Sterling Marine Battery SGFE User Manual
Operating Instructions  
Conveyor Hopper  
with blower-filter unit SGFE  
Sterling Material Processing  
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SGFE  
Sterling Material Processing  
5200 West Clinton Ave.  
Milwaukee, WI 53223  
Telephone: (414) 354-0970  
Fax: (414) 354-6421  
www.sterlco.com  
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
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SGFE  
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
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SGFE  
Table of contents  
1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1  
1.1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1  
1.2. For your safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2  
1.3. For the operating safety of the equipment . . . . . . . . . . . . . . . . . 1-5  
2. Concerning these Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . 2-1  
2.1. General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1  
2.2. Warning Messages and Symbols . . . . . . . . . . . . . . . . . . . . . . . . 2-2  
2.3. Explanations and Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3  
2.4. Notes on Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4  
3. Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1  
3.1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1  
3.2. Control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2  
3.2.1. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2  
3.2.2. Key assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3  
3.3. Switching on the control system . . . . . . . . . . . . . . . . . . . . . . . . . 3-3  
3.4. Setting the basic parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4  
3.5. Starting the conveying procedure . . . . . . . . . . . . . . . . . . . . . . . . 3-7  
3.6. The first conveying operations . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7  
3.7. Viewing Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8  
3.8. Switching off the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9  
4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1  
4.1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1  
4.2. Maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3  
4.3. Checking the direction of rotation of the vacuum generator . . . 4-5  
4.4. Testing the conduit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6  
4.5. Adjusting the suction tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7  
4.6. Cleaning/replacing the filter cartridge. . . . . . . . . . . . . . . . . . . . . 4-8  
4.7. Servicing the accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9  
4
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SGFE  
5. Assembly instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1  
5.1. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2  
5.2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2  
5.3. Material feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2  
5.4. Suction pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3  
5.5. Pipework. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4  
5.6. Vacuum generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5  
5.6.1. Rotary lobe vacuum pump GDK . . . . . . . . . . . . . . . . . 5-6  
5.7. Installing the accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6  
5.8. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7  
6. Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1  
6.1. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1  
7. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1  
8. Spare parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1  
9. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1  
o conveyor hopper SSE 15 / SSE 30  
o conveyor hopper _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  
o side vane vacuum pump GSV  
o rotary value pump GDS  
o rotary lobe vacuum pump GDK  
o _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  
10. Electrical manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1  
o Connection diagram no.: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  
o Currently not available; will be delivered at a later date!  
5
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General  
1. Safety instructions  
1.1. General  
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 equip-  
ment.  
Safety instructions 1-1  
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For your safety  
1.2. For your safety  
General  
The operating personnel of this equipment must be at least 16 years old.  
Please read these operating instructions carefully before taking into operation for  
the first time. Contact us should questions arise. This avoids injury and damage  
to equipment!  
These operating instructions must be kept available at all times at the place of  
operation of the equipment. Improper operation results in danger of accidents!  
Please note that, for reasons of clarity, not all conceivable cases regarding ope-  
ration or maintenance of the equipment can be covered in these operating in-  
structions.  
Please observe all safety instructions and warnings on the equipment. This  
avoids injury and damage to equipment!  
All work on the equipment is to be carried out by persons whose qualifications are  
specified in the pertaining chapters of the operating instructions. Improper opera-  
tion results in danger of accidents!  
The proper working clothes are to be worn during any work on the equipment.  
This avoids injury!  
The local regulations and requirements pertaining to this equipment must be ob-  
served.  
Disconnect electrical components from the mains supply before work is carried  
out on these components Caution: Danger to life through electrical shock!  
Compile detailed operating instructions based on these Operating instructions  
for the sequence of procedures to be carried out on this equipment. Improper  
operation results in danger of accidents!  
Please note that sound levels exceeding 85 db(A) may in the long term damage  
your health. Use the appropriate ear muffs. This avoids impairment of hearing!  
Safety instructions 1-2  
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For your safety  
Assembly  
Compare the connected loads with those of the mains supply. Danger of injury  
through electrical shock!  
When using lifting gear, please observe the pertaining regulations. Caution: Dan-  
ger of accidents!  
Do not modify, add other equipment or change the design of the equipment wit-  
hout the approval of the manufacturer. Caution: Danger of accidents!  
Attachments not supplied by Sterling must be manufactured in accordance with  
safety regulation EN 294. Danger of accidents!  
The equipment may only be operated when all the associated components are  
properly connected up and in accordance with the relevant regulations. This  
avoids injury and damage to equipment!  
Operate the device only if all its components are grounded. Danger: accident  
through electrical shock!  
Solid particles and dust must be separated before entry to the vacuum generator.  
This avoids damage to equipment!  
If PVC hoses are used for conveying, they must be grounded. This avoids injury  
and damage to equipment!  
An acoustic cover should be installed when vacuum generators are located in  
work rooms. This avoids impairment of hearing!  
Safety instructions 1-3  
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For your safety  
Operation  
Appoint an equipment foreman to be responsible for the equipment.  
Ensure that the operating personnel are provided detailed instruction in the ope-  
ration of the equipment. Improper operation results in danger of accidents!  
When the main switch is switched off for reasons pertaining to safety, it must be  
secured against unauthorized activation. Caution: Danger of accidents!  
Repair work may be carried out by trained personnel only.  
Caution: Danger of accidents!  
Never operate the equipment when partially dismantled!  
Danger! Limbs may be caught in machinery! Electric shock!  
In case of malfunction, shut down the equipment immediately. Have malfunctions  
corrected immediately. Danger of accidents!  
The equipment is intended only for conveying granulated plastics and regrinds.  
Any other or additional use is contrary to specifications.  
This equipment is not suitable for food processing.  
The safety instructions of the connected machines must be followed.  
Explosive gases and mixtures of gas and air must not be conveyed. Danger of ex-  
plosion! Avoids injury or damage to equipment!  
Maintenance  
Before starting maintenance work, appoint a supervisor.  
Inform the responsible personnel before maintenance work on the system is  
started. Caution: Danger of accidents!  
Disconnect the equipment from mains supply before starting maintenance proce-  
dures to ensure that it cannot be switched on unintentionally.  
Caution: Danger of accidents!  
All pipes, hoses and screwed connections should be checked regularly for leaks  
and damage. Any faults which arise should be corrected immediately.  
Danger of accidents!  
Depressurise all compressed air piping before starting maintenance work.  
Danger of accidents!  
Safety instructions 1-4  
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For the operating safety of the equipment  
1.3. For the operating safety of the equipment  
Never change settings if the consequences are not precisely known.  
Use only original Sterling spare parts.  
Please observe the maintenance schedule.  
Keep record of all maintenance and repair work.  
Please note that electronic components may be damaged by static discharge.  
Check all electrical connections for proper fit before the equipment is taken into  
operation for the first time and at regular intervals.  
Please ensure that the permitted operation temperature lies between 0 °C and  
+45 °C (32°F and 113°F).  
Please ensure that the permitted storage temperature lies between -25 °C and  
+55 °C (-13°F and 131°F).  
Note down all setting data.  
After connection to the electricity supply has been made, check the rotational di-  
rection of the vacuum generators (note the direction indicated by the arrow).  
Please ensure that all plugs are correctly plugged in.  
The operating instructions of the connected machines must be followed.  
All components must be sufficiently grounded.  
Please note that a compressed air supply is required for the operation of the unit.  
Never set a higher operating pressure than 6 bar (87.02 PSI) for the unit (system  
overpressure).  
Align the suction tubes correctly.  
Please note that the maximum permitted ambient and air temperature on entry to  
the vacuum generator is 40 °C (104°F).  
Safety instructions 1-5  
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General Information  
2. Concerning these Operating Instructions  
2.1. General Information  
These operating instructions are addressed to all users of the  
device.  
»
These operating instructions must be used by every person  
charged with work on the unit.  
Concerning these Operating Instructions 2-1  
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Warning Messages and Symbols  
2.2. Warning Messages and Symbols  
The following warning messages and symbols are used in these operating in-  
structions:  
This symbol indicates danger to life! Fatal or serious injury is  
possible if the corresponding instructions, regulations or war-  
nings are not observed.  
»
This symbol indicates that serious injury is possible if the cor-  
responding instructions, regulations or warnings are not ob-  
served.  
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.  
$
Concerning these Operating Instructions 2-2  
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Explanations and Definitions  
2.3. Explanations and Definitions  
In this operating manual, certain terms are used repeatedly for better clarity.  
Therefore please keep in mind that these terms stand for the explanations given  
here.  
Unit  
“Unit” may designate either a single device, a machine or a plant.  
·
User  
The user is the person who uses the unit on his or her own responsibility or on the  
responsibility of someone else.  
·
Operator  
·
The operator of a unit (production manager, foreman etc.) is the person responsi-  
ble for the sum of the processes. The operator instructs the users to do some-  
thing.  
Operating manual  
·
The operating manual describes the correlations between several units, proces-  
ses or manufacturing procedures. The operating manual must be prepared by  
the operator of the units.  
Co-ordinator  
If several users work on one unit, the “co-ordinator” co-ordinates the processes.  
The co-ordinator must be designated by the operator.  
·
Trained personnel  
Trained personnel are people who are qualified by their training to carry out the  
respective work in a professional manner.  
·
Concerning these Operating Instructions 2-3  
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Notes on Usage  
2.4. Notes on Usage  
Experienced operators can begin directly with the chapter on “Start-up” if the unit  
has been properly installed.  
·
·
If the unit has not been installed yet, observe the instructions in the chapter on  
“Assembly Instructions”.  
Concerning these Operating Instructions 2-4  
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General  
3. Start-up  
3.1. General  
»
This chapter is directed at the operator of the equipment.  
This chapter assumes general skills in dealing with conveying  
units and SPS control units.  
This chapter assumes that the functional description has been  
read and understood.  
It should be ensured in each and every case that the operators  
have the relevant skills.  
Explosive gases and mixtures of gas and air must not be con-  
veyed by the vacuum generator. Solid particles and dust must  
be separated before entry to the vacuum generator.  
Check the compressed air supply if pneumatic valves are  
present (5-6 bar (72.52-87.02 PSI) system overpressure).  
F
Check whether the plastic stoppers have been removed from  
the suction pipe of the vacuum generator.  
Check that the on/off switch is in position ”OFF".  
Start-up 3-1  
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Control system  
3.2. Control system  
The facility’s control system is factory-programmed. Nevertheless, you have to  
set specific values (basic parameters) which are dependent on the processed  
material, for instance.  
The set values are saved and remain saved even after switching off or after a po-  
wer fail. All entries are saved and can also be viewed at a later point in time. All  
messages are displayed in plain text.  
D
A
B
A=Lamp“ope ration”  
B=Lamp“alarm”  
C = Main switch  
D = Key “Reset”  
E = Control unit  
C
I: 1 2 3 4 5 6  
Mo 08:33  
Q: 1 2 3 4 RUN  
ESC  
OK  
E
Switchbox  
3.2.1. Operation  
The control system is operated via the  
keys “ESC”, “OK” and the arrow keys (A).  
Messages are displayed on a four-line  
display.  
B01 : T  
T = 01.00s  
A
In the first display line the parameter de-  
signation is displayed.  
Ta= 00.00s  
In the second display line the set value of  
the parameter is diplayed.  
ESC  
OK  
In the last display line the actual value of  
the parameter is displayed.  
Start-up 3-2  
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Switching on the control system  
3.2.2. Key assignment  
Arrow keys  
to select a value  
to scroll the menu pages  
to change a value  
OK  
Pushing the key “OK”  
to select a menu, to change values (the cursor bar jumps to  
the first digit of the value);  
to confirm value entries (with value acceptance).  
ESC  
Pushing the key “OK”  
to leave value entries (without value acceptance);  
to leave the menu “basic parameters”.  
3.3. Switching on the control system  
Connect the control system to mains supply by the device plug.  
Check that the on/off switch is in position ”OFF".  
F
Start-up 3-3  
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Setting the basic parameters  
3.4. Setting the basic parameters  
Select the menu “basic parameter”.  
ESC  
OK  
I: 1 2 3 4 5 6  
Mo 08:33  
Q: 1 2 3 4 RUN  
ESC  
OK  
Select “Set Param”.  
OK  
Set Clock  
> Set Param  
ESC  
OK  
Signal times flap (B01)  
(standard setting: 1 second).  
Changes only after consultation with  
the Sterling Service.  
B01 : T  
T = 01.00s  
Ta= 00.00s  
OK  
ESC  
OK  
Start-up 3-4  
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Setting the basic parameters  
Conveying time (B05)  
Enter the desired conveying time in se-  
conds.  
B05 : PAR  
LIM = ###  
OK  
Cnt = ###  
ESC  
OK  
Line clearing (B09)  
Enter the desired line clear time in se-  
conds.  
B09 : PAR  
LIM = ###  
OK  
Cnt = ###  
ESC  
OK  
Enter “0” if no line clearing valve is mounted.  
F
Emptying time (B14)  
Enter the desired emptying time in se-  
conds.  
B14 : PAR  
LIM = ###  
OK  
Cnt = ###  
ESC  
OK  
Start-up 3-5  
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Setting the basic parameters  
Blower run on time (B17)  
Enter the blower run on time in seconds .  
B17 : PAR  
LIM = ###  
OK  
Cnt = ###  
ESC  
OK  
Error tolerance (B22)  
Enter the error tolerance.  
B22 : PAR  
Par = ###  
OK  
Cnt = ###  
ESC  
OK  
Setting “0”: function not active  
Setting “1 -###”: an alarm is given when the error tolerance  
reaches this value.  
&
ESC  
I: 1 2 3 4 5 6  
Mo 08:33  
Q: 1 2 3 4 RUN  
ESC  
OK  
Start-up 3-6  
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Starting the conveying procedure  
3.5. Starting the conveying procedure  
Set the on/off switch in position ”ON”.  
If the hopper loader reports a lack of material, the conveying  
is started.  
&
3.6. The first conveying operations  
Check the rotational direction of the vacuum generators.  
F
Check the line system.  
Adjusting the suction tube.  
Material coming from the hopper loader during the first con-  
veying may not be used.  
Start-up 3-7  
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Viewing Alarm Messages  
3.7. Viewing Alarm Messages  
An alarm is given by steady light of the “alarm” lamp.  
&
Pressing the “Reset” key erases the steady light of the  
“alarm” lamp (the “alarm” lamp goes off). The failure is not re-  
paired.  
Failures must be repaired immediately.  
F
Possible events:  
- Fault hopper  
In the operating mode “probe conveying”, the level of material has not rea-  
ched the probe within the set conveying time.  
Possible causes: lack of material, false conveying time setting or defective probe.  
In the operating mode “time-controlled conveyance”, no signal change of the  
flap switch has occurred within the set emptying time.  
Possible causes: lack of material, false emptying time setting or defective flap.  
Start-up 3-8  
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Switching off the unit  
3.8. Switching off the unit  
Set the on/off switch in position ”OFF”.  
If the unit is switched off during a conveying procedure this  
operation will be finished.  
&
Disconnect the unit from mains supply by the device plug.  
Start-up 3-9  
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General  
4. Maintenance  
Version: 64.10-0198GB05WA 02/01  
4.1. General  
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 instruc-  
ted of the regulations for the prevention of accidents, the opera-  
ting conditions and safety regulations and their implementation.  
Ensure in each case that the personnel are informed.  
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 authori-  
zed personnel (appointed by Sterling).  
Maintenance 4-1  
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General  
Disconnect the equipment from mains supply before starting  
maintenance procedures to ensure that it cannot be swit-  
ched 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 4-2  
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Maintenance schedule  
4.2. Maintenance schedule  
Initial operation: Check the rotational direction of the vacuum  
generators  
Check the line system  
Adjust the suction tube  
Daily:  
Check warning signs on equipment for legibility  
and completeness  
Check the oil level in the oiler  
Empty the water separator  
Check operating pressure of the plant’s supply  
network (5-6 bar (72.52-87.02 PSI) system over  
pressure)  
Check the oil level in rotary valve pumps  
Follow the manufacturer’s operating instructions  
Weekly/monthly:  
Every six months:  
Clean the filter cartridge  
(according to the accumulation of dust)  
Check that the main switch on the equipment  
is functioning  
Replace the filter cartridge  
(according to the accumulation of dust)  
Check the settings on the level probes (if present)  
Check that all electrical and mechanical  
connections fit securely  
Change oil and oil filters on the rotary valve pumps  
Follow the manufacturer’s operating instructions  
Lubricate the bearings with high melting-point  
grease on the rotary lobe vacuum pumps  
Follow the manufacturer’s operating instructions  
Maintenance 4-3  
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Maintenance schedule  
After the first 100  
hours of operation:  
Change the oil on the rotary valve pumps  
Follow the manufacturer’s operating instructions  
After 500 hours  
of operation:  
Check oil level and condition of the oil in the gear  
box of the rotary lobe vacuum pumps  
Follow the manufacturer’s operating instructions  
After 20,000 hours  
of operation:  
Remove old grease from anti-friction bearing  
of side vane vacuum pump and apply fresh grease  
Follow the manufacturer’s operating instructions  
The given maintenance intervals are average values.  
F
Check whether in your individual case the maintenance in-  
tervals must be shortened.  
Maintenance 4-4  
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Checking the direction of rotation of the vacuum generator  
4.3. Checking the direction of rotation of the vacuum generator  
Start a conveying procedure.  
Wait until the vacuum generator begins to operate.  
Observe the rotational direction arrow on the vacuum generator housing.  
Stop the conveying procedure.  
Wait until the blower has come to a standstill.  
Switch off the unit.  
If the vacuum generator rotates in the wrong direction, correct the direction by  
changing the poles of two phases.  
Electrical connections should only be carried out by trained  
staff.  
»
Observe the regulations of your local Electricity Board.  
The wrong direction of rotation may lead to major defects or  
may interfere with the function of the vacuum generator.  
F
A proper conveyance is not possible.  
Maintenance 4-5  
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Testing the conduit system  
4.4. Testing the conduit system  
Detach the flexible line from the connected material take-up assembly.  
Close the open end of the line with your hand.  
Start a conveying procedure.  
Wait until the vacuum generator begins to operate; after this, the hand should be-  
come sensibly attached by suction within a few seconds.  
If no vacuum can be felt, the line system has a leak.  
Stop the conveying procedure.  
Wait until the blower has come to a standstill.  
Switch off the unit.  
Check the line system and seal the leakage.  
Re-connect the conveying line.  
Maintenance 4-6  
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Adjusting the suction tube  
4.5. Adjusting the suction tube  
To guarantee a trouble-free operating run, the suction tube must be exactly ad-  
justed.  
1. The suction tube should be placed in the basic setting  
In the basic setting, the inner pipe of the suction tube sticks out of the outer pipe  
approx. 120-160 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with Ø 40 mm  
.
approx. 150-180 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with Ø 50 mm  
(4.72-6.30 in)  
with (1.67 in)  
. . . . . . . (5.91-7.19 in) with (1.97 in)  
approx. 180-200 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with Ø 65 mm  
. . . . . . . (7.19-7.97 in)  
with (2.66 in)  
2. Start the conveying process.  
3. Observe the flexible line on the suction tube.  
The flexible line must not be describing any pulsating movements.  
4. Observe the flexible line on the separator.  
The supply hose may only move when conveying is taking place.  
If conditions (points 3 + 4) are not fulfilled:  
Pull the inner pipe further out of the outer pipe until the jerky conveying stops.  
If the conditions (points 3 + 4) are fulfilled:  
Push the inner pipe slowly into the outer pipe, until a pulsating of the flexible line  
or a jerky conveying starts.  
Pull the inner pipe back another bit, until the lines have stopped pulsing.  
Select the adjustment between the two pipes in such a way that that there is al-  
ways sufficient airflow in the material line.  
If the conveying is proceeding satisfactorily, tighten the wing screw on the suction  
tube.  
Maintenance 4-7  
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4.6. Cleaning/replacing the filter cartridge  
Stop the conveying procedure.  
»
Switch off the conveying system at the main switch.  
Interrupt the mains supply.  
Set all compressed-air lines at zero pressure.  
The conveying capacity is diminished by a clogged filter car-  
tridge.  
&
Loosen the screw connection on the filter  
housing (A).  
Remove the housing lid (A).  
Loosen the screw connection on the filter  
cartridge.  
Remove the filter cartridge.  
Replace the filter cartridge.  
Resp.  
Use compressed air to blow through the  
filter cartridge from the inside to the outsi-  
de.  
Clean the filter housing. Use lint-free clea-  
ning rags.  
Maintenance 4-8  
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Servicing the accessories  
Re-install the new/cleaned filter cartridge.  
Mount the housing lid.  
Purchase order number  
&
filter cartridge:  
ID 85612  
4.7. Servicing the accessories  
The operating instructions must be followed.  
F
Maintenance 4-9  
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5. Assembly 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 instruc-  
ted in the regulations for the prevention of accidents, the opera-  
ting conditions and safety regulations and their implementation.  
Ensure in each case that the personnel are informed.  
The installation instructions provided in the corresponding ope-  
rating 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 dis-  
connected 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 capaci-  
ty. Do not stand or work under suspended loads!  
Use suitable workshop equipment.  
F
Assembly instructions 5-1  
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Transport  
Install the equipment such that all parts are easily accessi-  
ble; this facilitates maintenance and repair work.  
5.1. Transport  
For transport, only the appropriate lifting gear should be used (eg fork lift or work-  
shop crane).  
Please ensure the adequate carrying capacity of the lifting gear.  
»
Please observe all safety regulations for the operation of lifting  
gear.  
5.2. Installation  
The location of the control unit should be chosen so that a clear view of the sepa-  
rators is guaranteed from the control unit. Thus any malfunctions which arise can  
be corrected more easily.  
The main switch on the control unit must be freely accessible at  
all times.  
»
5.3. Material feed  
Suction pipes type MV may be tilted by approx. 45 degrees in either direction to  
the vertical. Additional fastening is not required.  
When conveying from the bottom of storage containers (silos), a suction box with  
1-3 suction pipes is required.  
The connection of the suction pipes must be carried out with a piece of flexible  
line to provide sufficient movement.  
Assembly instructions 5-2  
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Suction pipe  
Please observe that the length of the hose should not exceed 3 m (9.84 ft.) Push  
the free pipe end into the flexible line to a depth of approx. 4-5 cm (1.67-1.97 in.)  
Connect both parts by means of a hose clamp.  
5.4. Suction pipe  
The suction pipe consists of an inner (A) and an outer pipe (B) which can be offset  
against each other.  
Push the free pipe end into the flexible line to a depth of approx. 4-5 cm (1.67-1.97  
in.)  
Connect both parts by means of a hose clamp.  
Please observe that the length of the hose should not exceed 3 m (9.84 ft.)  
Please check that the outer pipe is not covered as it provides for unhindered ac-  
cess of ambient air.  
When conveying from silos, material hoppers and storage  
containers, a suction box with 1-3 suction pipes is required.  
F
B
A
MV  
Assembly instructions 5-3  
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Pipework  
5.5. Pipework  
When all the positions and arrangement for material feed, hopper loader and blo-  
wer are determined, start assembling the pipework.  
Rigid pipes should always be laid next to each other and there should be the follo-  
wing minimum distances in between:  
40 mm (1.67 in.) pipe diameter. . . . . . . . . . . 75 mm (2.95 in.) center distance  
50 mm (1.97 in.) pipe diameter . . . . . . . . . . 85 mm (3.35 in.) center distance  
65 mm (2.66 in.) pipe diameter . . . . . . . . . 150 mm (5.91 in.) center distance  
Laying the pipe can be done on wall brackets, energy supply bridges or in ducts in  
the floor. Combinations are also possible. Devices according to the local environ-  
ment have to be provided to allow for screwing of the pipes if they are laid on. The  
distance between the individual supports should not be more than 3 to 4 m  
(9.84-13.12 ft) with smooth pipes. Elbows have to be fastened twice. Also it is ab-  
solutely necessary to provide support for conveying branches if there are any.  
Line laying is normally started with the suction line, parting from the blower. Initi-  
ally, a piece of flexible line of approx. 1 m (3.38 ft.) should be provided to avoid the  
transfer of oscillations. Flexible lines have to be pushed onto rigid lines and con-  
nection pieces at a depth of at least 5 cm (1.97 in.) Use hose clamps for fastening.  
Pipes are connected by means of wide band clamps and rubber muffs. Please  
check that the pipes are free from gaps and that the clamp is tight. Elbows have to  
be installed (also in the suction line) on joints from the vertical to the horizontal  
and where the direction changes. Minor directional changes can be overcome by  
bending straight lines. A minimum bending radius of 500 mm (19.79 in.) should al-  
ways be observed (energy loss!).  
When assembling conveying branches the minimum distance between machine  
throat center and discharge of conveying branch must be at least 1.5 m (4.92 ft.)  
to avoid too small a bending radius. When arranging the flexible connection line  
movements of the processing machine during operation or during mould change  
have to be taken into consideration! Assembly of the conveying line is started at  
material takeup . For line laying the same instructions given for suction line apply.  
If PVC hoses are used for conveying, they must be grounded: draw out the copper  
lead on both ends of the hose and jam it between hose and tube. For fastening,  
use threaded clamps.  
Assembly instructions 5-4  
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Vacuum generator  
5.6. Vacuum generator  
Explosive gases and mixtures of gas and air must not be con-  
veyed.  
»
Solid particles and dust must be separated before entry to the  
vacuum generator.  
For all work on the equipment, hearing protection should be  
worn.  
Avoids impairment of hearing!  
The manufacturer’s operating instructions should be followed.  
An acoustic cover should be installed when vacuum genera-  
tors are located in work rooms.  
L
When installing an acoustic cover, care should be taken that  
the ventilation of the eletric motors is not impeded.  
F
Examples for the expected noise level:  
side vane vacuum pump GSV  
&
2.2 kW:  
4.0 kW:  
approx. 72 dB (A)  
approx. 75 dB (A)  
rotary value pump GDS  
7.5 kW:  
11.0 kW:  
approx. 75 dB (A)  
approx. 77 dB (A)  
rotary lobe vacuum pump GDK  
4.0 kW: approx. 78 dB(A)  
Assembly instructions 5-5  
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Installing the accessories  
The vacuum generator should be installed near the equipment, to avoid loss of  
performance through leakage and friction.  
Only flexible connections should be used to join up the pipes.  
The control unit should be installed in clear view of the vacuum generator.  
To keep noise to a mininum, we recommend installation in an enclosed space.  
5.6.1. Rotary lobe vacuum pump GDK  
The fan is equipped with a separate electric motor which must  
be connected to 24 V.  
»
5.7. Installing the accessories  
The operating instructions must be followed.  
F
Assembly instructions 5-6  
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Electrical connection  
5.8. Electrical connection  
The regulations of the local Electricity Board must be observed.  
»
Before connection to the electricity supply, it should be ensured  
that the supply voltage and the power frequency are in accor-  
dance with the data on the name plate of the machine.  
The electrical connection may only be carried out by Sterling  
service staff or trained personnel authorised by Sterling.  
It is not permitted for other persons to undertake the electrical  
connection.  
Check that the on/off switch is in position ”OFF".  
F
The operating voltage is 480/3/60  
Special voltages on request.  
Depending on the model, the connected load is up to 11.0 kW.  
Assembly instructions 5-7  
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General  
6. Functional description  
6.1. General  
This functional description is intended for all operating person-  
nel of the equipment.  
»
Prerequisite for this functional description is general knowledge  
of conveying units and SPS control units.  
Ensure in each case that the operating personnel are sufficient-  
ly informed.  
Functional description 6-1  
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General  
The unit works on the pneumatic conveying principle. According to this, a vacuum  
generator (A) creates a vacuum, which extends through the pipe ducts and hose  
assemblies (B), through the separators (C) until it reaches the material take-up  
assembly (D).  
The material which has been conveyed is than separated from the air inside the  
separator.  
Depending on conveyor control system (E) and hopper loaders time conveying  
mode or probe conveying mode with conveying time used as monitoring time is  
possible.  
A filter cartridge (F) in front of the vacuum generator purifies the aspirated air.  
Conveying is not possible without movement of air in the ma-  
terial line.  
&
If the hopper loader reports a lack of material, the conveying is started.  
Following the conveying process, if line cleaning times are set, line cleaning ta-  
kes place. The line cleaning valves interrupt the flow of material and allow air to  
flow into the connecting pipe. In this way the connecting pipe is cleared of materi-  
al.  
Functional description 6-2  
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SGFE  
7. Technical data  
Version: 64.10-0198GB05TD 02/01  
Method of filling: . . . . . . . . . . time conveying mode or probe conveying mode  
. . . . . . . . . . . . . . . . . . . . . . . . . . with conveying time used as monitoring time  
Vacuum generator (depending on the model)  
Side vane vacuum pump GSV: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5-4.4 kW  
Noise level: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 75-78 dB(A)  
Rotary valve pump GDS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0-11.0 kW  
Noise level: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 73-75 dB(A)  
Rotary lobe vacuum pump GDK: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 kW  
Noise level: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx. 78 dB(A)  
Operating voltage (standard):. . . . . . . . . . . . . . . . . . . . . . . . 400 V/3 AC/50 Hz  
(other voltages possible)  
Permissible storage temperature: . . . . . . . . . . . . . . . . . . . . . . . . -25 to +55 °C  
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (-13° to +131° F)  
Permissible operating temperature: . . . . . . . . . . . . . . . . . . . . . . . . 0 to +45 °C  
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (32° to +113°F)  
+
Technical data 7-1  
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SGFE  
Dimension sheet SGFE  
All dimensions are in mm. (in.) Subject to alteration.  
Technical data 7-2  
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SGFE  
Dimension sheet GDK 4 kW  
All dimensions are in mm. (in.) Subject to alteration.  
Dimension sheet GSV  
All dimensions are in mm. (in.) Subject to alteration.  
Technical data 7-3  
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SGFE  
Dimension sheet GDS  
All dimensions are in mm. (in.) Subject to alteration.  
Technical data 7-4  
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SGFE  
8. Spare parts list  
This spare parts list is intended to be used only by trained per-  
sonnel.  
»
Other persons are not permitted to modify or repair the equip-  
ment.  
Spare parts list 8-1  
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SGFE  
Pos.  
ID-No.  
Designation  
1
93102  
93100  
pressure limiter valve (1.5 and 2.2 kW)  
pressure limiter valve (4.0 kW)  
2
86308  
88235  
83564  
side vane vacuum pump GSV 4.0 kW  
side vane vacuum pump GSV 2.2 kW  
side vane vacuum pump GSV 1.5 kW  
Optional  
84724  
98148  
rotary lobe vacuum pump GDK 4.0 kW  
manometer  
92156  
93650  
89430  
98148  
rotary valve pump GDS 5,5 kW  
rotary valve pump GDS 7,5 kW  
rotary valve pump GDS 11,0 kW  
manometer  
3
4
85612  
85486  
filter cartridge  
lock nut  
83411  
control unit LOGO  
Spare parts list 8-2  
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SGFE  
9. Accessories  
¨ conveyor hopper CSE 15 / CSE 30  
¨ conveyor hopper _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  
¨ side vane vacuum pump GSV  
¨ rotary value pump GDS  
¨ rotary lobe vacuum pump GDK  
¨ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  
¨ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  
¨ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  
Accessories 9-1  
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SGFE  
10. Electrical manual  
This electrical manual is intended to be used only by Sterling  
service personnel and trained personnel authorized by Sterling.  
»
Other persons are not permitted to modify or repair the equip-  
ment.  
¨ Connection diagram no.: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _  
¨ Currently not available; will be delivered at a later date!  
Electrical manual 10-1  
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