Sterling SDD 1 SGM - Manuals

Page 2 - Date of commissioning:

Parts & Ser vice de part ment: Tele phone: (800) 423-3183 Edi tion: 07/01 1 7 6- 1 M S SDD 1 SGM 2 Ster ling Ma te rial Pro cess ing 5200 West Clinton Ave. Mil wau kee, WI 53223 Tele phone (414) 354-0970 Fax: (414) 354-6421 www.sterlco.com This op er a tion man ual is for*: (* Please fill in per...

Page 3 - All rights re served.; SDD 1 SGM

Ster ling Ma te rial Pro cess ing re tains all rights to change the in for ma tion in theseop er at ing in struc tions at any time with out no tice. We as sume no li a bil ity for any er rors or di rect or in di rect dam age re sult ing in con -text with these op er at ing in struc tions. Copying, t...

Page 4 - Ta ble of con tents

Ta ble of con tents 1. Safety in struc tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.1. For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.2. For the...

Page 6 - Safety in struc tions; Knowl edge of the Eng lish lan guage is pre req ui site.

1. Safety in struc tions » These safety in struc tions ap ply to all per sons within the range of ac tion of the equip ment. Please in form all per sons within the range of ac tion of the equip ment of thedi rect and in di rect haz ards con nected with the equip ment. These op er at ing in struc tio...

Page 8 - Op er a tion; Ap point an equip ment fore man to be re spon si ble for the equip ment.; Main te nance; Be fore start ing main te nance work, ap point a su per vi sor.

Op er a tion Ap point an equip ment fore man to be re spon si ble for the equip ment. En sure that the op er at ing per son nel are pro vided de tailed in struc tion in the op er a tion of theequip ment. Im proper op er a tion re sults in dan ger of ac ci dents! When the main switch is switched off ...

Page 10 - Con cer ning the se Ope ra ting In struc tions

2. Con cer ning the se Ope ra ting In struc tions » The se ope ra ting in struc tions are ad dres sed to all users of the de vi ce. The se ope ra ting in struc tions must be used by every per son char ged withwork on the unit. 1 7 6- 1 M S SDD 1 SGM Con cer ning the se Ope ra ting In struc tions 2-1

Page 13 - Put ting into op er a tion; This chap ter is in ten ded for ope ra ting per son nel.; Put ting into op er a tion 3-1

3. Put ting into op er a tion » This chap ter is in ten ded for ope ra ting per son nel. Pre re qui si te for this chap ter is ge ne ral knowled ge of the ope ra ti on of do singand blen ding units on in jec ti on moul ding ma chi nes. Also pre re qui si te for this chap ter is that the functio nal ...

Page 14 - Put ting into op er a tion 3-2

3.1. Con trol Sys tem S 150 The Con trol sys tem is swit ched on by me ans of the On/Off switch (switch set in po si ti on “1"). Thecon trol sys tem is ope ra ted via the key board (B). The in di vi du al ope ra ting mo des are in di ca ted bysym bols (C). Mes sa ges ap pe ar on a 4-digit dis pl...

Page 15 - Put ting into op er a tion 3-3

3.1.1. Key As signment “re ci pe”For sa ving, cal ling up or mo di fy ing re ci pes “in put”For the in put of pro gram pa ram e ters “cal i bra tion”Switches to the cal i bra tion mode, the LED flashes in case the cal i bra tion pro cesswas started by press ing the “run” key.Starts the start ing mod...

Page 16 - Put ting into op er a tion 3-4

3.1.2. Sym bols “Screw re tract time” “Do sing disc” “Screw speed” “Per cent” “Alarm” “Se conds” “Mi nu tes” “Grams” “Ki lo grams” “Pound” 1 7 6- 1 M S S 150 Put ting into op er a tion 3-4 lb min g kg % s

Page 17 - In iti al ope ra ti on pro ce du re; If the va lue has been ex cee ded, an alarm mes sa ge w ill be sent.; Put ting into op er a tion 3-5

3.2. In iti al ope ra ti on pro ce du re The con trol sys tem is fac to ry-programmed. Ne ver the less, spe ci fic va lu es have to be pre de fi nedor to be che cked (ba sic pa ra me ter set ting). The in put va lu es will be sa ved and will still be avai la ble af ter ha ving swit ched off the sys ...

Page 18 - Only in case of ex ter nal de si red va lue spe ci fi ca ti on:; Rotation; Only in case of con nec ti on to a HOST:; Put ting into op er a tion 3-6

Only in case of ex ter nal de si red va lue spe ci fi ca ti on: Min. in put fre quen cy (see Fre quen cy Out put of the Ex tru der): . . . . . . . . . . . . . . . . . . . . . . . . . . or if a vol ta ge sig nal is avai la ble (0 - 10 V): Frequency [Hz] = Input voltage [V] x 10000 [Hz] 10 [V] or if a...

Page 19 - Put ting into op er a tion 3-7

De ter mi ning the Configura tion Va lue Mark the functions re quired. Move the nu me ri cal value to the emp ty field. Add the val ues at thebot tom for use in ba sic pa ram e ter setting. & Af ter Ster ling con sul ta tion ad di tional con fig u ra tions will be pos si ble forspe cial ap pli c...

Page 20 - or; Put ting into op er a tion 3-8

Ex am ple: le vel pro bes: raw ma te ri al pro be ad di ti ve pro be throughput: 10 through 65 kg/shot throughput: dis play ed in lb (kg) n raw ma te ri al pro be . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . __1 n ad di ti ve pro be . . . ...

Page 21 - Put ting into op er a tion 3-9

3.3. Ba sic Pa ra me ter Set ting Press key LED dis play dis play “7"pulses of the en coder reg u la tion: 14103 (12 rpm), 4387 (38 rpm),-blackmotor 11739 (6.5 rpm), 2135 (35.5 rpm)-bluemotor or 2100 (SDD S) re spec tively en ter the im pulses of the en coder “8"nom i nal cur rent of the mo ...

Page 22 - Put ting into op er a tion 3-10

Press key LED dis play dis play “10"con fig u ra tion value: 1, if Bauer mo tor pres -ent en ter con fig u ra tion value “11”min i mum in put fre quency or num ber of ma -chine cy cles per dosingstan dard reg u la tion: 50 HzOnly in jec tion mold ing op er a tion af ter con -tact with Ster ling ...

Page 23 - Put ting into op er a tion 3-11

Press key LED dis play dis play “13"com mu ni ca tion ad dressstan dard re gu la ti on: 1Only if Eu ro map17-report is in use en ter com mu ni ca ti on ad dress “14”material con tents of the mix ing hop per, stan dard reg u la tion: 5000 g (5 kg)Only in case of mount ing on a Mico mix -ing-hoppe...

Page 24 - Feed Sta tion w ith In ter me di ate Piece for Pro por tioning; Re move the blind lid at the in ter me di ate piece for pro por tion ing.; Put ting into op er a tion 3-12

3.4. Ca li brat ion F The ca li brat ion pro ce du re has to be re-determined for each ma te ri al to beme te red sin ce the ca li brat ion weight dif fers from ma te ri al to ma te ri al. $ Ca li brat ion weightme te red ma te ri al weight for one re vo lu ti on of the do sing disc The fol lo wing ...

Page 25 - Put ting into op er a tion 3-13

Stan dard Feed Sta ti on Open the sa fe ty screws at the tog gle-type fas te ner. Open the two tog gle-type fas te ner at the do sing mo tor. Lift the feed sta ti on from the do sing mo tor and turn the feed sta ti on (180°) so that the out put pointsaway from the mi xing hop per. Put the feed sta t...

Page 26 - It is re com men ded to car ry out at least five weig hing pro ce du res.; “Pro por tio ning”; Re mo ve the weig hing con tai ner.; Put ting into op er a tion 3-14

3.4.2. De ter mi ning the Ca li brat ion Weight F Be fo re the ac tu al weig hing, a fil ling pro cess ta kes pla ce which is no ta keninto ac count. It is re com men ded to car ry out at least five weig hing pro ce du res. Weigh the emp ty weig hing con tai ner and note the weight (= tare weight). ...

Page 27 - Put ting into op er a tion 3-15

Press key LED dis play dis play — — — — fil ling pro ce du re If cal i bra tion weight “0" in the rec ipe: The dos ing mo tor turns for one rev o lu tionat half of the max i mum ro ta tional speed. “pro por tio ning” and en try of the weight start pro por tio ning pro ce du re:The do sing mo tor...

Page 28 - Pre pa ring the Feed Sta ti on for Nor mal Ope ra ti on; Stan dard Feed Sta ti on; Put ting into op er a tion 3-16

3.4.3. Pre pa ring the Feed Sta ti on for Nor mal Ope ra ti on The de vice may only be started up if all com po nents have been prop erlyin stalled. Dan ger: Limbs may be caught in ma chin ery! Stan dard Feed Sta ti on Open the sa fe ty screws at the tog gle-type fas te ner. Open the two tog gle-typ...

Page 29 - Put ting into op er a tion 3-17

3.5. Mo di fy/Crea te Re ci pe & By press ing the “stop” key, you can quit the menu at any time while tak ingon the en tered val ues. The fol lo wing is re qui red: · the de si red co lou ring (%) · the shot weight (g, op tio nal ly: lb) · the screw re tract time/plas ti fi ca ti on time of the ...

Page 30 - Put ting into op er a tion 3-18

Press key LED dis play dis play “1"parts of the ad di ti ve (co lou ring) in % en ter parts of the ad di ti ve “2"shot weight in g or lb re spec ti ve ly en ter shot weight “3"plastification time of the ma chi ne in se - conds en ter plas ti fi ca ti on time “4"cal i bra tion weight ...

Page 31 - Put ting into op er a tion 3-19

Press key LED dis play dis play “5"main tained run ning time of the blen ding unit in se conds en ter main tai ned run ning time of the blen -ding unit “6” printerOnly if a printer (op tional) is avail able en ter printer parameters0 = no prin ting1 = print ing setpoints2 = print ing parameters3...

Page 32 - Put ting into op er a tion 3-20

3.5.1. Save Re ci pe Press key LED dis play dis play “L (= load)” and the most re cent ly cal led upre ci pe num ber “S (= save)” and the most re cent ly sa vedre ci pe num ber se lect re ci pe num ber (1 - 10) save re ci pe & If you want to save the re ci pe un der a num ber that al rea dy exis...

Page 35 - Put ting into op er a tion 3-23

3.10. Cal ling up the re ci pe Press key LED dis play dis play to ta li zer “L (= load)” and the most re cent ly cal led upre ci pe num ber se lect re ci pe num ber (1 - 10) call up re ci pe 3.11. Swit ching off the De vi ce Press key LED dis play dis play to ta li zer Switch off the de vi ce by pre...

Page 36 - Put ting into op er a tion 3-24

3.12. Alarm Mes sa ges In case a mal functi on oc currs, an alarm mes sa ge will be dis play ed. & An A and an er ror num ber will be shown in the dis play. The LED “alarm” is lit up. F The con trol sys tem can not re su me the ope ra ti on, un less the mal functi onhas been re me died. Press th...

Page 37 - Put ting into op er a tion 3-25

“A0001" Strap “sa fe ty switch” is mis sing. Ster ling Ser vi ce. “A0002" The no mi nal cur rent of the do sing mo tor (= 100 %, see name pla te) is being ex cee ded for morethan 2 se conds by 30 % or for a ma xi mum of 0.5 se conds by 80 %. Do sing mo tor de fec ti ve or jam med. Check the ...

Page 38 - Put ting into op er a tion 3-26

“A0008" The screw re tract time of the pro cess ing ma chine in shorter than 0.1 sec onds. The unit can not be ope ra ted in com bi na ti on with this pro ces sing ma chi ne. “A0009" The cal cu la ted speed of the mo tor is eit her too high or too low. Check ba sic pa ra me ter set ting and ...

Page 39 - not

4. Main te nance » This chap ter is in tended for per sons with skills in elec tri cal and me chan i calar eas due to their train ing, ex pe ri ence and re ceived in struc tions. Per son nel us ing the in struc tions in this chap ter must be in structed of the reg -u la tions for the pre ven tion of...

Page 42 - Re moving/re plac ing scraper in the SDD dos ing sta tion; Re moving the scraper

4.2. Re moving/re plac ing scraper in the SDD dos ing sta tion Re moving the scraper Empty the dos ing sta tion. » Switch the con trol unit off by means of the on/off switch. Dis con nect from mains volt age. Open the tight en ing strap (B) onthe dos ing hop per. Re move the dos ing hop per from the...

Page 43 - In stalling the scraper

In stalling the scraper Place the new scraper in the dos ing unit hous ing. En sure that the scraper is po si tioned cor rectly. Screw the scraper in place by means of 2 hexa gon socket screws (M5 x 16). Turn the dos ing disc to check for smooth move ment. Mount the cover on the con nect ing piece. ...

Page 44 - Dis man tling the dos ing sta tion

4.3. Cleaning the DD dos ing sta tion Dis man tling the dos ing sta tion Empty the dos ing sta tion. » Switch the con trol unit off by means of the on/off switch. Dis con nect from mains volt age. Open the tight en ing strap on the dos ing hop per. Re move the dos ing hop per from thedos ing unit. D...

Page 45 - In stalling the dos ing sta tion; Place the dos ing disc in the dos ing unit hous ing.

In stalling the dos ing sta tion Place the dos ing disc in the dos ing unit hous ing. Re move the screw (M6 x 60). Screw the dos ing disc in place by means of 2 hexa gon socket screws (M6 x 30). Mount the cen ter hexa gon socket screw (M6 x 12). In stall the scraper and then the dos ing unit. Turn t...

Page 46 - Changing the dos ing disc in the SDD dos ing sta tion; Re moving the dos ing disc

4.4. Changing the dos ing disc in the SDD dos ing sta tion Re moving the dos ing disc Empty the dos ing sta tion. » Switch the con trol unit off by means of the on/off switch. Dis con nect from mains volt age. Open the tight en ing strap on the dos ing hop per. Re move the dos ing hop per from the d...

Page 47 - Or der num bers

Ob serve that a dos ing and blend ing unit may only be put into op er a tion ifall dos ing sta tions and cov ers are in place. Dan ger of squeez ing! & Or der num bers Dosing disc72 cham bers: ID 31447 40 cham bers: ID 21710 25 cham bers: ID 21711 18 cham bers: ID 23057 Dosing disc, wear resista...

Page 53 - Feed sta tion; Pre lim i nary cal i bra tion value

4.7. Ex change able sta tions Dosing discs of the same type may be ex changed for each other with out any prob lems. If dos ing discs with a dif fer ent com part ment num ber are in stalled, this has to be en tered in thecon trol sys tem. En ter the (pre lim i nary) cal i bra tion value of the fresh...

Page 57 - As sem bly in struc tions; En sure in each case that the per son nel are in formed.

5. As sem bly in struc tions » These in stal la tion in struc tions are in tended for per sons with skills in elec tri -cal and me chan i cal ar eas due to their train ing, ex pe ri ence and re ceived in -struc tions. Per son nel us ing these in stal la tion in struc tions must be in structed in the...

Page 62 - Functio nal des crip ti on

6. Functio nal des crip ti on » This functio nal des crip ti on is in ten ded for all ope ra ting per son nel of theequip ment. Pre re qui si te for this functio nal des crip ti on is ge ne ral knowled ge of do singand blen ding units. En su re in each case that the ope ra ting per son nel are suf f...

Page 67 - Ot her per sons are not per mit ted to mo di fy or re pair the equip ment.

8. Spa re parts list » This spa re parts list is in ten ded to be used only by trai ned per son nel. Ot her per sons are not per mit ted to mo di fy or re pair the equip ment. 1 7 6- 1 M S SDD 1 SGM Spa re parts list 8-1

Page 71 - Values re quired for the ba sic pa ram e ter:; In case of ex ter nal de sired value spec i fi ca tion:

Values re quired for the ba sic pa ram e ter: Max. nom i nal cur rent of the mo tor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulses of the en coder: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 72 - Ac ces so ries; Ster ling Ma te rial Pro cess ing

Ac ces so ries Le vel pro beKCB-M32GP/015 1 7 6- 1 M S Ster ling Ma te rial Pro cess ing

Page 73 - Ad just ment of the le vel pro bes; Do not cle an the le vel pro bes be fo re the ad just ment.

Ad just ment of the le vel pro bes F Do not cle an the le vel pro bes be fo re the ad just ment. Fill the do sing sta ti on un til 1/3 of the le vel pro be is co ver ed. Re mo ve the plas tic screw. Turn the trim-pot un til the yel low con trol lamp is swit ched off. Don’t turn furt her un til the c...

Page 75 - Elec tri cal ma nu al

10. Elec tri cal ma nu al » This elec tri cal man ual is ex clu sively de ter mined for the use by Ster ling Ser -vice per son nel or by trained per son nel author ised by Ster ling only. Other per sons are not al lowed to per form mod i fi ca tions or re pairs on the de -vices. All work should be c...

Page 77 - Power sup ply

1 7 6- 1 M S SDD 1 SGM Elec tri cal ma nu al 10-3 J 15 Power sup ply J 16 1: Dosing mo tor -2: Dosing mo tor + J 8 1: 230 V, N2: PE3: Alarm COM (230 V, L1)4: Alarm NO J 9 1: 230 V, N 2: PE 3: Mixer COM (230 V, L1) 4: Mixer NO J 10 (RS485/422) 1: Ex ter nal feed max. 7 V2: GND extern3: TX+4: TX-5: RX...

Page 79 - S 150 jumper as sign ment; Equip ment sup ply volt age 115 V

· De fault set ting: In jec tion or ex tru sion with ex ter nal set value 0-10 kHz S 150 jumper as sign ment Ju1: 1-2: Mi cro pro ces sor in power save mode, open (stan dard) Ju2/3: 1-2 + 2-4: Ma te rial sen sor with open col lec tor out put 2-3 + 4-5: Ma te rial sen sor with source driver (stan dar...

Page 80 - Ex tru sion with ex ter nal set value 0-10 V

· Ex tru sion with ex ter nal set value 0-10 V S 150 jumper as sign ment Ju1: 1-2: Mi cro pro ces sor in power save mode, open (stan dard) Ju2/3: 1-2 + 2-4: Ma te rial sen sor with open col lec tor out put 2-3 + 4-5: Ma te rial sen sor with source driver (stan dard) Ju4/6: 1-2: Ex ter nal RS422 sup ...

Page 81 - Ex tru sion with ex ter nal set value 0-20 mA

· Ex tru sion with ex ter nal set value 0-20 mA S 150 jumper as sign ment Ju1: 1-2: Mi cro pro ces sor in power save mode, open (stan dard) Ju2/3: 1-2 + 2-4: Ma te rial sen sor with open col lec tor out put 2-3 + 4-5: Ma te rial sen sor with source driver (stan dard) Ju4/6: 1-2: Ex ter nal RS422 sup...

Page 82 - Con nec tion of an alarm horn to the equip ment volt age sup ply

· Con nec tion of an alarm horn to the equip ment volt age sup ply S 150 jumper as sign ment Ju1: 1-2: Mi cro pro ces sor in power save mode, open (stan dard) Ju2/3: 1-2 + 2-4: Ma te rial sen sor with open col lec tor out put 2-3 + 4-5: Ma te rial sen sor with source driver (stan dard) Ju4/6: 1-2: E...

Page 83 - Con nec tion of an alarm horn to an ex ter nal source of power

· Con nec tion of an alarm horn to an ex ter nal source of power » Be fore con nec tion of an ex ter nal power sup ply switch the equip ment off. Un plug the mains plug. Re move the fuses F4 (= blend ing unit) or F5 (= alarm). S 150 jumper as sign ment Ju1: 1-2: Mi cro pro ces sor in power save mode...