03 Series Hopper Loader - Exploded View

Figure 13: SSL/CSL 03 Series Hopper Loader Parts List

Refer to Figure 12 on the previous page for parts location

Item Quantity Part no. Description

1 1 A0556521 FLG, MT, ADPT

3 4 1 A0556513 CVR, WELD, 6” ID, SSTL 5 1 A0541543 GSKT, SILC, SGLS

6 7 1 A0541036 BOX, GANG, SGL, 4X2X2, UL 8 9 1 A0003254 WSHR, REDUC, 75˚ X .50” STEEL

10 1 A0003217 CDUT, NIP, ½” REGAL, #791

11 1 A0548359 PLUG, HEYCO, BLK, 5/B, #2663

12 3 A0541039 CORD, GRIP, ½”, .270-.480 #3231

13 1 A0556820 GSKT, U-CHNL, N PRN, .38 X .20 X .05W

14 1 A0541038 BOX, GANG, PLU, ½” NPT, UL

15 1 A558805 SW, ASSY, NC, LVL SNSR

16 1 A0558503 FLAP, DISCH, SS

17 4 W00002373 WSHR, FLAT, WI 3/16”, 100 PCS/3

18 2 W00016426 NUT, STOP, ¼-20, PLD

19 2 A0553718 SCR, SHC, SS, ¼-20 X ¾

20 2 A0556622 SCR, CAP, HEX, SOC, HD, 10-32X 1/2

21 1 A0559402 SCR, FLAT, CSLINK, 10-32X3/8, NYLOC

22 1 A0556544 CVR, SHRD, MTR

23 1 A0555771 NIP, S.S. 3/8” X 1˚ CLS

24 1 A0555770 NIP, S.S. 3/8” 3˚ LONG

25 1 A0555769 FTG, SS304, EL, 90, 3/8

26 3 A0533900 NUT, RIVET, STL, 1D-32, FLUSH

27 10 W00017594 HOSE, FLEX, CLR, VINYL, 1.5”

28 SEE VOLTAGE OPTIONS

29 2 W00001917 CLP, HOSE, DIX332, 1.56-2.50

30 1 A0560901 FLTR, SRL/I-1.0, POLY, FELT, GLAZED

31 1 A0505648 GROM, BLK, 0.5625X0.25X

32 1 A0533933 PICK, MATL, AL, SGL TUBE 1.5”

33 7 A0536966 CONN. WIRE NUT, IDEAL #AO-A1

34 .16 A0535193 TBG, HTSHRNK, 0.75ID, O.81 OD, 48” L

6 1 A0544850 MTR, 115V,2-STG,LAMB,11B212-00 36 1 A0544850 ASSY,CNTRL,SER 1,115 37 1 A0555792 SPLC, BUTT, PANDUIT, #PSN 16-M

28 1 A0556547 VLV, SOL, 3/8”, #JSF8210G1, 120V 39 1 A0558085 CORD, CONN, FEMALE, 33” GRAY 40 1 A0558086 CORD, CONN, MALE, 9”, GRAY

41 1 A0556087 CORD, CONN, MALE, 33” BLACK 42 1 A0558088 CORD, CONN, FEMALE, 9”, BLACK

1 A0553741 CONE, WELD, 6” ID, SSTL

1 A0556534 FLTR, FLAT, CLOTH, 6” OD

SEE VOLTAGE OPTIONS

1 A0541037 BOX, GANG, SGL, CVR, BLNK, GSKT

115 VAC Options

Figure 13: SSL/CSL 03 Series Hopper Loader Parts List (Continued)

230 VAC Options

34 .16 A0535193 TBG, HTSHRNK, 0.75ID, 0.81OD, 48”L 6 1 A0542190 MTR, 230, 2-STG, LAMB, 116125-01 36 1 A0544851 ASSY, CNTRL, SER, 1.230

37 1 A0555792 SPLC, BUTT, PANDUIT, #PSN16-M 28 1 A0556608 VLV, SOL, 3/8”, #JSF8201G1, 240/60 39 1 A0559414 ASSY, CORD, BLACK, FEMALE, 9” LONG

40 1 A0559415 ASSY, CORD, BLACK, MALE, 33” LONG 41 1 A0559416 ASSY, CORD, GRAY, FEMALE, 33” LONG 42 1 A0559417

ASSY, CORD, GRAY, MALE, 9” LONG

Figure 14: Typical SSL/CSL Series Hopper Loader, Version 2 - Exploded View

Figure 15: Typical SLC Series Hopper Loader Parts List, Version 2

Refer to Figure 14 on the previous page for parts location.

Item Quantity Part no. Description

1 1 A0563504 CONE, WELD, 9” DIA., SSR/SSL/CSL06

1 A0563505 CONE, WELD, 9” DIA., SSR/SSL/CSL11

1 A0535506 CONE, WELD, 14” DIA., SSR/SSL/CSL23 1 A0563507 CONE, WELD, 14” DIA., SSR/SSL/CSL45

2 1 A0559449 TUBE, INLET/POUTLET, 1 ½”, SSX06-11

3 1 A0560919 ACCUMULATOR, 3/8” NPT

4 2 A0563513 GASKET, THROAT, SEAL, SSR/SSL/CSL

5 1 A0567621 FLANGE, MTG., 12” DIA., SSL/CSL 03-45 6 1 A0556546 ORNG, SIL, 3.234 ID. X 0.139 THK

7 1 A0563516 BRACKET, J BOX, SRC/SLC 02-16

8 1 A0541036 BOX, SINGLE GANG, 4 X 2 X 2

9 1 A0541037 COVER, BOX, SINGLE GANG, 4 X 2

1 A0565925 FILTER, SSL/CSL/ I-02/04, POLY, GLAZED

10 1 A0565930 FILTER, SSL/CSL/ I-08/16, POLY, GLAZED

11 4 A0541039 CORD GRIP, ½”, .270-.480

12 1 A0541038 PLUG, BOX, GANG, ½” NPT

13 1 A0003254 WASHER, REDUCER, .75” X .5”

14 1 A0003217 NIPPLE, CONDUIT, ½” NPT 15 1 A0548359 PLUG, NYLON, 5/8”

1 A0556514 COVER, WELD, 9” ID SSTL, SSL/CSL06/11

16 1 A0565254 COVER, WELD, 14” ID SSTL, SLC23/45

17 3 A0556517 BOLT, J, 10-32 X 5.25L

18 1 W00020081 MOTOR, VACUUM, 115V

1 W00020082 MOTOR, VACUUM, 230V

1 W00020083 MOTOR, SPARE BRUSHES, 115V

1 W00020176 MOTOR, SPARE BRUSHES, 230 V

19 3 A0555771 FITTING, NIPPLE, 3/8”, CLS., SSTL

20 2 A0555769 FITTING, NIPPLE, 3/8”, ELBOW, SSTL 21 1 A0566970 FITTING, NIPPLE, 3/8” X 6”, SSTL

22 1 A0541543 GASKET, SILICONE, 3.75 OD X .188 THICK

23 1 SEE CHART VALVE, SOLENOID, 3/8”

24 1 A0567620 ASSEMBLY, 4” ANGLED THROAT S.S, SSL/CSL 02-16

25 1 A0533925 SWITCH, PROX 26 2 A0567628 SCREW, BTNHD PHILLIPS, #6-32 X ½ LG. S.S

27 2 FT. W00000890 HOSE, RUBBER, BLK, ¼” X 1/16”

28 1 A0533924 MAGNET CERAMIC

29 1 A0567627 SCREW, FLTHD, PHILLIPS, #6-32 X ½” LG. S.S

30 1 A0567624 VENT, LOUVER, 2” DIA. SSR/SSL/CSL 31 10’ W00017594 HOSE, FLEX, 1.5”, CLEAR VINYL

32 2 W00001917 CLAMP, NOSE, 1.5” – 2.5”

33 1 A0533933 WAND, PICK UP, 1.5” ALUMINUM

34 3 A0069197 NUT, STOP, PLD, 10/32

45 2 A0003215 CA, TIES, STD, 75” BUNDLE, 18# 46 1 W00018618 SCR, 10-32 X ½” , SELF TAPPING

47 7.5” A0102623 WIRE, 600V, GRE/YLW, 18GA

48 1 A0535118 TBG, NPRN, 80-DUR, 5.O” OD X 0.94 WALL

49 1 A0535193 TBG, HTSHRNK, 0.75 ID, 0.81 OD, 48” L

50 2 A0003236 FEMAL SPADE TERM—SIZE 14 51 3 W00017962 SCR, SHC, ¼-20 X 5/8, W/PATCH

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

GASKET SELECTION

Item Quantity Part no. Description

52A 1 W00012559 GSKT, THRT, EPT, BLACK, 4”, STD TEMP 52B 1 W00018024 GSKT, THRT, SILICONE, ORANGE, 4”, HI-TEMP 52C 1 W00016136 GSKT, THRT, NEOPRENE, WHITE, 4”, STD, TEMP (FDA)

Figure 16: Typical SSIL/CSIL Series Sight Glass Hopper Loader - Exploded View

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

Figure 17: SSIL/CSIL Series Sight Glass Hopper Loader Parts List

Refer to Figure 16 on the previous page for parts location.

Item Model no. Quantity Part no. Description

SSIL/CSIL03 1 A0553717 PLATE, MACH, TOP, ALU, SRI/IL03

SSIL/CSIL06/11 1 A0553725 PLATE, MACH, TOP, ALU, SRI/IL06/11

SSIL/CSIL03 1 A0553741 CONE, WELD, 6” ID, SSTL, SSR03

SSIL/CSIL06 1 A0553742 CONE, WELD, 9” ID, SSTL, SSX06 SSIL/CSIL11 1 A0553743 CONE, WELD, 9” ID, SSTL, SSX11 SSIL/CSIL03 1 A0556531 FILTER, FLAT, WIRE, 6” OD, SSR/I03

SSIL/CSIL03 1 A0556822 GASKET, U-CHANNEL, NEOPRENE, .38 X .20 X .06 W

SSIL/CSIL06/11 1 A0556535 FILTER, CLOTH, 9” OD, SSL/CSL/IL06/11

SSIL/CSIL03 1 A0556513 COVER, WELD, 6” ID, SSTL, SSR03

SSIL/CSIL06/11 1 A0556514 COVER, WELD, 9” ID, SSTL, SSL/CSL/IL06/11

5. SSIL/CSIL06/11 1 A0553728 ORNG, SIL, 2.234 ID X 0.139 THK

6. SSIL/CSIL06/11 1 A0556504 TUBE, IN/OUT, 1.5”, SSX06/11

SSIL/CSIL03 1 A0556544 COVER, SHROUD, MTR, SSL/CSL/IL01 SSIL/CSIL03 1 A0542189 MOTOR, 115 V, 2-STG, LAMB, 116212-00

SSIL/CSIL06/11 1 W0020081 MOTOR, 120 V, 3-STG, AMETEK-IS14787

8. SSIL/CSIL06/11 3 A0556517 J-BOLT, 10-32 x 5.25L, SSL/CSL06-45

SSIL/CSIL03 2 A0553714 GASKET, BODY, SIL, SSI/IL03

SSIL/CSIL06/11 2 A0553722 GASKET, BODY, SIL, SSI/IL06/23

10.

11.

12.

13. All 8 A0553718 SCREW, SHC, SS, 1/4-20 x ¾

14.

15. All 1 A0541543 GASKET, SILC, SGLS, MVH01X

16.

17. All 1 A0541036 BOX, GANG, SGL, 4 x 2 x 2, UL WETLOC

18.

19. All 1 A0548359 PLUG, HEYCO, BLACK, 5/8, #2663

20. All 1 A0003254 REDUCTION WASHER, .75” X .50” STEEL

21. All 5 / 2 A0541039 CORD, GRIP, 1/2”, .270-.480 #3231

22. All 1 A0541037 BOX, GANG, SGL, CVR, BLNK, GSKT

28.

29. All 2 A0556529 SCREW, RTRCT, 1/4-20, SCO #47116220

31. All 1

32. All 2 A0556822 CAP SCREW, HEX,SOC, HD, 10-32X ½

SSIL/CSIL03 1 A0553727 SIGHT GLASS, PYREX, SSI/IL03

SSIL/CSIL06/11 1 A0553726 SIGHT GLASS, PYREX, SSI/IL06/23

SSIL/CSIL03 4 A0553715 SUPPORT ROD, BODY, ALU, SSI/IL03

SSIL/CSIL06/11 4 A0553723 SUPPORT ROD, BODY, ALU, SSI/IL06/23

SSIL/CSIL03 1 A0553712 BASE, MACH, BODY, ALU, SSI/IL03 SSIL/CSIL03 2 A0553728 ORNG, SIL, 2.234 ID X 0.139 THK SSIL/CSIL03 1 A0553710 BASE, MACHINE MOUNT, THRT, SSI/IL03

SSIL/CSIL06/11 1 A0553720 BASE, MACH, BOCY, ALU, SSI/IL06-23

SSIL/CSIL06/11 4 W0002373 FLAT WASHER, WI, 3/16”, 100 PCS/#

SSIL/CSIL03 1 A0553713 BRACKET, JBOX/PROX, ALU, SSI/IL03

SSIL/CSIL06/11 1 A0553721 BRACKET, JBOX/PROX, ALU, SSI/IL06-23

SSIL/CSIL03 1 A0003217 CDNUT, NIP, 1/2”, #CN 50

SSIL/CSIL06/11 1 A0003217 CDNUT, NIP, 1/2”, REGAL #791

SSIL/CSIL03 1 A0556503 FLAP, DISCHARGE, SS, SSR03

SSIL/CSIL06/11 1 A0553731 FLAP, DISCHARGE, SS, SSXX06-11

A0542138 PROXIMITY SWITCH, 115 VAC, KI-2015-BBOR/NI A0556548 PROXIMITY SWITCH, 24 VDC, KI-3015-FNKG/NI

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

Figure 18: Typical SSIL/CSIL 03 Series Sight Glass Hopper Loader – Exploded View

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

Figure 19: SSIL 03 Series Sight Glass Loader Parts List

Refer to Figure 18 on the previous page for parts location.

ITEM QTY PART NO. PART DESCRIPTION

1 1 A0556531 FLTR, FLAT, WIRE, 8” OD 2 1 A0556820 GSKT, U-CHNL, NPRN, .38 X .20 X .06 W 3 2 A0556822 SCR, CAP, HEX, SCC, HD, 10-32 X 1/2 4 2 A0556529 SCR, RTRCT, ¼-20, 500 # 471162210 5 1 A0553717 PL, MACH, TOP, ALU 6 4 A0553715 ROD, SUPT, BODY, ALU 7 2 A0553714 GSKT, BODY, SIL 8 1 A0553727 GLAS, SIGHT, PYREX 9 1 A0553712 BASE, MACH, BODY, ALU 10 1 A0553713 BRKT, JBOX/PROX, ALU 11 2 A0553728 CRNG, 5IL, 2.234 ID X 0.139 THK 12 1 A0553710 BASE, MACH MOUNT, THRT 13 1 A0003254 RDUC, WSHR, .75” X .50” STEEL 14 1 A0003217 CDUT, NIPPLE, ½” 3CN 50 15 1 A0548359 PLUG, HEYCO, BLK, 5/8 #2663 16 1 A0541038 BOX, GANG, SNGLE, 4X2X2, UL 17 1 A0558548 SW, PROX, 30 MM, 24V, NO/NC, 3K15208 18 2 A0541038 BOX, GANG, PLUG, ½” NPT, UL 19 2 A0541039 CORD, GRIP, ½”, .270-.480 33231 20 1 A0541037 BOX, GANG, SNGLE, COVER, BLNK, GSKT 21 1 A0556503 FLAP, DISCHARGE, SS 22 1 A0553741 CONE, WELD, 6” ID, SSTL 23 1 A0556513 CVR, WELD 5” ID, SSTL 24 1 A0541543 GSKT, SILC, SGLS 25 1 --- SEE OPTIONS 26 3 A0533900 NUT, RIVET, STL, 10-32, FLUSH 27 1 A0565770 NIP, 5.5, 3/8” X 3” LONG 28 1 A0585769 FTG, SS3D4, EL, 90, 3/8 29 1 A0555771 NIP, 5.5..3/3” X 1” CLS 30 1 A0556545 VLV, SOL, ASCO, 3/8”, 8210G1, 115 V 31 1 A0556544 CVR, SHRD, MTR 32 2 W00018618 SCR, 10-32, SELF TAPPING 34 3 A0559418 SCR, MTR, SHRD, 10-32 X ½ 35 8 A0553718 SCR, SHC SS, ¼-20 X 3/4

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

Chapter 8: Troubleshooting

SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Standard Series One Controllers

Problem

Hopper loader does not work.

Vacuum motor does not work.

Possible cause Solution

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 sensor arm.

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.

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.

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Standard Series One Controllers Cont’d.

Problem

Blowback does not work properly.

Hopper does not completely fill.

Power light does not work.

Hopper over-fills repeatedly.

Possible cause Solution

Increase air pressure to at

Air pressure is too low.

least 80 psi (551.6 kPa/5.52 bars).

Air supply to blowback is restricted.

Blowback valve assembly is not connected to controller.

Control wiring connections are loose on the circuit board.

Solenoid valve or valve coil has failed.

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.

Material supply is low. Refill material supply.

Select a more suitable Selected conveying sequence is too short.

sequence from the 16

selections; see Section 4-4 on

for more information. Material probe not properly positioned in material supply.

Adjust material probe at

material pickup point.

Adjust material probe to Material probe not adjusted for flow characteristics of material.

compensate for flow

characteristics; see Section

3-8 for more information.

Obstructions in supply line.

Filter is dirty.

Filter is clogged, holding open the flapper discharge valve.

Terminal connection is loose.

Clear all obstructions in the

line.

Clean or replace filter as

needed.

Replace filter as needed.

Secure terminal connections

on the terminal board. Light is burned out. Replace light. Wire has been cut. Replace wire; replace light.

Select a more suitable The loading sequence is too long.

sequence from the 16

selections; see Section 4-4 for

more information.

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

SSL/CSL, SLC, and SSIL/CSIL Series Hopper Loaders with Optional Series One Plus Controllers

Problem

No LED display.

AEC

is displayed at power-

up, but vacuum motor

doesn’t start when the

START/STOP

START/STOP/SELECT/

key is pressed. The

SET

screen continues to display

AEC

Control and display appear to operate normally, but the vacuum motor never starts.

Control and vacuum motor are operating normally, but the blowback cycle isn't working. The blowback solenoid clicks.

Possible cause Solution

No power to control box.

Plug in power cord; check

main disconnect. Power switch is off. Turn ON control box. External fuse 1FU is blown Replace fuse 1FU. Internal fuse FU2 is blown Replace fuse FU2. TB1 is disconnected or loose. Reconnect or tighten TB1. Ribbon cable to the display is loose.

Tighten ribbon cable; check

both ends. Loose wiring in the control. Check and tighten wiring. Circuit board has failed. Replace circuit board.

Bin full sensor reed switch is tripped.

Misaligned bin full sensor reed switch magnet. Bin full sensor reed switch has failed. Bin full sensor reed switch wiring is loose/disconnected.

Wait for machine bin material

level to drop, then manually re-

start the hopper loader.

Realign magnet.

Replace.

Repair the wiring fault.

TB2 is loose or disconnected. Re-connect or tighten. Ribbon cable to the display is loose or disconnected.

Re-connect or tighten.

Defective keypad. Call the Service Department. Vacuum motor unplugged from

the control. Vacuum time is set to zero (0)

on Menu

The vacuum motor has failed.

Plug in the vacuum motor.

Reset Menu

to an appropriate time. Repair or replace vacuum motor as needed.

Solid-state relay has failed. Replace. The circuit board has failed. Call the Service Department.

No or insufficient compressed air.

Fix compressed air supply. Connect to 80 psi (551.6 kPa/

5.5 bars) supply.

Restricted compressed air line. Find and fix restriction.

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Optional Series One Plus Controllers Cont’d.

Problem

Control and vacuum motor are operating normally, but the blowback cycle isn't working. The blowback solenoid makes no sound.

Hopper doesn't fill completely.

Proximity switch trips before tank is full.

Possible cause Solution

The blowback valve is unplugged. The number of blowback pulses on Menu 2 is set to zero.

Plug in the blowback valve cable.

Restore Menu 2 to an appropriate value.

TB1 is loose or disconnected. Secure TB1. Solenoid valve or its coil has failed.

Repair or replace as needed.

The circuit board has failed. Call the Service Department. Material supply is low. Fix material supply problem. Material wand is not properly

positioned in material supply.

Material wand not adjusted for the flow characteristics of the material conveyed.

Obstructions in supply line.

Filter is dirty.

Filter is clogged, holding open the flapper discharge valve.

Vacuum time is set too low.

Material residue buildup on proximity sensor. Proximity sensor sensitivity is set too high.

Material possesses excessive static properties.

Control wiring connections on circuit board are loose.

Adjust material wand at material pickup point. Adjust material wand to compensate for flow characteristics. See Section 3-6 for more information. Clear all obstructions in the line. Clean or replace filter as needed.

Replace filter as needed.

Set Menu 1 to an appropriate value.

Clean proximity sensor.

Reduce sensitivity of sensor.

Additional grounding is necessary. Contact the Engineering Department. Secure connections on circuit board.

Proximity sensor wire is cut. Replace proximity sensor.

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Optional Series One Plus Controllers Cont’d.

Problem

The screen displays the

Er. 1

No Convey message.

The screen does not display the No Convey

error message when the

material supply is empty.

No-Convey alarm triggers, but the material supply bin is full.

Hopper over-fills repeatedly.

error

Er.

Possible cause Solution

Low material supply. Replenish material supply. Material supply obstructed. Clear all obstructions.

Proximity sensor misadjusted.

Vacuum timer is set too low.

Menu 5 is set to zero. Set Menu 5 to 1, 2, or 3. The proximity sensor has

failed. Proximity sensor wiring loose. Tighten the connector on TB2.

PC board failure.

Corrupted program.

Pickup wand is not positioned properly in the material supply.

Dirty filter.

Proximity sensor is not adjusted properly for material being conveyed.

Material line has obstruction.

Convey distance exceeds vacuum time.

Motor requires service.

Buildup on flapper valve.

Proximity sensor sensitivity is not properly adjusted.

Proximity sensor connections are loose. Proximity sensor has failed. Replace proximity sensor.

Increase sensitivity of proximity sensor.

Set Menu time.

Repair or replace proximity sensor as needed.

Contact the Service Department. See the last step of Section 510 for information on restoring factory settings.

Adjust material probe.

Clean or replace filter as needed.

Increase sensitivity of proximity sensor.

Clear material line of all obstructions.

Set Menu

Repair or replace motor as needed. Clean and readjust for material flow characteristics.

Increase sensitivity of the proximity sensor to match the characteristics of material being conveyed.

Secure terminal connections.

to an appropriate

to a longer time.

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

SSL/CSL, SLC and SSIL/CSIL Series Hopper Loaders with Optional Series One Plus Controllers Cont’d.

Problem

The screen displays the error message.

The screen displays power-up. Set parameters are not being retained.

The screen displays

Proportioning valve doesn't shift. (PP models only).

Only one material is conveyed during proportioning operation (PP models only).

No SPI communication (SPIequipped models only).

The screen displays 0 when an internal test is attempted (SPI equipped models only).

The screen displays (HOLD).

Er. 2

PLUS

EEEE

HOLD

Possible cause Solution

The customer-supplied auxiliary proximity switch is tripped because of a low material level in the machine bin. An auxiliary proximity switch is

enabled (Menu but one isn't installed.

Battery-backed RAM has failed.

PC board failure.

No compressed air.

Defective valve or solenoid. Repair or replace as needed. TB1 loose or disconnected. Tighten TB1 connections. Defective PC board. Call the Service Department.

Material supply problem.

Improper network cabling. See Figure (5). SPI communication feature hasn't been enabled.

SPI baud rate is incorrect.

The unit address is incorrect or two units on the network have the same address.

The SPI option wasn't purchased with this unit.

PC board failure. Call the Parts Department. External input enabled not

present.

is set to zero (0 ).

set to 2 ),

Correct the material supply problem.

Install an auxiliary proximity switch, or disable this feature by

setting Menu

See the last step of Section 5-10 for information on restoring factory settings.

Call the Parts Department for service.

Connect to 80 psi (551.6 kPa/

5.52 bars) air supply.

Correct material supply problem. Replenish, move pickup wand, remove obstructions.

Set Menu Material B you want.

Set Menu

Make sure all networked equipment in the network are transmitting at the same baud rate. Set each unit on the network to a unique address. The SS/CS Series hopper loader address is

set on Menu Contact your sales

representative to purchase an SPI-ready SS/CS Series hopper loader.

Disable input, or supply same.

to zero (0 ).

to the percentage of

to 1.

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

Technical Assistance

Parts Department

Call toll-free 7am–5pm CST [800] 423-3183 or call [630] 595-1060, Fax [630] 475-7005 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.

Service Department

Call toll-free 8am–5pm CST [800] 233-4819 or call [630] 595-1060 Emergencies after 5pm CST, call [847] 439-5655

We have a qualified service department ready to help. Service contracts are available for most products.

Sales Department

Call [630] 595-1060 Monday–Friday, 8am–5pm CST 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.

Contract Department

Call [630] 595-1060 Monday–Friday, 8am–5pm CST 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.

ACS Group

2900 S. 160

Street

New Berlin, WI 53151

SSL/CSL and SSIL/CSIL Series Sight Glass Hopper Loaders

Sterling SSL, SSIL User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual