Sterling Film Camera SSV 05 2R User Manual

Operating Instructions  
Single Conveyor Unit  
SSV 05/2R  
Sterling Material Processing  
 
SSV 05/2R  
Sterling Material Processing  
5200 West Clinton Ave.  
Milwaukee, WI 53223  
Telephone: (414) 354-0970  
Fax: (414) 354-6421  
Technical service:  
Service department  
Telephone: (800) 423-3183  
Edition: 08/99  
This operation manual is for*:  
(* Please fill in personally)  
Serial number:  
Built in:  
Date of delivery:  
Number of delivery:  
Date of commissioning:  
Location:  
Group of machines:  
2
 
SSV 05/2R  
Sterling Material Processing retains all rights to change the information in these  
operating instructions at any time without notice.  
We assume no liability for any errors or direct or indirect damage resulting in con-  
text with these operating instructions.  
Copying, translation or publication in any form except for personal use of pur-  
chaser requires approval from Sterling Material Processing.  
All rights reserved.  
3
 
SSV 05/2R  
Table of contents  
1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
1.1. Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
1.2. Explanations and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
1.3. For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
1.4. For the safety of the units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
2. Installation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
2.1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
2.2. Installing the conveyor hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
2.3. Installing the control and maintenance unit . . . . . . . . . . . . . . . . . 16  
2.4. Connecting the compressed-air supply . . . . . . . . . . . . . . . . . . . . 17  
2.5. Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
3. Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
3.1. Method of functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
3.2. Control and maintenance unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
4. Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
4.1. Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
4.2. Setting the mixing ratio of the components . . . . . . . . . . . . . . . . . 22  
4.3. Basic setting of the filling level in the conveyor hopper . . . . . . . 23  
4.3.1. Fine adjustment of the filling level in the  
conveyor hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24  
5. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
5.1. Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27  
5.2. Cleaning/replacing the filter cartridge . . . . . . . . . . . . . . . . . . . . . 28  
5.3. Adjusting the level probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
5.4. Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
4
 
SSV 05/2R  
6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31  
6.1. Dimension sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
6.2. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33  
5
 
SSV 05/2R  
1. Safety instructions  
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 equip-  
ment of the direct and indirect hazards connected with the  
equipment.  
These operating instructions are to be used by all persons as-  
signed activities connected with the equipment.  
Knowledge of the English language is prerequisite.  
Ensure in each case that the operating personnel are familiar  
with the operating instructions and the function of the  
equipment.  
Safety instructions 6  
 
 
SSV 05/2R  
1.1. Warnings and symbols  
The following warnings 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 warn-  
ings are not observed.  
»
This symbol indicates that serious injury is possible if the cor-  
responding instructions, regulations or warnings are not  
observed.  
L
This symbol indicates that extensive damage to equipment  
is possible if the corresponding instructions, regulations or  
warnings are not observed.  
F
This symbol indicates information important for becoming fa-  
miliar with the equipment, i.e. technical correlations.  
&
This symbol indicates that a technical term is explained at  
this point.  
$
Safety instructions 7  
 
 
SSV 05/2R  
1.2. Explanations and information  
Various terms and designations are used frequently in these operating instruc-  
tions to ensure clarity. Therefore please note that the terms used in the text stand  
for the corresponding explanations listed below.  
Equipment  
”Equipment” can mean an individual unit, a machine or an installation.  
·
Operating personnel  
The ”operating personnel” are persons operating the equipment on their own re-  
sponsibility or according to instructions (minimum age: 16).  
·
Operator  
·
The ”operator” of the equipment (production manager, foreman, etc.) is the per-  
son responsible for all production sequences. The operator instructs the operat-  
ing personnel of what is to be done.  
Operating instructions  
·
The ”plant operating instructions” describe the interaction of the equipment, pro-  
duction sequences or methods. The plant operating instructions must be com-  
piled by the operator of the equipment.  
Equipment foreman  
·
When several operating personnel work on one machine, the ”equipment fore-  
man” coordinates the sequences. The equipment foreman must be appointed by  
the operator.  
Trained personnel  
”Trained personnel” are persons who, due to their training, are authorized to carry  
out the required work in good practice.  
·
Safety instructions 8  
 
 
SSV 05/2R  
1.3. For your safety  
The operators of this unit must be at least 16 years old.  
·
Before initial operation, read this operating manual carefully. Observe all points.  
Inquire in case of uncertainties.  
This will avoid danger to persons and damage of material!  
·
Store this operating manual in such a way that it is always available on the site of  
operation for the unit. Faulty operation may lead to accidents!  
·
·
·
·
Note that, for reasons of clarity, not every possible case of operation or mainte-  
nance can be mentioned.  
Note the instructions for safety and the danger signs on the unit.  
This will avoid danger to persons and damage of material!  
All work on the unit may only be carried out by persons whose qualification corre-  
sponds with the individual chapters of the operating manual.  
Faulty operation may lead to accidents!  
For all types of work on the unit, proper working clothes must be worn.  
This will avoid danger to persons!  
·
·
·
Compare the connected loads to those of the mains supply.  
Danger of electrical shock!  
When using lifting gear, observe the specific instructions.  
Danger of accidents!  
Observe the local regulations and requirements concerning the plant.  
·
·
Interrupt the mains supply for all types of work on electrical components.  
Danger to life due to electrical shock!  
Safety instructions 9  
 
 
SSV 05/2R  
Do not carry through modifications, attachments or alterations of the unit without  
the manufacturer’s permission. Danger of accidents!  
·
·
By means of this operating manual, prepare precise instructions for use of this  
unit. Faulty operation may lead to accidents!  
Designate a unit leader responsible for the unit.  
·
·
In any case, the operators of this unit must be thoroughly instructed.  
Faulty operation may lead to accidents!  
If the unit has been switched off for reasons of safety, it must be protected from  
unathorised activation. Danger of accidents!  
·
Before beginning maintenance work, designate a supervisor.  
·
·
Before beginningmaintenance work, inform the responsible operating personnel.  
Danger of accidents!  
Before beginning maintenance work, interrupt the mains supply so that the unit is  
not switched on unintentionally. Danger of accidents!  
·
·
·
·
·
·
Repair work may only be carried through by trained personnel.  
Danger of accidents!  
The unit may never be operated when it is partially disassembled.  
Limbs may be drawn in! Electrical shock!  
In case of functional disturbances, switch off the unit immediately. Errors must be  
eliminated immediately. Danger of accidents!  
The unit is exclusively intended for conveying plastic granules and regrind. Any  
other usage is not permitted.  
This unit is not suitable for processing foods.  
Safety instructions 10  
 
SSV 05/2R  
Attachments which are not delivered by Sterling must be constructed according  
to the safety standard EN 294. Danger of accidents!  
·
·
Check all lines, hoses and coupling pieces in regular intervals for leakages and  
damage. Any errors must be eliminated immediately.  
Danger of accidents!  
Before beginning maintenance work, set all compressed-air lines on the unit at  
zero pressure. Danger of accidents!  
·
·
·
The unit may only be operated if all corresponding components have been prop-  
erly connected and are in accordance with the relevant regulations.  
Observe the safety instructions for the connected units.  
Safety instructions 11  
 
SSV 05/2R  
1.4. For the safety of the units  
The unit may only be used for conveying cylindrical plastic granules and regrind  
on injection moulding machines.  
·
·
Never change settings unless you are able to precisely foresee the conse-  
quences.  
Use only original Sterling spare parts.  
·
·
·
·
·
Observe the maintenance intervals.  
Keep a book on all maintenance and repair work.  
Note that electronic subassemblies may be damaged by static discharge.  
Before initial operation and in regular intervals, check all electrical connections for  
proper fit.  
Never modify sensors without knowing their precise functions.  
Make sure that all plugs are connected properly.  
·
·
·
·
Observe the carrying capacity of the machine flange.  
Observe the operating manuals of the connected units.  
Safety instructions 12  
 
 
SSV 05/2R  
2. Installation instructions  
These installation instructions are intended for persons with  
skills in electrical and mechanical areas due to their training, ex-  
perience and received instructions.  
Personnel using these installation instructions must be in-  
structed in the regulations for the prevention of accidents, the  
operating conditions and safety regulations and their implemen-  
tation.  
»
Ensure in each case that the personnel are informed.  
The installation instructions provided in the corresponding oper-  
ating instructions apply for all connected equipment.  
Observe safety regulations with regard to lifting gear handling.  
All installation work must be carried out with the equipment  
disconnected from electrical power and compressed air supply.  
For installation work taking place at heights of over approx.  
1829 mm. (6 ft), use only ladders or similar equipment and  
working platforms intended for this purpose. At greater  
heights, the proper equipment for protection against falling  
must be worn.  
L
Use only suitable lifting gear which is in proper working order  
and load suspension devices with sufficient carrying capac-  
ity. Do not stand or work under suspended loads!  
Use suitable workshop equipment.  
Install the equipment such that all parts are easily accessi-  
ble; this facilitates maintenance and repair work.  
F
Installation instructions 13  
 
 
SSV 05/2R  
2.1. General information  
Unpack all parts of the single conveyor unit and make sure that everything is  
available:  
conveyor hopper with level probe (1)  
·
control and maintenance unit (2)  
·
2 x injector tube (3)  
·
2 x supply hose (4) with 4 hose clamps  
·
compressed-air hose  
·
operating instructions  
·
4
1
0
3
2
1
Installation instructions 14  
 
 
SSV 05/2R  
2.2. Installing the conveyor hopper  
The single conveyor unit is not sensitive to shocks and can be installed directly on  
the processing machine.  
Make sure that all connections are tight so that the conveying performance is not  
impaired.  
The conveyor hopper is equipped with a universal flange.  
Depending on the position, drill the holes for fastening the conveyor hopper to the  
processing machine.  
Mount the conveyor hopper on the processing machine.  
Install the supply hoses on the conveyor hopper and on the injector tubes by  
means of the hose clamps which are part of the supply.  
Note that the hopper may not touch any other component.  
F
Installation instructions 15  
 
 
SSV 05/2R  
2.3. Installing the control and maintenance unit  
Install the control and maintenance  
unit at a freely accessible site.  
Observe the length of the connection  
cable.  
1
0
Observe the length of the supplied  
hoses to the injector tubes.  
During installation, observe the length of the supply lines.  
F
Installation instructions 16  
 
 
SSV 05/2R  
2.4. Connecting the compressed-air supply  
Check compressed-air piping for correct installa-  
tion and assembly.  
Check fittings, length and quality of the hose con-  
nections for agreement with requirements.  
Check all compressed-air lines for leakages.  
You need a compressed-air supply with 5 - 6 bar  
(72.52-87.02 PSI) system overpressure. The air  
should be free from oil and water, if possible.  
Connect the compressed-air hose, which is part  
of the supply, to the injector tube and to the control  
and maintenance unit. To this end, the com-  
pressed-air hose is firmly pressed into the con-  
necting sockets.  
Connect the control and maintenance unit to the compressed-air supply (max. in-  
put pressure 10 bar (145.04 PSI) system overpressure).  
Set the pressure on the pressure reducer at 5 - 6 bar (72.52-87.02 PSI).  
Maximum input pressure 10 bar (145.04 PSI) (system  
overpressure).  
F
Maximum output pressure 6 bar. (87.02 PSI)  
Installation instructions 17  
 
 
SSV 05/2R  
2.5. Electrical connection  
Observe the regulations of the local electricity board.  
»
The operating voltage is 230 V, AC, PE, 50/60 Hz.  
Special voltages available on request.  
The connected load is approx. 15 W.  
The connection takes place by means of a mains connector.  
A separate protection of the socket is not necessary.  
Connect the plug of the probe cable to the control unit.  
Plug the mains connector into a corresponding socket.  
Installation instructions 18  
 
 
SSV 05/2R  
3. Functional description  
This functional description is intended for the operating person-  
nel of the equipment.  
»
General knowledge of operating conveyor units is prerequisite.  
Ensure in each case that the operating personnel are  
sufficiently informed.  
The single conveyor unit SSV 05/2R is designed for convey-  
ing 2 dust-free components (plastic granules and/or regrind)  
directly on the injection moulding machine.  
F
Functional description 19  
 
 
SSV 05/2R  
3.1. Method of functioning  
The single conveyor unit works according  
to the venturi principle. An external com-  
pressed-air supply is needed.  
A venturi meter (A) is integrated in the in-  
jector tube. The venturi meter aspirates  
the material in the lower part of the tube (C)  
and then conveys the material into the con-  
veyor hopper by means of compressed air  
in the upper part (B). In the hopper loader,  
the material is separated from the air.  
B
C
A
The filling level in the conveyor hopper is  
monitored and controlled by means of a  
level probe.  
3.2. Control and maintenance unit  
The unit is switched on and off at the control and maintenance unit.  
On the pressure reducers, the operat-  
ing pressure and the mixing ratio be-  
tween component 1 and component 2  
is adjusted.  
1
0
A water separator is integrated.  
Functional description 20  
 
 
SSV 05/2R  
4. Set-up  
This chapter is intended for the operating personnel of the  
equipment.  
»
General knowledge of operating conveyor units is prerequisite.  
The functional description must have been read and under-  
stood.  
Ensure in each case that the operating personnel are  
sufficiently informed.  
Set-up 21  
 
 
SSV 05/2R  
4.1. Preparations  
Check whether the injector tubes are inserted in the material to be conveyed.  
Switch on the compressed-air supply.  
Switch on the conveyor unit at the control and maintenance unit.  
The conveyor unit should now convey until the conveyor hopper is filled up to the  
level probe.  
4.2. Setting the mixing ratio of the components  
The mixing ratio of the components is adjusted on the pressure reducers.  
The adjustment on the pressure reducers will vary according  
to the material, flow properties, particle size and conveying  
distance.  
&
Set-up 22  
 
 
SSV 05/2R  
4.3. Basic setting of the filling level in the conveyor hopper  
The filling level in the conveyor hopper is mainly determined by the level probe.  
Filling level too low  
By means of a screwdriver, turn the adjust-  
ment screw of the level probe (A)  
¼ rotation counterclockwise.  
Observe the filling level during the next con-  
veying procedure.  
Repeat the process until the desired filling  
level in the conveyor hopper is reached.  
A
Filling level too high  
By means of a screwdriver, turn the adjustment screw (A) of the level probe ¼ ro-  
tation clockwise.  
Observe the filling level during the next conveying procedure.  
Repeat the process until the desired filling level in the conveyor hopper is  
reached.  
Set-up 23  
 
 
SSV 05/2R  
4.3.1. Fine adjustment of the filling level in the conveyor hopper  
Before the fine adjustment, carry through a basic adjust-  
ment.  
&
During operation, carefully turn the adjustment screw (A) of the level probe by  
means of a screwdriver until the desired fill-  
ing level is reached.  
A
Clockwise rotation makes  
the filling level fall.  
&
Counterclockwise rotation makes the filling level rise.  
If the filling level in the conveyor hopper cannot be lowered far enough by means  
of the level probe, the pressure on the control and maintenance unit can be re-  
duced step by step.  
Set-up 24  
 
 
SSV 05/2R  
5. Maintenance  
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 in-  
structed of the regulations for the prevention of accidents, the  
operating conditions and safety regulations and their implemen-  
tation.  
Ensure in each case that the personnel are informed accord-  
ingly.  
For maintenance work taking place at heights of over approx  
1829 mm.(6 ft.), use only ladders or similar equipment and  
working platforms intended for this purpose. At greater heights,  
the proper equipment for protection against falling must be  
worn.  
Use only suitable lifting gear which is in proper working order  
and load suspension devices with sufficient carrying capacity.  
Do not stand or work under suspended loads!  
Ensure that the electric motors/switch cabinets are sufficiently  
protected against moisture.  
Use only suitable workshop equipment.  
Before starting maintenance work, appoint a supervisor.  
Inform the responsible personnel before maintenance work on  
the system is started.  
Never operate the equipment when partially dismantled.  
All maintenance and repair work not described in this chapter  
may only be carried out by Sterling service personnel or  
authorized personnel (appointed by Sterling).  
Maintenance 25  
 
 
SSV 05/2R  
Disconnect the equipment from mains supply before starting  
maintenance procedures to ensure that it cannot be  
switched on unintentionally.  
L
Depressurize all compressed air piping of the equipment be-  
fore starting maintenance work.  
Please observe the maintenance intervals.  
F
Before starting maintenance work, clean the equipment of  
oil, fuel or lubricants.  
Ensure that materials and incidentals required for operation  
as well as spare parts are disposed of properly and in an en-  
vironmentally sound manner.  
Use only original Sterling spare parts.  
Keep record of all maintenance and repair procedures.  
Maintenance 26  
 
SSV 05/2R  
5.1. Maintenance intervals  
daily: Check the setting of the pressure reducer.  
Empty the water separator.  
Check the danger signs on the unit for legibility  
and completeness.  
monthly:  
Clean the filter and sieve  
(depending on accumulation of dust!).  
Blow out the filter from the inside out by means  
of compressed air.  
Check the unit plugs for proper functioning.  
every six months: Check all electrical and mechanical connections  
for proper fit.  
Replace the filter and the sieve  
(depending on accumulation of dust!).  
The given maintenance intervals are average values.  
F
Check whether in your individual case the maintenance in-  
tervals must be shortened.  
Maintenance 27  
 
 
SSV 05/2R  
5.2. Cleaning/replacing the filter cartridge  
Switch off the unit.  
»
Disconnect the mains plug.  
Disassembly  
Remove the filter cartridge (A).  
Blow out the filter cartridge (A) from the inside out by means of compressed air or  
replace the filter.  
Open the toggle-type fastener (B) and fold the hopper lid upwards.  
Check the sieve (C) within the lid for material residue. Disassembling the sieve for  
cleaning: draw the sieve out of the fit of the sealing ring.  
Clean the sieve (C) by means of compressed-air.  
Replace the sieve and sealing ring in case of damage.  
A
C
A
B
Maintenance 28  
 
 
SSV 05/2R  
Assembly  
Assemble the sieve and the sealing ring.  
Check the sieve for proper fit.  
Clean the hopper loader by means of a vacuum cleaner.  
Close the hopper lid.  
Close the toggle-type fastener.  
Assemble the filter cartridge.  
Order number  
filter cartridge:  
&
ID 98171  
Sieve:  
Sealing ring:  
ID 29252  
ID 28628  
5.3. Adjusting the level probe  
See chapter “set-up”.  
F
Order number  
level probe:  
&
ID 85480  
Maintenance 29  
 
 
SSV 05/2R  
5.4. Trouble-shooting  
Problem  
Remedy  
The unit is not conveying  
and is not active  
a, b, g, h  
The unit is not conveying;  
the compressed-air valve is switched  
when the device is switched on  
c, f  
The unit is not conveying,  
the compressed air is flowing audibly  
c, d, e, f, i, j, k  
g, l, m  
The unit is overfilled  
The unit is not filled properly  
Test steps  
c, d, e, f, i, j, k, l  
a) Check whether the unit is switched on.  
b) Check whether the mains connector is connected and mains voltage is pres-  
ent.  
c) Check whether sufficient compressed air is available.  
d) Check whether the injector tube is inserted in the material.  
e) Check whether the compressed-air hose is properly connected to the injector  
tube.  
f) Check whether the compressed-air hose is properly connected to the mainte-  
nance unit.  
g) Check whether the level probe is properly adjusted.  
h) Check whether the cable of the level probe is properly connected.  
i) Check whether the filter is clogged.  
j) Check whether the sieve is clogged.  
k) Check whether the conveyor hose is properly connected.  
l) Check whether the compressed-air supply is properly adjusted.  
Maintenance 30  
 
 
SSV 05/2R  
6. Technical data  
Max. permissible shot weight  
of the injection moulding machine: . . . . . . . . . . . . . . . 100 kg/h (with 0.6 kg/l)  
(220.56 lbs/hr) (1.32 lbs./l)  
Weight: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 3 kg  
(6.61 lbs.)  
Operating voltage: . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 V, AC, PE, 50/60 Hz  
Special voltage on request  
Connected load: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 15 W  
Total noise level: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . < 75 dB (A)  
Compressed-air supply: . . . . . . . . . . . . . . . . . . 5-6 bar (system overpressure)  
(72.52-87.02 PSI)  
Max. product temperature:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 °C  
( 176°F)  
Technical data 31  
 
 
SSV 05/2R  
6.1. Dimension sheet  
Dimensions and data are not binding. All dimensions are in mm. (in.) All data are subject to change.  
Technical data 32  
 
 
SSV 05/2R  
6.2. Spare parts list  
2
3
1
6
1
0
4
5
Technical data 33  
 
 
SSV 05/2R  
Pos.  
ID-No.  
Designation  
1
2
85480  
level probe  
98171  
29252  
28628  
filter cartridge  
sieve  
sealing ring  
3
84426  
97784  
conveyor hose  
hose clamp  
4
5
6
31683  
31177  
88351  
injector tube  
maintenance and control unit  
compressed-air hose  
Technical data 34  
 

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