Instruction/ maintenance manual of the product SDD 1 SGM Sterling
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Op er ating In struc tions SDD 1 SGM with S 150 con trol unit 1 7 6 - 1 M S Ster ling Ma te rial Pro cess ing.
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.
Ster ling Ma te rial Pro cess ing re tains all rights t o change the in for ma tion in these op er at ing in struc t ions 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 t ions.
Ta ble of con tents 1. Safety in struc tions ........................................................ 1-1 1.1. For your safety ................................................... 1-2 1.2. For the op er at ing safety of the equip ment .................
5. As sem bly in struc tions ..................................................... 5-1 5.1. Trans port ........................................................ 5-2 5.2. SDD 1 SGM ...................................................... 5-2 5.2.1. Mount ing on the pro cess ing ma chine .
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 the di rect and in di rect haz ards con nected with the equip ment.
1.1. For your safety Gen eral The op er at ing per son nel of this equip ment must be at least 16 years old. Please read these op er at ing in struc tions care fully be fore tak ing into op er a tion for the first time. Con tact us should ques tions arise.
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 the equip ment.
1.2. For the op er at ing safety of the equip ment Never change set tings if the con se quences are not pre cisely known. Use only orig i nal Ster ling spare parts. Please ob serve the main te nance in ter vals. Keep re cord of all main te nance and re pair pro ce dures.
2. Con cer nin g 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 with work on the unit.
2.1. War ning Mes sa ges and Sym bols The fol lo wing war ning mes sa ges and sym bols are used in the se ope ra ting in struc tions: » This sym bol in di cates dan ger to life! Fa tal or se ri ous in jury is pos si ble if the cor re spond ing in struc tions, reg u la tions or warn ings are not ob served.
2.2. Ex pla na tions and De fi ni t ions In this ope ra ting ma nu al, cer tain terms are used re pea ted ly for bet ter cla ri ty. The re fo re plea se keep in mind that the se terms stand for the ex pla na tions gi ven here. · Unit “Unit” may de sig na te eit her a sing le de vi ce, a ma chi ne or a plant.
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 sing and 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 des crip ti on has been read and un ders tood.
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"). The con 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 by sym bols (C).
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 cess was started by press ing the “run” key.
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 P.
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 ned or 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 tem or a po wer fai lu re.
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): ..................
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 the bot 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 for spe cial ap pli ca tions.
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 .......
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),-black motor 11739 (6.5 rpm), 2135 (35.5 rpm)-blue motor 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 tor Bauer mo tor: 0.
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 .
Press key LED dis play dis play “13" com mu ni ca tion ad dress stan dard re gu la ti on: 1 Only if Eu ro map17-report is in use en ter com mu ni ca ti on ad dress “14” material con tents o.
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 be me te red sin ce the ca li brat ion weight dif fers from ma te ri al to ma te ri al.
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 points away from the mi xing hop per.
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 ken into 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).
Press key LED dis play dis play — — — — fil ling pro ce du re If cal i bra tion w eight “0" in the rec ipe: The dos ing mo tor turns for one rev o lu tion at half of the max i mum ro ta tional speed.
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 erly in 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.
3.5. Mo di fy/Crea te Re ci pe & By press ing the “stop” key, y ou can quit the menu at any tim e while tak ing on the en tered val ues. The fol lo wing is re qui red: · the de si red co lou .
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" .
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” printer Only if a printer (op t.
3.5.1. Save Re ci pe Press key LED dis play dis play “L (= load)” and the most re cent ly cal led up re ci pe num ber “S (= save)” and the most re cent ly sa ved re ci pe num ber se lect re ci.
3.6. Starting mode F Only in case of moun ting on a Mico mix ing-hopper. Press key LED dis play dis play ma te rial con tents of the mix ing-hoppe mixing the material total through put 3.7. Star ting the Con ti nu ous Ope ra ti on Press key LED dis play dis play to ta li zer 1 7 6 - 1 M S S 150 Put ting into op er a tion 3 - 21 lb kg bzw .
3.8. Vie wing the Ac tu al Va lu es Press key LED dis play dis play to ta li zer throughput ro ta tio nal speed of the do sing mo tor no mi nal cur rent of the mo tor in % 3.
3.10. Cal ling up t he re ci pe Press key LED dis play dis play to ta li zer “L (= load)” and the most re cent ly cal led up re 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 pres sing the On/Off switch.
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 on has been re me died.
“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 more than 2 se conds by 30 % or for a ma xi mum of 0.5 se conds by 80 %.
“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.
4. M ain te nance » This chap ter is 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.
L Dis con nect the equip ment from mains sup ply be fore start ing main te - nance pro ce dures to en sure that it can not be switched on un in ten tion ally. Depressurize all com pressed air pip ing of the equip ment be fore start ing main te nance work.
4.1. Main te nance in ter vals Daily: Check warn ing signs on equip ment for good leg i bil ity and com plete ness Weekly: Check func tion of the on/off switch Ev ery 3 months: Check scraper in dos in.
4.2. Re moving/r e 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) on the dos ing hop per.
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.
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 the dos ing unit.
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.
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.
Ob serve that a dos ing and blend ing unit may only be put into op er a tion if all dos ing sta tions and cov ers are in place. Dan ger of squeez ing! & Or der num bers Dosing disc 72 cham bers: I.
4.4.1. In stalling Dif fer ent Types of Dosing Discs 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 the con trol sys tem.
4.5. Re moving/r e plac ing the scraper in the SDT 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 (C) of the dos ing con - tainer.
In stall the new scraper along with the hold ing plate. Tighten down the 3 plas tic screws. Make sure that the strip per is fit ted par al lel to the dos ing plate. F Use only plas tic screws (DT- t: metal screws). In stall the dos ing con tainer along with the dos ing hop per on the dos ing hous ing (pay at ten tion to the guide pins).
4.6. Cleaning the SDT 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 (C) of the dos ing con - tainer. Re move the tight en ing strap (C).
Mount the dos ing hous ing onto the dos ing mo tor. Ob serve that the guide pins are locked into po si tion. F Close the tog gle-type fas ten ers. Mount the safety srews. In stall the dos ing con tainer along with the dos ing hop per on the dos ing hous ing (pay at ten tion to the guide pins).
4.7. Ex change able sta ti ons 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 the con trol sys tem.
4.8. Ex changing Fuses » These tasks may be car ried out by trained per son nel only. Stop the con tin u ous op er a tion. Wait un til the dos ing unit has come to a stand still. Switch off the de vice by means of the On/Off switch. Cut off the volt age sup ply.
Open the screws (A) and re move the lid (B). Re move the blind lid (C) and open the screws. Move the lid (D) aside. 1 7 6 - 1 M S SDD 1 SGM M ain te nance 4 - 17 S 150.
Re move the de fec tive fuse from the fuse car rier. In stall the new fuse (while ob serv ing the value). Mount the lid (D). Fas ten the screws and the blind lids (C).
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.
5.1. Trans port The equip ment is de li ver ed as a com ple te as sem bly. Only use for trans port of the equip ment a suit ab le hoist (e. g. a fork lift truck or a work shop cra ne). » Plea se en su re ade qua te car ry ing ca pa ci ty of the lif ting gear.
5.2.1. Mount ing on the pro cess ing ma chine Re mo ve the ma chi ne hop per from the pro ces sing ma chi ne. Check the car ry ing ca pa ci ty of the ma chi ne flan ge. F If the car ry ing ca pa ci ty is not suf fi cient, a sup port must be moun ted. Check whet her the hop per piece fits on the ma chi ne flan ge.
5.3. Con trol sys tem S 150 The con trol sys tem may be in stal led eit her di - rect ly at the hop per pie ce or se pa ra te ly (ver ti - cal in stal la ti on). The con trol sys tem has to be fi xed at the pre - de ter min ed fas te ning sta ti on. De sign an ap pro pria te dril ling jig and drill the re spec ti ve ho les.
5.4. Elec tri cal Con nec ti on » The elec tri cal con nec ti on may be car ried out by trai ned per son nel only. Ot her per sons are not per mit ted to car ry out the elec tri cal con nec ti on. The re gu la tions of the lo cal elec tri ci ty board must be ob ser ved.
6. Functio nal des crip t i on » This functio nal des crip ti on is in ten ded for all ope ra ting per son nel of the equip ment. Pre re qui si te for this functio nal des crip ti on is ge ne ral knowled ge of do sing and blen ding units. En su re in each case that the ope ra ting per son nel are suf fi cient ly in form ed.
6.1. SDD 1 SGM The SDD 1 SGM is a syn chro nized, dig i tal dos ing sys tem de signed to pre cisely dose plas tic ad di - tives (ei ther in pel let or pow der form) on any plas tics pro cess ing ma chine, whether in jec tion mold - ing, blow mold ing, or all ex tru sion ap pli ca tions.
7. Tech ni cal Data 7.1. SDD 1 SGM Ba sic Ver sion • Com po nents to dose gran u late, mi cro-batch/pel lets or pow der (please spec ify re quire ment) • Quick dis con nect for change over/clean i.
7.2. Con trol uni t S 150 Ba sic equip ment • 5 digit LED dis play • Mem ory backup for rec ipe and data stor age • Dry con tact cy cle sig nal in put • In put for level probe for both raw ma .
7.3. Di men sion sheet 1 7 6 - 1 M S SDD 1 SGM Tech ni cal Data 7 - 3 All di men sions in mm (in.). Spec i fi ca tions may be sub ject to al ter ations.
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.
Dosing sta tion SDD De scrip tion Or der-Num ber Scraper 21392 Dosing disc 72 cham bers: 31447 40 cham bers 21710 25 cham bers 21711 18 cham bers 23057 Dosing disc, wear re sis tant 40 cham bers 28214.
9. Ac ces so ries o Drilling jig o Values re quired for the ba sic pa ram e ter o Le vel probe KCB-M32GP/015 o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.
1 7 6 - 1 M S SDD 1 SGM Ac ces so ries 9 - 2.
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: .......................................................... Con fig u ra tion value: .........
Ac ces so ries Le vel pro be KCB-M32GP/015 1 7 6 - 1 M S Ster ling Ma te rial Pro cess ing.
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.
& Tur ning the trim-pot to the left de crea ses - tur ning the trim-pot to the right in crea ses the swit ching-distance. Fill the do sing sta ti on un til 2/3 of the le vel pro be is co ver ed. The yel low con trol lamp must now switch on again. Mount the plas tic screw.
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.
» Switch off the de vi ce by me ans of the On/Off switch. Cut off the vol ta ge supp ly. Wait at least one mi nu te be fo re star ting to work at the swit ching ca bi net. Dan ger to life! Disch ar ge of high-voltage pos si ble! Loosen the screws (A) and re mo ve the lid.
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, N 2: PE 3: 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.
Ter mi nal As sign ment S150 (115/230 V), from se rial num ber 031.03-0108162090 on w ards From the se rial num ber cited above on wards the blend ing unit and alarm re lay is once again im ple - mented as a change-over con tact on the J9 or J8 ter mi nal.
· 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 .
· 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 o.
· 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 .
· 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 wit.
· 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.
Ter mi nal As sign ment S150 (115/230 V) A make con tact func tion is avail able; the switch - able re lay out put can be op er ated with out po ten - tial or with po ten tial. The aux il iary volt age con sists of 230 VAC. Mixer: non-operative sta tus J9: 3 - 4 open, in op er a tion J9: 3 - 4 closed.
Ter mi nal As sign ment S150 (230 V, old ver sion) Po ten tial-free change-over con tacts are avail able for this de vice gen er a tion. Blower 1: func tion not used Mixer: non-operative sta tus J9: 1 - 2 closed, in op er a tion J9: 2 - 3 closed.
An important point after buying a device Sterling SDD 1 SGM (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Sterling SDD 1 SGM yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Sterling SDD 1 SGM - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Sterling SDD 1 SGM you will learn all the available features of the product, as well as information on its operation. The information that you get Sterling SDD 1 SGM will certainly help you make a decision on the purchase.
If you already are a holder of Sterling SDD 1 SGM, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Sterling SDD 1 SGM.
However, one of the most important roles played by the user manual is to help in solving problems with Sterling SDD 1 SGM. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Sterling SDD 1 SGM along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
