Operating Instructions SM4-618 Conveyor Hopper with blower-filter unit SGFE Sterling Material Processing
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SGFE Sterling Material Processing 5200 West Clinton Ave. Milwaukee, WI 53223 Telephone: (414) 354-0970 Fax: (414) 354-6421 www.sterlco.
SGFE Sterling Material Processing retains all rights to change the information in these operating instructions at any time without notice. SM4-618 We assume no liability for any errors or direct or indirect damage resulting in context with these operating instructions. Copying, translation or publication in any form except for personal use of purchaser requires approval from Sterling Material Processing. All rights reserved.
SGFE Table of contents 1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2. For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3. For the operating safety of the equipment . . . . . . . . . . . . . . . . . 1-5 2. Concerning these Operating Instructions . . . . . . . . . . . . . . . . . . . .
SGFE 5. Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1. 5.2. 5.3. 5.4. 5.5. 5.6. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Material feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Suction pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 1. Safety instructions 1.1. General » These safety instructions apply to all persons within the range of action of the equipment. Please inform all persons within the range of action of the equipment of the direct and indirect hazards connected with the equipment. These operating instructions are to be used by all persons assigned activities connected with the equipment. Knowledge of the English language is prerequisite.
For your safety 1.2. For your safety General The operating personnel of this equipment must be at least 16 years old. Please read these operating instructions carefully before taking into operation for the first time. Contact us should questions arise. This avoids injury and damage to equipment! These operating instructions must be kept available at all times at the place of operation of the equipment.
For your safety Assembly Compare the connected loads with those of the mains supply. Danger of injury through electrical shock! When using lifting gear, please observe the pertaining regulations. Caution: Danger of accidents! Do not modify, add other equipment or change the design of the equipment without the approval of the manufacturer. Caution: Danger of accidents! Attachments not supplied by Sterling must be manufactured in accordance with safety regulation EN 294.
For your safety Operation Appoint an equipment foreman to be responsible for the equipment. Ensure that the operating personnel are provided detailed instruction in the operation of the equipment. Improper operation results in danger of accidents! When the main switch is switched off for reasons pertaining to safety, it must be secured against unauthorized activation. Caution: Danger of accidents! Repair work may be carried out by trained personnel only.
For the operating safety of the equipment 1.3. For the operating safety of the equipment Never change settings if the consequences are not precisely known. Use only original Sterling spare parts. Please observe the maintenance schedule. Keep record of all maintenance and repair work. Please note that electronic components may be damaged by static discharge. Check all electrical connections for proper fit before the equipment is taken into operation for the first time and at regular intervals.
General Information 2. Concerning these Operating Instructions 2.1. General Information » These operating instructions are addressed to all users of the device. SM4-618 These operating instructions must be used by every person charged with work on the unit.
Warning Messages and Symbols 2.2. Warning Messages and Symbols The following warning messages and symbols are used in these operating instructions: » This symbol indicates danger to life! Fatal or serious injury is possible if the corresponding instructions, regulations or warnings are not observed. This symbol indicates that serious injury is possible if the corresponding instructions, regulations or warnings are not observed.
Explanations and Definitions 2.3. Explanations and Definitions In this operating manual, certain terms are used repeatedly for better clarity. Therefore please keep in mind that these terms stand for the explanations given here. · Unit “Unit” may designate either a single device, a machine or a plant. · User The user is the person who uses the unit on his or her own responsibility or on the responsibility of someone else. rator · Ope The operator of a unit (production manager, foreman etc.
Notes on Usage 2.4. Notes on Usage perienced operators can begin directly with the chapter on “Start-up” if the unit · Ex has been properly installed. SM4-618 not been installed yet, observe the instructions in the chapter on · If“Asthesemunitblyhas Instructions”.
General 3. Start-up 3.1. General » This chapter is directed at the operator of the equipment. This chapter assumes general skills in dealing with conveying units and SPS control units. This chapter assumes that the functional description has been read and understood. It should be ensured in each and every case that the operators have the relevant skills. Explosive gases and mixtures of gas and air must not be conveyed by the vacuum generator.
Control system 3.2. Control system The facility’s control system is factory-programmed. Nevertheless, you have to set specific values (basic parameters) which are dependent on the processed material, for instance. The set values are saved and remain saved even after switching off or after a power fail. All entries are saved and can also be viewed at a later point in time. All messages are displayed in plain text.
Switching on the control system 3.2.2. Key assignment Arrow keys to select a value to scroll the menu pages to change a value OK Pushing the key “OK” to select a menu, to change values (the cursor bar jumps to the first digit of the value); to confirm value entries (with value acceptance). ESC Pushing the key “OK” to leave value entries (without value acceptance); to leave the menu “basic parameters”. 3.3. Switching on the control system Connect the control system to mains supply by the device plug.
Setting the basic parameters 3.4. Setting the basic parameters Select the menu “basic parameter”. ESC OK I: 1 2 3 4 5 6 Mo 08:33 Q: 1 2 3 4 RUN ESC OK ESC OK ESC OK Select “Set Param”. OK Set Clock > Set Param Signal times flap (B01) (standard setting: 1 second). Changes only after consultation with the Sterling Service. Ta= 00.00s SM4-618 OK B01 : T T = 01.
Setting the basic parameters Conveying time (B05) Enter the desired conveying time in seconds. OK B05 : PAR LIM = ### Cnt = ### ESC OK ESC OK ESC OK Line clearing (B09) Enter the desired line clear time in seconds. B09 : PAR LIM = ### OK Cnt = ### Enter “0” if no line clearing valve is mounted. F Emptying time (B14) Enter the desired emptying time in seconds.
Setting the basic parameters Blower run on time (B17) Enter the blower run on time in seconds . B17 : PAR LIM = ### OK Cnt = ### ESC OK ESC OK Error tolerance (B22) Enter the error tolerance. OK B22 : PAR Par = ### Cnt = ### & Setting “0”: function not active Setting “1 -###”: an alarm is given when the error tolerance reaches this value.
Starting the conveying procedure 3.5. Starting the conveying procedure Set the on/off switch in position ”ON”. & If the hopper loader reports a lack of material, the conveying is started. 3.6. The first conveying operations F Check the rotational direction of the vacuum generators. Check the line system. Adjusting the suction tube. SM4-618 Material coming from the hopper loader during the first conveying may not be used.
Viewing Alarm Messages 3.7. Viewing Alarm Messages & An alarm is given by steady light of the “alarm” lamp. Pressing the “Reset” key erases the steady light of the “alarm” lamp (the “alarm” lamp goes off). The failure is not repaired. F Failures must be repaired immediately. Possible events: SM4-618 - Fault hopper In the operating mode “probe conveying”, the level of material has not reached the probe within the set conveying time.
Switching off the unit 3.8. Switching off the unit Set the on/off switch in position ”OFF”. & If the unit is switched off during a conveying procedure this operation will be finished. SM4-618 Disconnect the unit from mains supply by the device plug.
General 4. Maintenance Version: 64.10-0198GB05WA 02/01 4.1. General » This chapter is intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions. Personnel using the instructions in this chapter must be instructed of the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation. Ensure in each case that the personnel are informed.
General L Disconnect the equipment from mains supply before starting maintenance procedures to ensure that it cannot be switched on unintentionally. Depressurize all compressed air piping of the equipment before starting maintenance work. F Please observe the maintenance intervals. Before starting maintenance work, clean the equipment of oil, fuel or lubricants.
Maintenance schedule 4.2. Maintenance schedule Initial operation: Check the rotational direction of the vacuum generators Check the line system Adjust the suction tube Daily: Check warning signs on equipment for legibility and completeness Check the oil level in the oiler Empty the water separator Check operating pressure of the plant’s supply network (5-6 bar (72.52-87.
Maintenance schedule After the first 100 hours of operation: After 500 hours of operation: After 20,000 hours of operation: Check oil level and condition of the oil in the gear box of the rotary lobe vacuum pumps Follow the manufacturer’s operating instructions Remove old grease from anti-friction bearing of side vane vacuum pump and apply fresh grease Follow the manufacturer’s operating instructions The given maintenance intervals are average values.
Checking the direction of rotation of the vacuum generator 4.3. Checking the direction of rotation of the vacuum generator Start a conveying procedure. Wait until the vacuum generator begins to operate. Observe the rotational direction arrow on the vacuum generator housing. Stop the conveying procedure. Wait until the blower has come to a standstill. Switch off the unit. If the vacuum generator rotates in the wrong direction, correct the direction by changing the poles of two phases.
Testing the conduit system 4.4. Testing the conduit system Detach the flexible line from the connected material take-up assembly. Close the open end of the line with your hand. Start a conveying procedure. Wait until the vacuum generator begins to operate; after this, the hand should become sensibly attached by suction within a few seconds. If no vacuum can be felt, the line system has a leak. Stop the conveying procedure. Wait until the blower has come to a standstill. Switch off the unit.
Adjusting the suction tube 4.5. Adjusting the suction tube To guarantee a trouble-free operating run, the suction tube must be exactly adjusted. 1. The suction tube should be placed in the basic setting In the basic setting, the inner pipe of the suction tube sticks out of the outer pipe approx. 120-160 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with Ø 40 mm . (4.72-6.30 in) with (1.67 in) approx. 150-180 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6. Cleaning/replacing the filter cartridge » Stop the conveying procedure. Switch off the conveying system at the main switch. Interrupt the mains supply. Set all compressed-air lines at zero pressure. & The conveying capacity is diminished by a clogged filter cartridge. Loosen the screw connection on the filter housing (A). Remove the housing lid (A). Loosen the screw connection on the filter cartridge. Remove the filter cartridge. Replace the filter cartridge. Resp.
Servicing the accessories Re-install the new/cleaned filter cartridge. Mount the housing lid. & Purchase order number filter cartridge: ID 85612 4.7. Servicing the accessories SM4-618 F The operating instructions must be followed.
5. Assembly instructions » These installation instructions are intended for persons with skills in electrical and mechanical areas due to their training, experience and received instructions. Personnel using these installation instructions must be instructed in the regulations for the prevention of accidents, the operating conditions and safety regulations and their implementation. Ensure in each case that the personnel are informed.
Transport Install the equipment such that all parts are easily accessible; this facilitates maintenance and repair work. 5.1. Transport For transport, only the appropriate lifting gear should be used (eg fork lift or workshop crane). » Please ensure the adequate carrying capacity of the lifting gear. Please observe all safety regulations for the operation of lifting gear. 5.2.
Suction pipe Please observe that the length of the hose should not exceed 3 m (9.84 ft.) Push the free pipe end into the flexible line to a depth of approx. 4-5 cm (1.67-1.97 in.) Connect both parts by means of a hose clamp. 5.4. Suction pipe The suction pipe consists of an inner (A) and an outer pipe (B) which can be offset against each other. Push the free pipe end into the flexible line to a depth of approx. 4-5 cm (1.67-1.97 in.) Connect both parts by means of a hose clamp.
Pipework 5.5. Pipework When all the positions and arrangement for material feed, hopper loader and blower are determined, start assembling the pipework. Rigid pipes should always be laid next to each other and there should be the following minimum distances in between: 40 mm (1.67 in.) pipe diameter. . . . . . . . . . . 75 mm (2.95 in.) center distance 50 mm (1.97 in.) pipe diameter . . . . . . . . . . 85 mm (3.35 in.) center distance 65 mm (2.66 in.) pipe diameter . . . . . . . . . 150 mm (5.91 in.
Vacuum generator 5.6. Vacuum generator » Explosive gases and mixtures of gas and air must not be conveyed. Solid particles and dust must be separated before entry to the vacuum generator. For all work on the equipment, hearing protection should be worn. Avoids impairment of hearing! The manufacturer’s operating instructions should be followed. An acoustic cover should be installed when vacuum generators are located in work rooms.
Installing the accessories The vacuum generator should be installed near the equipment, to avoid loss of performance through leakage and friction. Only flexible connections should be used to join up the pipes. The control unit should be installed in clear view of the vacuum generator. To keep noise to a mininum, we recommend installation in an enclosed space. 5.6.1. Rotary lobe vacuum pump GDK » The fan is equipped with a separate electric motor which must be connected to 24 V. 5.7.
Electrical connection 5.8. Electrical connection » The regulations of the local Electricity Board must be observed. Before connection to the electricity supply, it should be ensured that the supply voltage and the power frequency are in accordance with the data on the name plate of the machine. The electrical connection may only be carried out by Sterling service staff or trained personnel authorised by Sterling. It is not permitted for other persons to undertake the electrical connection.
General 6. Functional description 6.1. General » This functional description is intended for all operating personnel of the equipment. Prerequisite for this functional description is general knowledge of conveying units and SPS control units. SM4-618 Ensure in each case that the operating personnel are sufficiently informed.
General The unit works on the pneumatic conveying principle. According to this, a vacuum generator (A) creates a vacuum, which extends through the pipe ducts and hose assemblies (B), through the separators (C) until it reaches the material take-up assembly (D). The material which has been conveyed is than separated from the air inside the separator. Depending on conveyor control system (E) and hopper loaders time conveying mode or probe conveying mode with conveying time used as monitoring time is possible.
SGFE 7. Technical data Version: 64.10-0198GB05TD 02/01 Method of filling: . . . . . . . . . . time conveying mode or probe conveying mode . . . . . . . . . . . . . . . . . . . . . . . . . . with conveying time used as monitoring time Vacuum generator (depending on the model) Side vane vacuum pump GSV: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5-4.4 kW Noise level: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 75-78 dB(A) Rotary valve pump GDS: . . . . . .
SGFE Dimension sheet SGFE SM4-618 All di mensions are in mm. (in.) Subject to alteration.
SGFE Dimension sheet GDK 4 kW All di mensions are in mm. (in.) Subject to alteration. SM4-618 Dimension sheet GSV All di mensions are in mm. (in.) Subject to alteration.
SGFE SM4-618 Dimension sheet GDS All di mensions are in mm. (in.) Subject to alteration.
SGFE 8. Spare parts list » This spare parts list is intended to be used only by trained personnel. SM4-618 Other persons are not permitted to modify or repair the equipment.
SGFE Pos. ID-No. Designation 1 93102 93100 pressure limiter valve (1.5 and 2.2 kW) pressure limiter valve (4.0 kW) 2 86308 88235 83564 side vane vacuum pump GSV 4.0 kW side vane vacuum pump GSV 2.2 kW side vane vacuum pump GSV 1.5 kW 84724 98148 rotary lobe vacuum pump GDK 4.
SGFE 9.
SGFE 10. Electrical manual » This electrical manual is intended to be used only by Sterling service personnel and trained personnel authorized by Sterling. Other persons are not permitted to modify or repair the equipment. ¨ Connection diagram no.
