Sterling SSL, SSIL User Manual 2

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.

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