Three Phase Hopper Loader (3PH)

+
Simplified Support Frame (SFS)

Software version : 2.10.x

Manual revision : rev.01
Language : ENG
Date : August 2020
Index

1 Introduction 3
Safety Directions 3
Reliability 3
Use 3
Limitations 4
Safety and Regulations 4
Construction 4
Operating Principles 4
Symbols 5
Terms 5
Transport 5
Receipt 5
Disclaimer 5
2 General information 6
Safety 6
Certification 6
Operating environmental conditions 6
3 Installation 7
Mechanical connection 7
Electrical connection 8
4 Configuration 9
Configuration of the 3PH loader 9
Configuration of the MCTC loader function 11
4.2.1 Configuring the 3PH loader 11
4.2.2 Component configuration 12
4.2.3 3PH hopper loader settings 13
4.2.4 Advanced loader settings 14
5 Alarms 15
6 Maintenance 16
Maintaining the air filter and the base filter 16
Maintaining the bottom flap SVR (stainless steel) 16
7 Trouble shooting 17
8 Spare parts 18
APPENDIX A: Technical Specifications 19
APPENDIX B: Receiver Dimensions 20

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1 Introduction

Safety Directions

This manual contains important measures to be observed when operating and handling the unit.

The manual is directed to users involved in operating and servicing the conveyor. The manual should always
be available to the operating staff.

The manual should be read through before the conveyor is put into operation. The section containing to
Safety is especially important to the operating staff, as it also contains information of signboards and their
meaning.

Reliability

Capacity and liability of the Movacolor 3PH loaders are dependent on competent operation and careful
maintenance. Incorrect operation and insufficient or inadequate maintenance may cause stoppage.

Sufficient and lasting reliability may be achieved only by correct operation and careful maintenance.

A qualified operator, following the correct procedures must operate the 3PH loader.

See section “Maintenance” for a thorough description of maintenance and control to ensure the proper
maintenance of the conveying unit.

The service section of this manual does not contain instruction to extensive renovation of the machine.
Movacolor’s service department is trained to carry out renovation.

NOTE! Only original Movacolor spare parts should be employed. Spare parts are available from Movacolor’s
service department at any time (see section “Service”).

Movacolor makes reservations against damages arisen from not complying with the directives of this manual
or incorrect use of the conveyor.

Movacolor’s service department is at your disposal with any additional information to the understanding of
this manual.

The manual has been divided into main sections and subsections with an index listing the main section.

Special measures should be taken in order to ensure optimal usage, proper running and simple operation of
the conveying unit.

Use

The 3PH loader is used for automatic conveyance of free-flowing, granule-formed raw material (min. grain
size of 3 mm) with a very limited dust content from bag or container to machine hopper on the production
machine.

Any other application of the conveyor - like use which might exceed the purpose described above – is
considered as a non-compliance. Movacolor takes reservation for damages arising as a consequence of such
an application. In such case the operator carries the risk alone.

For an appropriate use of the conveyor the prescribed demands in the manual must be kept in order to
comply with the conditions for maintenance and service.

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 Limitations

• The device must not be used for any other purpose than stated. The device cannot be used for
materials in powder form nor in liquid form. The temperature on the conveyed material must not
exceed the maximum permitted surrounding temperature of the device.
• The device must be operated by a qualified operator, and in accordance with correct procedures,
only.
• The device must not be used in areas where explosion might occur.

Safety and Regulations

The owner and/or the personal who is responsible for connection and initial operation of the device, must
ensure that the installation of the device is in accordance with the suggested demands in this manual, and
that it fulfills the demands of the local authorities.

Operation of the device must only be made by a qualified operator and the control shall be in accordance
with the procedures described in this manual.

Service must be made by an authorized service engineer, and shall be made in accordance with the
guidelines and instructions stated in the service and maintenance manual of this product.

If the device is operated by an unauthorized or non-qualified person, and this leads to damages – or if the
owner let 3rd person operate the device on his behalf - all demands against Movacolor BV, which might have
been included in the product warranty will be considered as cancelled. Any commitment or claim after
consequence damages likewise ceases.

The right to carry out changes in the construction of the device is reserved to Movacolor - or a representative
selected by Movacolor. This limit without Movacolor undertaking any modification obligation nor for
equipment already delivered. Changes do not demand the owner’s nor the operator’s consent.

In general this applies for:

• Damages caused by non-compliance of the regulations in the manual - or as a consequence of an
inappropriate use of Movacolor’s conveyor - is outside Movacolor’s liability.

The content in this manual is based on our knowledge on the time of the development of the product, and its
purpose is to switch important information which is a requirement to ensure working conditions with - and
by the conveyor. The manual is directed first and foremost to employees in connection with the use and
service of the conveyor. The manual does not give a further and specific description of the behavior of the
product - or its different areas of application. The manual is neither a working guidance for use by larger
repairs on the machine.

Construction
The device is constructed by stainless steel to ensure a long lifetime and minimize cleaning.

Operating Principles
The device can handle 2 (two) different operation principles:
1. Ordinary conveyance
2. Discharge of grinder

As an option the device can be equipped with a compressed air filter cleaning blow back valve.
The conveyor is designed to work in combination with a Simplified Support Frame (SFS) and the Movacolor
Touchscreen controller
The start and stop of the motor is controlled by the Movacolor Touchscreen controller.

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 Symbols

 Important note.

Attention; safety regulations for the operator.

Terms

Operator: A person charged to operate, adjust, maintain and clean the machine.
Qualified Technician: A specialized, suitable trained person authorized to execute the installation,
non-routine maintenance, or repairs requiring special knowledge of the
machine and how it operates.
Multi component: Two or more dosing systems on one machine.

Transport

To protect the Movacolor unit against damage during transport, the unit is packed in a cardboard box filled
with polyurethane foam. Delivery terms are Ex-Works Sneek, The Netherlands. Buyer is responsible for the
transport. Movacolor cannot be held liable for any damage during transport.

Receipt

Check the unit thoroughly upon receipt for damages or missing parts. Pass any remarks to the local agent or
Movacolor within 8 days upon receipt of goods.

Disclaimer

Movacolor does not warrant that the hardware or software will work properly in all environments and
applications, and makes no warranty and representation, either implied or expressed, with respect to the
quality, performance, merchantability or fitness for a particular purpose.

Movacolor has made every effort to ensure that this user’s manual is accurate; Movacolor disclaims liability
for any inaccuracies or omissions that may have occurred.

Information in this user’s manual is subject to change without notice and does not represent a commitment
on the part of Movacolor. Movacolor assumes no responsibility for any inaccuracies that may be contained in
this user’s manual. Movacolor makes no commitment to update or keep the current information in this
user’s manual, and reserves the right to make improvements to this user’s manual and/or to the products
described in this user’s manual, at any time without notice.

If you find information in this manual that is incorrect, misleading or incomplete, we would appreciate your
comments and suggestions.

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2 General information

Safety

The equipment is only designed and may only be used for the dosing of dry additives.
Any use that is not in conformity with the instructions is considered improper and as such frees the
manufacturer from any liability regarding damage to things and/or persons.

Before switching on the unit for the first time, ensure that the mains power voltage
applied is between 95 and 250VAC.

Ensure that all parts are securely fixed to the extruder, injection molding machine or machine
support.

Always switch off the Movacolor control cabinet and disconnect the mains power plug from electrical
power before performing maintenance.

Dangerous voltages are present inside the control cabinet for up to 2 minutes after it has been
switched off.

Always disconnect the main compressed air connection before performing maintenance.

Certification

The Movacolor dosing unit is designed and produced in conformity with the following European regulations:
1. standards for machinery (health, safety, environment).
2. EMC (electromagnetic compatibility).
3. 2006/42/EG.
4. RoHS.

Operating environmental conditions

1. The unit must be protected against weather conditions.

2. Operating temperature -20 to +70 degrees Celsius.
3. Protection class: IP-50.

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3 Installation

Mechanical connection

The 3PH loader is mounted on the SFS support frame by means of the included ring and 4 (M8) bolts.

The bolts and the hose clamps should not be overtightened. Also make sure that the anti-static wire which is
sealed in the material transport hose makes contact between the hopper loaders receiver and the suction
probe.

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 Electrical connection

Be sure the mains power of the loader is disconnected!

The 3PH hopper loader needs to be prepared before connecting it to the MCTC dosing equipment.

1. Open de control box of the loader blower.

2. Once opened the box, start with setting the right production mode of the loader by setting the first
dipswitch to ON position.

Program P2
3. A Movacolor valve cable is supplied with your order. Prepare the right length of this cable (from
MCTC/BC controller to the Hopper loader control box).
4. Connect the brown and white wire to the “LEVEL COMP.2” input (-X3 terminals 13 and 14) of the
blower control unit.
 The flap sensor on the receiver is not used, the blower is controlled by the MCTC. Disconnect the flap sensor wire if it is
connected.

5. Close the 3PH hopper loader control box.

6. Connect the other side of the Movacolor valve cable to OUT-3 of the MCTC/BC

• White wire to clamp 41 OUT-3

• Brown wire to clamp 42 OUT-3

For further installation and configuration of the MCTC refer to the MCTC manual or ask your Movacolor
representative.

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4 Configuration

Configuration of the 3PH loader

The 3PH hopper loader can be programmed and operated with 6 buttons

Follow the next sequence to setup the 3PH hopper loader to be able to operate in conjunction with the
MCTC/BC

1. Press to enter programming mode

2. Conveying time is displayed change this setting to 20 seconds.

3. Press to accept new value (alarm lamp will flash 3 times)

4. Press to go to next parameter (Ratio selector 1)

5. Press to go to next parameter (Ratio selector 2)

6. Press to go to next parameter (Pipe cleaning)

7. Pipe cleaning time is displayed, change this setting to 0 seconds.

8. Press to accept new value (alarm lamp will flash 3 times)

9. Press to go to next parameter (Pause 1)

10. Pause 1 time is displayed, change this setting to 5 seconds.

11. Press to accept new value (alarm lamp will flash 3 times)

12. Press to go to next parameter (Filter cleaning/reverse)

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 13. Press to go to next parameter (Pause 2)

14. Pause 2 time is displayed change this setting to 5 seconds.

15. Press to accept new value (alarm lamp will flash 3 times)

16. Press ESCAPE/QUICK to end programming mode

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 Configuration of the MCTC loader function

The information in this chapter assumes that the dosing system is already setup and configured. This chapter
only describes the configuration of the loader function.

How the 3PH loader is being controlled

The 3PH loader is using a separate blower motor and a separate receiver
mounted on the simplified support frame (SFS).
A SFS support frame is not equipped with a knife gate, the 3PH loader
dumps directly into the MCBalance hopper (12 liter)
If the filling start level is reached (default 1800gr.) the 3PH loading sequence
is started to transfer material into the loader receiver. The motor will run
for a period of time, to be set in the blower configuration using the blower
control panel.
When the loader was not able to load sufficient material to
reach the high level (default 2300gr.) a new loading sequence 3PH loader receiver
will be initiated. + SFS

3PH loader
SFS/6 SFS/12 SFS/15 blower

 When a third party loader is mounted on a simplified support frame, the options 3PH or MV can be used to configure/control the
loader. The magnetic level sensor valve of the loader receiver needs to overruled by using OUT-3 potential free relay of the
MCTC/BC

4.2.1 Configuring the 3PH loader

Login at the MCTC as supervisor.

Go to the device configuration menu of the unit on which the loader is mounted.

 In case of multiple units configured, toggle between units can be done using the left and right arrow buttons.

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4.2.2 Component configuration

Select 3PH type loader:

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4.2.3 3PH hopper loader settings

5
1

2 6

High High Level (1)

The Highest level. If this level is reached a “High High level” event appears.

High level (2)

The level where filling cycle will stop.

Hopper loader start level (3)

Filling starts when the hopper weight gets below this level.

Empty level (4)

When the hopper weight drops below this level, an empty level event is generated.

Manual fill (5)

This button can be used to fill the hopper manually. As long as the button is pressed, the loader will fill the
hopper.
Manual fill is only enabled when the MCTC is not running.

Advanced loader settings (6)

This button opens the advanced loader level menu.

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4.2.4 Advanced loader settings

Alarm time (1)

if the hopper weight is not above the High level within this time, the alarm starts. The alarm time cannot be
set lower than the fill time.

Alarm mode (2)

The ‘Fill alarm mode’ is used to set the loader ‘ON’ or ‘OFF’ if a fill alarm occurs. When this mode is set to
‘OFF’, the loader will turn off when an alarm occurs.

Manual fill (3)

This button can be used to fill the hopper manually. As long as the button is pressed, the loader will fill the
hopper.
Manual fill is only enabled when the MCTC is not running.

Recommended settings for 3PH hopper loader:

• The Volume of the hopper is 12 litres. To set the 3PH-H level (stop filling). It is recommended to take a
safety margin to stop the loader preventing unnecessary additional loading sequences and to prevent
the hopper of overfilling;
• 3PH-H (gr.) = 3PH-L + (7 (litre) x bulk density (gr./litre))/10 - safety margin;
• The 3PH-HH (gr.) should be set higher, recommended 700 x 7 = ~4500 gr;
• Overfilling of the hopper should be avoided because it influences the measurement.

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5 Alarms

The 3PH hopper loader is equipped with the following alarms

1. » E » shown in the display indicates that motor is overheated and is disconnected by the thermic
protection. The 3PH is totally disconnected and the alarm lamp is blinking. The temperature is measured by
a clixon contact built in the motor.
Terms for resetting: Motor cooled to temperature with in the specifications. Turn off and turn on the 3PH at
the main switch.

2. “Transport alarm” By insufficient martial flow the transport alarm is activated. If the 3PH has been
running 3 (Three) conveying cycles without additional material it will go into conveying alarm.
This alarm will be accompanied by an alarm on the MCTC: Filling system unable to load material, after which
the unit will stop dosing. In case of this alarm popping up, elimination of this alarm results in that the dosing
unit automatically starts again when the hopper weight has exceeded low-level.

The number of conveying cycles before the conveying alarm is activated can be selected between 0 and 5

Press and

Press 2 x Number of conveying cycles will now be shown on the display.

Note:
- By “0“ the conveying alarm will not be activated..
- The operating of the 3PH will continue during conveying alarm.
- The conveying will automatically be reset if the high level sensor has been activated.
- The conveying alarm can be reset by pushing the reset button.

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6 Maintenance

Maintaining the air filter and the base filter

 The air filter and the base filter should be checked at every 24 hours of operation as a minimum.

Air filter
1. Turn off the machine on the power switch. Open the lid on the SVR hopper loader.
2. Remove the filter (93) and the filter bag by loosening the fly nut (92).
3. Pull the filter bag over the air filter.
4. Shake to have the dust bag cleared. Clean using compressed air, if necessary
5. Clean the air filter using compressed air, and check that the filter is in working order.
6. Clean the filter surfaces.
7. Replace the filter bag over the filter and fasten the filter.
8. Close the lid.

Base filter
1. Turn off the machine on the power switch. Open the snap lock (94).
2. Remove the fine base filter (95) from the base filter (96). Clean using compressed air and check
that the filter is in working order.
3. Insert the filter mesh and close the snap lock (94).

Maintaining the bottom flap SVR (stainless steel)

The function of the bottom flap should be checked once a month. A damaged or bent bottom flap must
be replaced.

1. Remove the base filter.

2. Check visually whether the bottom flap is intact.
3. Verify that the bottom flap can move freely.
4. Check that the gap between the discharge branch and the bottom flap is approx. 10-30 mm when
the bottom flap hangs loose.
5. Replace the filter (96).

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7 Trouble shooting

The 3PH does not start

No Connect properly
Has the 3PH been connected properly to
the mains voltage?
Yes

Is the power switch turned to position 1? No Turn the power switch to position 1.
Yes

Are the control fuses in working order? No Replace fuse.

Yes

Has the overload protection disconnected the No Press the reset button at the overload
control voltage? protection.

The 3PH has reduced capacity

Is the disc filter clean and unclogged? No Clean or replace the filter.
Yes

Has the suction probe been adjusted No Adjust the suction probe correctly.
correctly?
Yes

Has the conveying time been adjusted No Adjust the conveying time.
correctly (setting of conveying time with
reference to conveying distance)
Yes

Is the phase sequence correct? Replace No Check according to section 4.3.

phase, if necessary.
Yes

Does the blow-back valve change position? No Check: Compressed air connection, air filter on
solenoid valve, connection of solenoid valve.

The 3PH stops at short intervals because the overload protection has been activated

Is the disc filter cleaned and unclogged? No Clean or replace the disc filter.
Yes
Have the settings on the overload protection No Check settings. Adjust according to diagram, if
been adjusted correctly? necessary.
Yes

Does the machine start at short No Increase conveying time.

intervals?

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8 Spare parts

1. 3PH CYCLONE-38 Cyclone with filter Ø38 for 3PH4/8 loader. Mounted on blower console.
3. MFD HOSE32 Material hose Ø32mm. with anti-static wiring.
4. 3PH HOSE38 Material hose Ø38mm.With antistatic wire.
5. 3PH HOSE50 Material hose Ø50mm.With antistatic wire.
6. 3PH 32PIPE Stainless steel suction pipe for 3PH loader, Ø32mm.
7. 3PH/38PIPE Stainless steel suction pipe for 3PH loader, Ø38mm.
8. 3PH 50PIPE Stainless steel suction pipe for 3PH loader, Ø50mm.
9. 3PH FILTER BAG Filter bag return air 3PH 4-50.
10. 3PH BASE FILTER Base filter 3PH 4-50.
11. 3PH BOTTOM FLAP Bottom flap 3PH 4-50 complete.

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APPENDIX A: Technical Specifications

Specifications
Electric connection, voltage: 3~220-480V 50/60 Hz
Control voltage: 24 VDC
Motor power (kW): 0,5-4,2
Motor speed [RPM]: 2820 - 3470
Surrounding temperature 40°C max.
Hopper content, liter: 4 – 75
Suction hose (inner diameter): 32 mm – 38 mm
Suction pipe length mm: 840
Noise level 58-72 dB

 Right to alteration is reserved.

Conveying capacities

3PH 4-150/S Horizontal

Blower 0.4 kW
1 3 6 12 18 24 30 36 42 48 54
Capacity table
[kg/h]
kg/h
Vertical 3 216 202 198 188 177 167 156 144 133 121 109
Conveying 4 206 189 180 169 158 147 138 129 120 112 103
Distance [m] 5 183 168 166 156 145 134 127 119 112 103 93

3PH 8-300/S Horizontal

Blower 1.1 kW
1 3 6 12 18 24 30 36 42 48 54
Capacity table
[kg/h]
kg/h
Vertical 3 316 264 264 259 254 249 243 236 230 221 213
Conveying 4 306 256 256 252 248 244 238 233 227 218 209
Distance [m] 5 283 247 241 237 232 228 225 221 218 210 202

The above capacities kg/h at the respective distances set out in the table are based on the
assumption that the vacuum hopper is completely filled during each conveying cycle.

Over and above to the vertical and horizontal conveying distances, the available capacity depends on the
characteristics of the pellet, size and bulk density.
The specified capacities are based on a general bulk density of 0.6 kg/land the above capacity table states
recommended values only.

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APPENDIX B: Receiver Dimensions

Code Liters A (mm) B (mm)

3PH 4-150/S 4 275 555
3PH 8-300/S 8 275 610

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