Page 2 - Machine-Side Hopper Loaders; ii; Sterling Material Processing
Machine-Side Hopper Loaders ii Sterling Material Processing 5200 West Clinton Ave. Milwaukee, WI 53223 Telephone: (414) 354-0970 Fax: (414) 354-6421 www.sterlco.com Technical service: Service departmentTelephone: (800) 423-3183 Edition: 03/04 Bulletin #: SM4-615.2 These operating instructions are fo...
Page 3 - iii
Machine-Side Hopper Loaders iii Sterling Material Processing retains all rights to change the information in theseoperating instructions at any time without notice. We assume no liability for any errors or direct or indirect damage resulting in contextwith these operating instructions. Copying, tran...
Page 4 - iv
Page 6 - Table of Contents
Machine-Side Hopper Loaders v Table of Contents 1. General instructions......................................................................................................... 1-1 1.1. Warnings and symbols ................................................................................................
Page 8 - General instructions 1-1; General instructions
Machine-Side Hopper Loaders General instructions 1-1 1. General instructions M These instructions apply to all persons within the range of action of theequipment. These operating instructions are to be used by all persons assigned activitiesconnected with the equipment.
Page 9 - -2 General instructions
Machine-Side Hopper Loaders 1-2 General instructions 1.1. Warnings and symbols The following warnings and symbols are used in these operating instructions: M This symbol indicates danger to life. Fatal or serious injury is possible if thecorresponding instructions, regulations or warnings are not ob...
Page 10 - General instructions 1-3; authorized to carry out the required work.
Machine-Side Hopper Loaders General instructions 1-3 1.2. Explanations and information Various terms are used in these operating instructions to ensure clarity. Thereforeplease note that the terms used in the text stand for the corresponding explanationslisted below.• Equipment: ”Equipment” can mean...
Page 12 - Safety instructions 2-1; Safety instructions; Knowledge of the English language is prerequisite.
Machine-Side Hopper Loaders Safety instructions 2-1 2. Safety instructions M These safety instructions apply to all persons within the range of action of theequipment, and should be used by all persons assigned activities connectedwith the equipment. Please inform all persons within the range of act...
Page 13 - -2 Safety instructions; us should questions arise.
Machine-Side Hopper Loaders 2-2 Safety instructions 2.1. For your safety 2.1.1. General To prevent injury and/or damage to equipment, observe the following safety rules: • Read these operating instructions carefully before operating for the first time. Contact us should questions arise. • These oper...
Page 14 - Safety instructions 2-3; • Compare the connected loads with those of the main supply.
Machine-Side Hopper Loaders Safety instructions 2-3 2.1.2. Assembly To prevent injury and/or damage to equipment, observe the following safety rules: • Compare the connected loads with those of the main supply. • Use care when using lifting gear, and observe any pertaining regulations. • Do not modi...
Page 15 - -4 Safety instructions
Machine-Side Hopper Loaders 2-4 Safety instructions 2.1.3. Operation To prevent injury and/or damage to equipment, observe the following safety rules: • Appoint an equipment foreman to be responsible for the equipment. • Ensure that the operating personnel are provided detailed instruction in the op...
Page 16 - Safety instructions 2-5; For the operating safety of the equipment
Machine-Side Hopper Loaders Safety instructions 2-5 2.2. For the operating safety of the equipment Never change settings if the consequences are not precisely known. Use only original manufacturer-approved spare parts. Please observe the maintenance schedule. Keep record of all maintenance and repai...
Page 19 - Please check packing on delivery for transport damage.; The main power switch must be freely accessible.
Machine-Side Hopper Loaders 3-2 Transport, assembly and storage 3.1. Transport and packing M Please ensure adequate carrying capacity of the lifting equipment. The equipment passes rigorous testing in the factory and is packed carefully to avoidtransport damage. Please check packing on delivery for ...
Page 20 - Assembly instructions 4-1; Assembly instructions; Use only suitable workshop equipment.
Machine-Side Hopper Loaders Assembly instructions 4-1 4. Assembly instructions M These installation instructions are intended for persons with skills in electricaland mechanical areas due to their training, experience and receivedinstructions. Personnel using these installation instructions must be ...
Page 21 - -2 Assembly instructions; material inlet nozzle.; The controller must be freely accessible.
Machine-Side Hopper Loaders 4-2 Assembly instructions 4.1. Unpacking The loader is insensitive to shocks and can bemounted directly onto the processing machine, ona machine hopper, a drying hopper or a dosingand blending unit. The equipment is delivered as a completeassembly. Use the following proce...
Page 22 - Assembly instructions 4-3; Figure 3: Lower side of the controller
Machine-Side Hopper Loaders Assembly instructions 4-3 4.2. Installing the dump valve sensor The controller uses a dump valve sensor (A) with amagnet (B) to determine demand. When the dumpvalve is closed, indicating demand, the magnet ispushed towards the sensor. The presence of themagnet near the se...
Page 23 - -4 Assembly instructions; Use the following procedure to attach the pickup wand:
Machine-Side Hopper Loaders 4-4 Assembly instructions 4.3. Attaching the pickup wand Use the following procedure to attach the pickup wand: 1. The pickup wand must be connected to flexible hose to allow sufficient movement. The length of the hose should not exceed 10 feet (3 meters). Push the free p...
Page 24 - Assembly instructions 4-5
Machine-Side Hopper Loaders Assembly instructions 4-5 4.4. Mounting Please check during assembly that the admissible bearing loads are not exceeded. Mount the loader in such a way that the outlet flap swings in a right angle to the directionof machine movement. Please check that all connecting point...
Page 25 - -6 Assembly instructions; Observe the bearing capacity of the machine flange.
Machine-Side Hopper Loaders 4-6 Assembly instructions 4.4.1. Mounting on the processing machine A VT Series adapter is required to mount theloader on the processing machine. Two-litermodels require a VT 1.0 adapter. Five-litermodels require a VT 2.3/70 or VT 2.8/70adapter. Use the following procedur...
Page 26 - Assembly instructions 4-7
Machine-Side Hopper Loaders Assembly instructions 4-7 4.4.3. Mounting onto mixing hoppers with lateral inlet A VT Series adapter is required to mount theloader on a mixing hopper with a laterial inlet.Two-liter models require a VT 1.0 adapter. Five-liter models require a VT 2.3/70 or VT 2.8/70adapte...
Page 27 - -8 Assembly instructions; The regulations of the local electrical codes must be observed.; The equipment is connected to main power supply by a standard plug.
Machine-Side Hopper Loaders 4-8 Assembly instructions 4.5. Electrical connection M The regulations of the local electrical codes must be observed. Before connection to the electricity supply, ensure that the supply voltage andthe power frequency are in accordance with the data on the nameplate of th...
Page 28 - Assembly instructions 4-9; Installation of the optional proportioning valve; Connecting the proportioning valve:
Machine-Side Hopper Loaders Assembly instructions 4-9 4.7. Installation of the optional proportioning valve & Before proceeding, review the connecting diagram included with the unit. For more information, refer to the manual that shipped with the proportioningvalve. Connecting the proportioning ...
Page 29 - -10 Assembly instructions; Connecting Material Lines:
Machine-Side Hopper Loaders 4-10 Assembly instructions Connecting Material Lines: Component 1 – connected to the intake port furthest from the air cylinder (regrind) Component 2 – connected to the intake port closest to the air cylinder (virgin) Setting the ratio: When the loader motor is not runnin...
Page 30 - Functional description 5-1; Functional description
Machine-Side Hopper Loaders Functional description 5-1 5. Functional description M This functional description is intended for all operating personnel of theequipment. General knowledge of conveying systems is required to operate the equipment Ensure in each case that the operating personnel are suf...
Page 31 - -2 Functional description; Figure 11: Controller
Machine-Side Hopper Loaders 5-2 Functional description 5.1. Sequence of operation The sequence of operation is as follows: 1. Plug in the machine and move the on/off switch to the “on” position 2. All LEDs on the controller blink, and the software version is displayed on the screen. 3. A 2-second bl...
Page 32 - This chapter is intended for operating personnel.
Machine-Side Hopper Loaders Operation 6-1 6. Operation M This chapter is intended for operating personnel. General knowledge of the operation of conveying systems is required toperform these tasks. Make sure you have read and understood the FunctionalDescription chapter in this manual before operati...
Page 33 - Remove the pickup wand from the flexible hose.
Machine-Side Hopper Loaders 6-2 Operation 6.1. Switching on the unit Locate the power switch on the left side of the control box and switch it to the “on”position. 6.2. Checking the flexible hose Before operating the equipment, check to make sure the suction is working: 1. Remove the pickup wand fro...
Page 34 - Do not overfill the hopper loader; Turn on the hopper loader; The conveying time that was last selected appears in the display.; • If the hopper loader is overfilling, reduce the conveying time.
Machine-Side Hopper Loaders Operation 6-3 6.3. Setting the conveying time F Do not overfill the hopper loader & The conveying time cannot be set while the unit is in the process of conveyingmaterial. By correctly setting the conveying time, you can reduce vacuum motor wear, saveenergy, and reduc...
Page 35 - To set the purge time, press and hold the “change-over” key; The purge time can be set at 1 to 99 seconds.; Reconnect the dump valve sensor. Conveying should start.
Machine-Side Hopper Loaders 6-4 Operation 6.4. Setting the purge time (optional) To set the purge time, press and hold the “change-over” key while using the “arrow key” to adjust the time. & The purge time that was last selected appearsin the display. The purge time can be set at 1 to 99 seconds...
Page 36 - This material should not be used again.
Machine-Side Hopper Loaders Operation 6-5 6.5. Initial operation Metal shavings may be inside the pipe from cutting down pipes into lengths. These arepulled during the first conveying process and collected in the separator. F This material should not be used again. 6.6. Switching off the unit Locate...
Page 39 - An “E” appears in the display and an error number.; The following error messages can be displayed:
Machine-Side Hopper Loaders 7-2 Troubleshooting 7.1. Alarms An alarm will be triggered if there is no material to convey or if the loader overheats. & An “E” appears in the display and an error number. And alarm will sound. F Do not restart operation until the malfunction has been corrected. The...
Page 41 - Please observe the maintenance intervals.
Machine-Side Hopper Loaders 8-2 Maintenance F Please observe the maintenance intervals. Before starting maintenance work, clean the equipment of oil, fuel orlubricants. Ensure that materials and incidentals required for operation as well as spareparts are disposed of properly and in an environmental...
Page 42 - The given maintenance intervals are average values.
Machine-Side Hopper Loaders Maintenance 8-3 8.1. Maintenance intervals Daily: Check that warning labels on the equipment are clear andreadable Clean the sieve or filter Use compressed air to blow through the sieve or filter (accordingto the accumulation of dust) Monthly: Check function of the power ...
Page 43 - Disconnect the unit from main power supply by unplugging it.; nozzle of the material outlet.; Order number sealing ring “material outlet”:
Machine-Side Hopper Loaders 8-4 Maintenance 8.2. Servicing the loader M Disconnect the unit from main power supply by unplugging it. Depressurize all system sections of the equipment (only units with activecleaning). 8.2.1. Changing the sealing ring of the outlet flap 1. Open the toggle fasteners (A...
Page 44 - Stop the conveying cycle by; Order numbers
Machine-Side Hopper Loaders Maintenance 8-5 8.2.2. Adjusting the dump valve sensor 1. Stop the conveying cycle by disconnecting the dump valvesensor from the controller. With thedump valve sensor disabled, nodemand will be indicated, andconveying will stop. 2. Connect an ohmmeter to PINS 2 and 3 of ...
Page 45 - Open the toggle fasterner on the tension ring.; Order number
Machine-Side Hopper Loaders 8-6 Maintenance 8.2.3. Cleaning the unit 1. Open the toggle fasterner on the tension ring. 2. Tilt the turbine head upwards. 3. Remove the filter. 4. Clean the filter by means of compressed-air. 5. Clean the hopper loader by means of a vacuum cleaner. 6. Mount the filter....
Page 46 - Cleaning the filter cloth:
Machine-Side Hopper Loaders Maintenance 8-7 Cleaning the filter cloth: 1. Open the toggle fasteners (A) and the access door (B) of the hopperloader. 2. Check the filter cloth (C) and the wire cloth (D) for material residue.Clean the filter by means ofcompressed air. 3. Close the access door (B) and ...
Page 47 - This work must be carried out by qualified personnel only.; Remove the latch carefully from; Figure 15: Replacing the carbon brushes
Machine-Side Hopper Loaders 8-8 Maintenance 8.2.4. Replacing carbon brushes at the motor The carbon brushes in the motor must be replaced after approximately 1000 hours ofoperation. The brushes can be replaced twice before the entire motor has to bereplaced. “BL” model loaders feature brushless moto...
Page 48 - Verify that no cables are pinched or cut.
Machine-Side Hopper Loaders Maintenance 8-9 F Verify that no cables are pinched or cut. Carbon brushes can be replaced twice. After that the turbine has to be completely replaced. & Order numbers Turbine (230 V, 1200 W): ID 83380 Carbon brushes (switching off): ID 85628 Turbine (230 V, 800 W): I...
Page 49 - To dispose of the products, you should take the following action:
Machine-Side Hopper Loaders 8-10 Maintenance 8.3. Taking out of service, dismantling, disposal M Only skilled personnel qualified for this work may dismantle the individualproduct modules. Parts that are under mechanical stress should be dissembled with utmost careto avoid the energy trapped in thes...
Page 52 - Dimension Sheet
Machine-Side Hopper Loaders Technical data 9-3 Dimension Sheet Two-liter model:
Page 54 - Spare parts list 10-1; Spare parts list; Other persons are not permitted to modify or repair the equipment.
Machine-Side Hopper Loaders Spare parts list 10-1 10. Spare parts list M This spare parts list is intended to be used only by trained personnel. Other persons are not permitted to modify or repair the equipment. & Wear Code: A = Wearing part, wears quickly B = Wearing part C = Spare part, reorde...
Page 55 - 0-2 Spare parts list
Machine-Side Hopper Loaders 10-2 Spare parts list 10.1. Parts breakdown, brush-type motor
Page 56 - Spare parts list 10-3; Designation
Machine-Side Hopper Loaders Spare parts list 10-3 10.2. Parts lists, 2-liter model 10.2.1. 230 V, 50 Hz Pos. Order no. Designation Wear Code 1 37767 Turbine head complete, with turbineand controller 2 37765 Covering cap 3 18491 Sieve 4 34197 Isolation 5 37768 Support 6 85629 Turbine (800 W) D 85628 ...
Page 57 - 0-4 Spare parts list
Machine-Side Hopper Loaders 10-4 Spare parts list 10.2.2. 110 V, 60 Hz Pos. Order no. Designation Wear Code 1 37777 Turbine head complete, with turbineand controller 2 37765 Covering cap 3 18491 Sieve 4 34197 Isolation 5 37768 Support 6 85844 Turbine (800 W) D 84716 Carbon brushes (switching off) B ...
Page 58 - Spare parts list 10-5; 30 V, 50 Hz with active cleaning; 10 V, 60 Hz with active cleaning
Machine-Side Hopper Loaders Spare parts list 10-5 10.2.3. 230 V, 50 Hz with active cleaning Pos. Order no. Designation Wear Code 1 37755 Filter with sealing A 2 37222 Basket 3 82593 Solenoid valve B 4 97745 Bush D 5 37800 Breather tube D 10.2.4. 110 V, 60 Hz with active cleaning Pos. Order no. Desig...
Page 59 - 0-6 Spare parts list
Machine-Side Hopper Loaders 10-6 Spare parts list 10.3. Parts list, 5-liter model 10.3.1. 230 V, 50 Hz (V66372, V66363) Pos. Order no. Designation Wear Code 1 38242 Turbine head complete, with turbineand controller 2 37765 Covering cap 3 18491 Sieve 4 34197 Isolation 5 37768 Support 6 83380 Turbine ...
Page 60 - Spare parts list 10-7
Machine-Side Hopper Loaders Spare parts list 10-7 10.3.2. 110 V, 60 Hz (V66378US) Pos. Order no. Designation Wear Code 1 S39361 Turbine head complete, with turbineand controller 2 37765 Covering cap 3 18491 Sieve 4 34197 Isolation 5 37768 Support 6 82559 Turbine (1200 W) D 82552 Carbon brushes (swit...
Page 61 - 0-8 Spare parts list
Machine-Side Hopper Loaders 10-8 Spare parts list 10.3.3. 230 V, 50 Hz with active cleaning (V66364) Pos. Order no. Designation Wear Code 1 34179 Filter with sealing A 2 37222 Basket 3 82593 Solenoid valve B 10.3.4. 110 V, 60 Hz with active cleaning Pos. Order no. Designation Wear Code 1 34179 Filte...
Page 62 - Spare parts list 10-9
Machine-Side Hopper Loaders Spare parts list 10-9 10.4. Parts breakdown and list, 5-liter model with brushless motor
Page 66 - Electrical manual 12-1; Electrical manual
Machine-Side Hopper Loaders Electrical manual 12-1 12. Electrical manual This electrical manual is intended to be used only by the manufacturer’s servicepersonnel and trained personnel authorized by the manufacturer. Other persons are not permitted to modify or repair the equipment.
Page 76 - Quick Start Guide
Machine-Side Loaders Quick Start Guide Quick Start Guide Turning on the loader: • Locate the power switch on the left side of thecontrol box and move to the ‘ON’ position. Setting the loader convey time: • It is only possible to set the convey time when theunit is not conveying material 1. Disconnec...
