Sterling Webcam SM3 615a User Manual

Operating Instructions  
Conveyor Hopper  
SSK 5-DURO  
Sterling Material Processing  
 
SSK 5-DURO  
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: 10/01  
These operating instructions are for:*  
(* Please fill in personally)  
Serial number:  
Built in:  
Date of delivery:  
Number of delivery:  
Date of commissioning:  
Location:  
Group of machines:  
2
 
SSK 5-DURO  
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 purcha-  
ser requires approval from Sterling Material Processing.  
All rights reserved.  
3
 
SSK 5-DURO  
Table of contents  
1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
1.1. Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
1.2. Explanations and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
1.3. For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
1.4. For the safety of the equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
2. Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
2.1. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
2.2. Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
2.3. Compressed-air supply (only with compressed-air valves) . . . . . . . . . . . . . . . . 11  
2.4. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
3. Functional description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
4.1. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
4.2. Servicing the hopper loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
4.2.1. Replace the sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
4.2.2. Adjust the flap switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
4.2.3. Replacing the filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
4.2.4. Cleaning the hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
5. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
6. Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27  
4
 
SSK 5-DURO  
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 equipment of the  
direct and indirect hazards connected with the equipment.  
These operating instructions are to be used by all persons assigned activi-  
ties connected with the equipment.  
Knowledge of the English language is prerequisite.  
Ensure in each case that the operating personnel are familiar with the operat-  
ing instructions and the function of the equipment.  
Observe the safety instructions of the connected conveying system.  
Safety instructions 5  
 
 
SSK 5-DURO  
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 warnings are not observed.  
»
This symbol indicates that serious injury is possible if the corresponding  
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 familiar with  
the equipment, i.e. technical correlations.  
&
This symbol indicates that a technical term is explained at this point.  
$
Safety instructions 6  
 
 
SSK 5-DURO  
1.2. Explanations and information  
Various terms and designations are used frequently in these operating instructions to ensure clar-  
ity. 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 responsibility or ac-  
cording to instructions (minimum age: 16).  
·
Operator  
The “operator” of the equipment (production manager, foreman, etc.) is the person responsible for  
allproductionsequences. Theoperatorinstructstheoperatingpersonnelofwhatistobedone.  
·
Operating instructions  
The “plant operating instructions” describe the interaction of the equipment, production se-  
quences or methods. The plant operating instructions must be compiled by the operator of the  
equipment.  
·
Equipment foreman  
When several operating personnel work on one machine, the “equipment foreman” 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 7  
 
 
SSK 5-DURO  
1.3. For your safety  
It is absolutely necessary that you observe the operating instructions for the corresponding con-  
veying system.  
·
·
The device is intended exclusively for conveying plastic granules and regrind. Any other usage is  
not permitted.  
This device is not suitable for processing foods.  
·
·
Before beginning maintenance work, set all compressed air piping on the device at zero pressure.  
Danger of accidents!  
The device may only be operated if all corresponding components have been properly connected  
and are in accordance with the relevant regulations.  
·
1.4. For the safety of the equipment  
It is absolutely necessary that you observe the operating instructions for the corresponding con-  
veying system.  
·
For the operation of the hoppers, a compressed-air supply is necessary.  
·
Never set the operating pressure of the hoppers at more than 6 bar (87.02 PSI) (system  
overpressure).  
·
Install the hoppers in such a way that the outlet flap is hinged in a right angle to the direction of  
movement of the machine.  
·
Make sure that all plugs are connected properly.  
·
Observe the carrying capacity of the machine flange.  
·
Safety instructions 8  
 
 
SSK 5-DURO  
2. Installation instructions  
These installation instructions are intended for persons with skills in electri-  
cal and mechanical areas due to their training, experience and received in-  
structions.  
»
Personnel using these installation instructions must be instructed in the reg-  
ulations for the prevention of accidents, the operating conditions and safety  
regulations and their implementation.  
Ensure in each case that the personnel are informed.  
The installation instructions provided in the corresponding operating instruc-  
tions 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. 6 feet, 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 capacity. Do not stand or  
work under suspended loads!  
Use suitable workshop equipment.  
Install the equipment such that all parts are easily accessible; this facili-  
tates maintenance and repair work.  
F
Installation instructions 9  
 
 
SSK 5-DURO  
2.1. Transport  
For transport, only the appropriate lifting gear should be used (e.g. fork lift or workshop crane).  
Observe the carrying capacity of the lifting gear.  
Observe the safety instructions for the handling of lifting gear.  
»
2.2. Set-up  
The arrangement of the hopper loaders may vary depending on the type of device to be conveyed  
on and the material used. Fastening onto fixed machine throats is provided by means of strap re-  
tainers. However, additional support of the hopper loader is necessary if the devices are not suffi-  
ciently capable of bearing the load.  
Mount the hopper loader in such a way that the outlet flap swings in a right-hand angle to the direc-  
tion of machine movement. Please check during assembly that the admissible bearing loads are  
not exceeded.  
Please check that all connecting points are tight to ensure that the conveying performance is not  
impaired.  
It should moreover be observed, particularly if custom produced connecting parts are used, that  
the material discharged from the hopper loader must neither get into the open nor must it clog the  
filter surfaces (observe angle of repose!).  
Do not excessively load inlet nozzle of hopper loader, remove hose sepa-  
rately, if necessary!  
F
J
L
Assembly  
Installation instructions 10  
 
 
SSK 5-DURO  
2.3. Compressed-air supply (only with compressed-air valves)  
For operating the control valves, a com-  
pressed-air supply is necessary.  
Check compressed-air piping for correct  
installation and assembly.  
Check fittings, length and quality of the  
hose connections for agreement with re-  
quirements.  
The operating pressure is 5-6 bar (72.52-  
87.02 PSI) (system overpressure).  
Check the compressed-air supplied by the  
plant’s supply network.  
Adjust compressed-air pressure to 5-6 bar  
PSI)  
(72.52- 87.02  
overpressure).  
(system  
Connect the unit to the plant’s supply net-  
work by means of a hose.  
Maintenance unit  
Depressurize compressed-air supply lines which must be opened.  
L
Compressed air must be dewatered, dust-free and oil-free.  
Install a maintenance unit if required.  
F
Adjust pressure to a max. value of 6 bar (87.02) PSI (system  
overpressure).  
Installation instructions 11  
 
 
SSK 5-DURO  
2.4. Electrical connection  
The electrical connection may only be carried out by trained personnel.  
Other persons are not permitted to carry out the electrical connection.  
»
The rules of the local electricity board must be observed.  
Before beginning the electrical connection, make sure that the mains voltage  
and the power frequency are in accordance with the data on the name plate  
of the device.  
All work may only be carried out when the unit is at zero voltage and at zero  
pressure.  
Installation instructions 12  
 
 
SSK 5-DURO  
AV = cleaning valve  
KS = flap switch  
SV = diaphragm valve  
1 = flap switch (KS)  
2 = cleaning valve (AV)  
3 = diaphragm valve (SV)  
4 = KS  
5 = AV  
6 = SV  
Installation instructions 13  
 
SSK 5-DURO  
3. Functional description  
The conveyor hopper is used for the automatic conveyance of thermoset duroplast material as  
well as thermoplastic powder.  
The hopper can only function in connection with a vacuum conveyor plant.  
The hopper works with a filter cartridge. The shut-off valve of the vacuum line is operated with  
compressed air (compressed-air valve). The automatic filter cleaning is achieved by intense  
vibration.  
Functional description 14  
 
 
SSK 5-DURO  
4. 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 instructed of the reg-  
ulations for the prevention of accidents, the operating conditions and safety  
regulations and their implementation.  
Ensure in each case that the personnel are informed accordingly.  
For maintenance work taking place at heights of over approx.1828.8 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 sus-  
pension 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).  
Disconnect the equipment from mains supply before starting mainte-  
nance procedures to ensure that it cannot be switched on unintentionally.  
L
Depressurize all compressed air piping of the equipment before starting  
maintenance work.  
Maintenance 15  
 
 
SSK 5-DURO  
Please observe the maintenance intervals.  
Before starting maintenance work, clean the equipment of oil, fuel or lubri-  
cants.  
F
Ensure that materials and incidentals required for operation as well as  
spare parts are disposed of properly and in an environmentally sound  
manner.  
Use only original Sterling spare parts.  
Keep record of all maintenance and repair procedures.  
Maintenance 16  
 
SSK 5-DURO  
4.1. Maintenance intervals  
Daily:  
check warning signs on equipment for good  
legibility and completeness.  
with compressed-air valve:  
check the oil level in the oiler  
empty the water separator  
check the operating pressure in the factory ductwork system  
(max. 6 bar (87.02 PSI) system overpressure)  
Every six months:  
check all electrical and mechanical connections for proper fit  
check the settings of the level probes (if available)  
check the sealing rings on the locking flaps  
Yearly:  
replace the sealing rings on the locking flaps  
replace filter cartridge (depending on amount of dust)  
The given maintenance intervals are average values.  
Check whether in your individual case the maintenance intervals must be  
shortened.  
F
4.2. Servicing the hopper loader  
Individual hoppers can also be maintained during operation. However,  
Sterling recommends that you switch off the conveying plant for all types  
of work on the hopper.  
&
Wait until the conveying procedure has stopped.  
Disassemble the vacuum line on the hopper.  
Close the disassembled vacuum line so that the vacuum for the active hopper-loaders does not  
break down.  
Depressurize the compressed-air line to the hopper (only with compressed-air valve).  
Disassemble the material line on the lateral inlet of the hopper.  
Disassemble the hopper.  
Maintenance 17  
 
 
SSK 5-DURO  
4.2.1. Replace the sealing rings  
Nonreturn valve  
Loosen the tightening strap at the hopper lid.  
Remove the hopper lid .  
Draw the old sealing ring off the nozzle (A).  
Install the new sealing ring. Observe the direc-  
tion of installation (B).  
Mount the hopper lid.  
Mount the tightening strap.  
Install the hopper.  
A
B
SSK 5-DURO  
Order number sealing ring: ID 85610  
&
Maintenance 18  
 
 
SSK 5-DURO  
Outlet flap  
Draw the old sealing ring off the nozzle of  
the material outlet.  
Install the new sealing ring.  
Outlet flap  
Observe the direction of installation.  
F
Install the hopper.  
Order number sealing ring: ID 23098  
&
Maintenance 19  
 
SSK 5-DURO  
4.2.2. Adjust the flap switch  
Remove the connecting plug “flap switch”  
from the connection housing of the hopper.  
Connect an ohmmeter to PINS 1 and 4 of  
the connecting plug “flap switch”.  
Release the nuts (A) of the flap switch (B)  
until the support can be displaced.  
Open the outlet flap (C) so far that the front  
tip of the outlet flap is approx. 35-40 mm  
(1.48-1.67 in.) away from the sealing sur-  
face.  
35  
- 40  
Displace the flap switch (B) until the con-  
tact of the magnet switch is closed.  
C
B
A
Tighten the nuts (A) of the flap switch.  
Check the adjustment:  
In case of free hanging outlet flap (empty  
hopper loader) the contact of the magnet  
switch must be closed.  
Flap switch  
If the outlet flap cannot be properly adjusted, replace the flap switch or the outlet flap with magnet.  
Install the hopper.  
Order numbers  
&
flap switch:  
outlet flap with magnet:  
ID 28839  
ID 23093  
Maintenance 20  
 
 
SSK 5-DURO  
4.2.3. Replacing the filter cartridge  
Loosen the tightening strap (A).  
Remove the hopper lid (B).  
B
A
Remove the locking pin from the threaded  
rod (C).  
Loosen the 2 flat nuts (D) and remove the  
safety plate (E).  
Remove the washer (F).  
Pull the filter cartridge (G) from the threa-  
ded rod.  
Use compressed air to blow through the  
filter cartridge from inside out or replace  
the old filter cartridge.  
G
F
C
D
E
Put the new filter cartridge/cleaned filter  
cartridge (G) onto the threaded rod.  
SSK 5-DURO  
Mount the washer (F) and a flat nut (D).  
Put back the safety plate (E).  
Mount the second flat nut (D).  
Put a new locking pin in the threaded rod (C).  
Mount the hopper lid (B).  
Mount the tightening strap (A).  
Install the hopper.  
Order numbers  
&
filter cartridge:  
locking pin:  
ID 85612  
ID 96093  
Maintenance 21  
 
 
SSK 5-DURO  
4.2.4. Cleaning the hopper  
Loosen the tightening strap.  
Remove the hopper lid.  
Clean the hopper loader by means of a  
vacuum cleaner.  
Mount the hopper lid.  
Mount the tightening strap.  
A
B
C
Open the toggle-type fasteners (A) on the  
flap of the hopper loader.  
Check the filter cloth (B) and the wire cloth  
(C) for material residue. Clean the filters  
by means of compressed air.  
Close the toggle-type fasteners (A) on the  
flap of the hopper loader.  
Install the hopper.  
SSK 5-DURO  
Maintenance 22  
 
 
SSK 5-DURO  
5. Spare parts list  
This parts list is only for the use of trained personnel only.  
All other persons are not permitted to repair or to change the equipment.  
»
Wear Code:  
&
A = Wearing part, fast used up  
B = Wearing part  
C = Spare part, storekeeping for 1 year  
D = Spare part, storekeeping for 2 years  
E = Spare part, storekeeping for more than 2 years  
Spare parts list 23  
 
 
SSK 5-DURO  
V 66412 SSK 5-DURO, complete  
4
2
8
74  
13  
78, 79  
40  
41  
44  
78, 79  
75  
Spare parts list 24  
 
SSK 5-DURO  
Pos.  
Order no.  
26487  
26491  
23066  
09646  
85489  
02128  
85612  
03141  
96093  
13021  
85610  
85533  
26451  
28420  
Designation  
compressed-air valve, complete  
diaphragm valve, complete  
cylinder with valve  
sealing ring  
sieve  
Wear Code  
E
2
C
C
C
C
B
C
B
E
B
E
E
C
4
8
13  
40  
41  
44  
74  
75  
78  
hose  
filter cartridge  
vibrator  
locking pin  
sealing  
sealing  
tension ring  
fastener  
79  
sealing ring  
Spare parts list 25  
 
SSK 5-DURO  
87  
86  
78, 79  
93  
94  
89  
88  
Pos.  
Order no.  
85533  
26451  
28420  
23091  
28626  
28625  
28839  
26462  
23098  
23093  
Designation  
tension ring  
fastener  
Wear Code  
78  
E
E
B
C
C
B
D
D
B
E
79  
86  
87  
88  
89  
sealing ring  
wire cloth  
filter cloth  
sealing  
flap switch with plug and cable  
cover  
93  
94  
sealing ring  
outlet flap with magnet  
Spare parts list 26  
 
SSK 5-DURO  
6. Technical data  
Dimension Sheet  
Dimensions and data without obligation. Dimensions in mm (in.) Specifications may be subject to alterations.  
Technical data 27  
 
 
SSK 5-DURO  
Electrical manual  
This electrical manual is intended to be used only by Sterling service person-  
nel and trained personnel authorized by Sterling.  
»
Other persons are not permitted to modify or repair the equipment.  
Technical data 28  
 

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