USER GUIDE UGC011-0902 TLM Model Tube Loaders

TLM Model Tube LoadersHopper Loading and Direct Feed Configurations with MLC2 Control

Corporate Office: 724.584.5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

U S E R G U I D EUGC011-0902

www.conairgroup.com

Please record your equipment’smodel and serial number(s) andthe date you received it in thespaces provided.

It’s a good idea to record the model and serial number(s) of your equipment and thedate you received it in the User Guide. Our service department uses this information,along with the manual number, to provide help for the specific equipment you installed.

Please keep this User Guide and all manuals, engineering prints and parts lists togetherfor documentation of your equipment.

Date:

Manual Number: UGC011-0902

DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, con-sequential damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but notlimited to the implied warranties of merchantability and fitness for a particular purpose.

Copy r i gh t 2014 l Cona i r l A l l r i gh t s r ese r ved

UGC011/0902 TLM Loaders

TABLE OFCONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . .1-2ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3

DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1What is the TLM Loader? . . . . . . . . . . . . . . . . . . . . . . . . .2-2Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Features and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Installing the direct feed configuration . . . . . . . . . . . . . . . .3-3Installing the hopper loading configuration . . . . . . . . . . . .3-4Connecting the control . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Connecting a compressed air supply . . . . . . . . . . . . . . . . .3-6Connecting material lines . . . . . . . . . . . . . . . . . . . . . . . . . .3-7Loader operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1How it works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2Using the swing clamps . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3Adjusting the load time . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4Operation and adjustment of the optional blowback . . . . . .4-5Types of feed tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6Vertical feed tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6Horizontal feed tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1Preventative maintenance schedule . . . . . . . . . . . . . . . . . . .5-2Removing the filter for cleaning . . . . . . . . . . . . . . . . . . . . .5-3Inspecting the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4Cleaning and washing the filter . . . . . . . . . . . . . . . . . . . . .5-4Cleaning the compressed air filter bowl (optional) . . . . . . .5-5Motor brush inspection and replacement . . . . . . . . . . . . . .5-6

TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1Conveying problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

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TLM Loaders UGC011/0902

TABLE OFCONTENTS

APPENDIXService/Warranty information .................................Appendix AInstalling optional equipment (blowback and remote on/off switch) ..............................................Appendix B

PARTS/DIAGRAMSThis section has been provided for you to storespare parts lists and wiring, plumbing or assemblydiagrams.

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1-1UGC011/0902 TLM Loaders

●● Purpose of the User Guide . . . .1-2●● How the guide is organized . . . .1-2●● Your responsibilities as a user .1-2●● ATTENTION: Read this so

no one gets hurt . . . . . . . . . . .1-3

INTRODUCTION

TLM Loaders UGC011/09021-2 INTRODUCTION

This User Guide describes the Conair TLM Loaders withmanual or potentiometer controls. It explains step-by-step howto install, operate, maintain and repair this equipment.

Before installing this product, please take a few moments to read the User Guide and review the diagrams and safetyinformation in the instruction packet. You also should reviewmanuals covering associated equipment in your system. Thisreview won’t take long, and it could save you valuable instal-lation and operating time later.

Symbols have been used to help organize the User Guide andcall your attention to important information regarding safeinstallation and operation.

Symbols within triangles warn of conditions that couldbe hazardous to users or could damage equipment.Read and take precautions before proceeding.

Numbers within shaded squares indicate tasks or stepsto be performed by the user.

A diamond indicates the equipment’s response to anaction performed by the user.

An open box marks items in a checklist.

A shaded circle marks items in a list.

You must be familiar with all safety procedures concerninginstallation, operation and maintenance of this equipment.Responsible safety procedures include:

● Thorough review of this User Guide, paying particularattention to hazard warnings, appendices and related diagrams.

● Thorough review of the equipment itself, with carefulattention to voltage sources, intended use and warninglabels.

● Thorough review of instruction manuals for associatedequipment.

● Step-by-step adherence to instructions outlined in thisUser Guide.

PURPOSE OFTHE USERGUIDE

HOW THEGUIDE ISORGANIZED

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YOURRESPONSIBILITYAS A USER

UGC011/0902 TLM Loaders INTRODUCTION 1-3

We design equipment with the user’s safety in mind. You canavoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide.

ATTENTION:READ THIS SO NOONE GETS HURT

WARNING: Voltage hazard

This equipment is powered by single-phasealternating current, as specified on the machineserial tag and data plate.

A properly sized conductive ground wire fromthe incoming power supply must be connectedto the chassis ground terminal inside the elec-trical enclosure. Improper grounding can resultin severe personal injury and erratic machineoperation.

Always disconnect and lock out the incomingmain power source before opening the electri-cal enclosure or performing non-standard oper-ating procedures, such as routine maintenance.Only qualified personnel should perform trou-bleshooting procedures that require access tothe electrical enclosure while power is on.

WARNING: Improper installation,operation or servicing may result inequipment damage or personal injury.

This equipment should be installed, adjusted,and serviced by qualified technical personnelwho are familiar with the construction, opera-tion and potential hazards of this type ofmachine.

All wiring, disconnects and fuses should beinstalled by qualified electrical technicians inaccordance with electrical codes in your region.Always maintain a safe ground. Do not operatethe equipment at power levels other than whatis specified on the the machine serial tag anddata plate.

DESCRIPTION 2-1UGC011/0902 TLM Loaders

●● What is the TLM loader? . . . . . .2-2●● Typical applications . . . . . . . . . .2-2●● Features and options . . . . . . . . .2-3

DESCRIPTION

The TLM Loader is a self-contained vacuum loader designedto transfer plastic pellets by vacuum from boxes, bins or hop-pers to an end-use destination such as molding machines,extruders or other hoppers or bins.

The tube loader is available in two configurations:

The operation of both loaders is very similar.

Here’s the difference :

The Direct Feed Model comes equipped with a cylindricalsight glass on the bottom allowing it to be mounted directly toa machine throat. The sight glass assembly has a small funnelat the bottom to direct the flow of material from the loaderthrough the glass and into the machine throat.

The Hopper Loading Model is intended to be mountedthrough a hole in the flat top of a bin or hopper.

WHAT IS THETLM LOADER?

TLM Loaders UGC011/09022-2 DESCRIPTION

TYPICALAPPLICATIONS

Direct Feed Hopper Loading

UGC011/0902 TLM Loaders DESCRIPTION 2-3

OVERVIEW OFFEATURES ANDOPTIONS

Features

The standard TLM Loader is equipped with a Model MLC2control box with an internal load time setting. The control’son/off switch is also a lighted circuit breaker.

The TLM loader features no-tools, swing clips that allow easyaccess for maintenance.

Options

An optional, Model MLC6 control is available. The MLC6control allows numerous other loading functions includingpurging or ratio loading. See alternate instructions for thiscontrol.

A Blowback can be selected as an option and has its owntiming control. Clean, dry compressed air is required if theTLM is equipped with the blowback option. Blowback willextend the life of the cartridge filter inside the tube loader.

A remote on/off switch for the TLM is available as anoption.

INSTALLATION 3-1UGC011/0902 TLM Loaders

●● Unpacking the boxes . . . . . . . . .3-2●● Installing the direct feed

model . . . . . . . . . . . . . . . . . . . .3-4●● Installing the hopper loading

model . . . . . . . . . . . . . . . . . . . .3-4●● Connecting the control . . . . . . .3-6●● Connecting a compressed

air supply (optional) . . . . . . . .3-4●● Connecting material lines . . . . .3-8●● Loader operation . . . . . . . . . . . .3-8

INSTALLATION

The TLM Loader comes fully assembled in a single crate.

Carefully uncrate the TLM Loader and its components.

Remove all packing material, protective paper, tape,and plastic. Compare contents to the shipping papers toensure that you have all the parts.

Carefully inspect all components to make sure nodamage occurred during shipping. Check all wire terminalconnections, bolts, and any other electrical connections,which may have come loose during shipping.

Take a moment to record serial numbers andspecifications in the blanks provided on the back of theUser Guide’s title page. The information will be helpful if you ever need service or parts.

You are now ready to begin installation.

UNPACKINGTHE BOXES

TLM Loaders UGC011/09023-2 INSTALLATION

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The Tube Loader is equipped with a discharge valve on thebottom that allows the loader to be vacuum sealed while it isloading.

The Direct Feed Model comes equippedwith a cylindrical sight glass on the bot-tom allowing it to be mounted directly toa machine throat. The sight glass has asmall funnel at the bottom to direct theflow of material from the loader throughthe glass, to the machine throat.

Drill the glass chamber’smounting base as needed to match the moldingmachine throat.

Bolt the direct feed chamber directly to theprocessing machine throat.

Secure the loader onto the glass chamber. The loader may be oriented as needed. Secure the threeperimeter clamps to hold the loader securely.

INSTALLING THEDIRECT FEEDCONFIGURATION

UGC011/0902 TLM Loaders INSTALLATION 3-3

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TIP: We recommendthe loader be placedwith the inlet tube ori-ented towards thematerial source, so thatthe conveying hose fol-lows the shortest,straightest route possi-ble. Orient the controlso that it is both visibleand easy to access.

TIP: Gasket material(not supplied) may beinstalled between theglass chamber and theprocessing machinethroat to assure a dust-free seal, but it is notrequired for normalloader operation.

CAUTION: To avoid personal injury or damageto the loader, the loader must be mounted firmlyto the machine it is filling. If the unit is not mount-ed firmly the loader could be accidentally movedout of position or come loose when the loader lidis tilted back for typical filter maintenance orcleaning.

NOTE: An additional adaptor may be required to fun-nel the outlet of the sight glass down to the size of theprocessing machine throat.

NOTE: To make installation easier, the tube loaderseparates from the glass chamber with three perimeterclamps located just above the glass section.

The Hopper Loading Model isintended to be mounted through ahole in the flat top of a bin or hopper.

Place the discharge valvedown into the top of the hopper to be filled.Use the loader’s mounting flange, as the interfacing sur-face with the hopper the loader will fill. A 6-5/8 inchdiameter clearance hole in the destination hopper isrequired for mounting. Make sure the loader’s dischargevalve can move freely once it is in its mounted position.

Note: If the discharge valve does not move freely becauseof the close clearances with the hopper, A “riser” (avail-able from Conair) may be used to mount the tube loaderabove the hopper lid.

Secure the loader into its mounting hole. The loader can be secured withbolts or hold-down clips. Usethe pre-drilled holes in themounting flange to bolt theloader into position OR use thehold-down clips (supplied withmost Conair hoppers), tight-ened against the outer edge ofthe mounting flange.

Note: Most Conair hoppers aresupplied with hold down clips(and an appropriately sizedhole) for easy mounting. If theloader is to be used in a holethat is too large an adaptorplate must be used for securemounting.

INSTALLING THEHOPPERLOADINGCONFIGURATION


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TIP: Gasket material(not supplied) may beinstalled between themounting flange of theloader and the receivinghopper to assure adust-free seal, but it isnot required for normalloader operation.

CAUTION: To avoid personal injury or damageto the loader the loader must be mounted firmlyto the hopper or bin it is filling. If the unit is notmounted firmly the loader could be accidentallymoved out of position or come loose when theloader lid is tilted back for typical filter mainte-nance or cleaning.

TIP: We recommendthe loader be placedwith the inlet tube ori-ented towards thematerial source, so thatthe conveying hose fol-lows the shortest,straightest route possi-ble. Orient the controlso that it is both visibleand easy to access.

CONNECTINGTHE CONTROL


WARNING: Improper installation couldresult in equipment damage and severe personal injury from electrical shock.

Electrical connections should be made only byqualified personnel. This machine requires awell-grounded circuit and single-phase alternat-ing current as specified on the data plate. If thecorrect power supply is not available, you mustinstall a transformer between the building sup-ply and the machine. A properly sized conduc-tive ground wire from the power supply must beconnected to the ground terminal on the loader.

The TLM loader uses a control that is mounted directly to theloader’s mounting flange, and preconnected to all loader func-tions.

Connect the power cord to an appropriate electric power source.

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IMPORTANT: Have a qualifiedelectrician check the loader’sdata plate that gives voltageand amperage and make sure it matches your electricalpower source.

If your TLM Loader has the optional blowback solenoid youwill need compressed air for operation. The blowback is asmall solenoid that is installed on one of the pipes extendingfrom the base of the motor unit.

Connect the compressed air to the 1/4 inch NPTfemale inlet. The compressed air source must deliver amaximum of 125 psi of clean, dry (non-lubricated), air pressure.

CONNECTING ACOMPRESSEDAIR SUPPLY


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IMPORTANT: The compressed air connected to theTube Loader must be non-lubricated, if it is not, the filter media used in the Tube Loader will becomeblocked, severely reducing conveying performance.

TIP: We recommend installing a filter (available fromConair, 800-458-1960) in the compressed air line toremove moisture from the line. It should be installed inthe compressed air line leading to the loader and in alocation that accommodates frequent servicing.

CONNECTINGMATERIALLINES


Typical Tube Loader installations use the included flex hoseto connect the material inlet of the loader to the materialsource.

Connect the material inlet ofthe loader to the materialsource. Attach flex hose over theinlet stub of the loader and secure thehose with a hose clamp. The hoseshould be fitted over the inlet stub atleast 1-1/2 inches. Position the hoseclamp at least 1/4 inch from the end ofthe inlet.

Connect to the material source’s vertical feedtube or distribution box. Attach the flex hose in the same manner as describedabove.

When connecting to vertical feed tubes orwands: (used for conveying out of open-top boxes) sufficientslack should be left to allow movement of the feed tubewhen the material supply gets low, but “valleys” or droopsshould be avoided.

When connecting to horizontal feed tubes: (use for conveying from surge bins, silos or granulators)less slack will be needed, but flex hose is still suggestedto allow easy disconnection in the event of trouble. A hoseclamp should be installed to prevent disconnection of thehose from the feed tube.

IMPORTANT: The material line should beas straight as possible. Avoid loops and S-curves in flexible hose This can hurt con-veying performance.

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LOADEROPERATION


Insert the feed tube into the material supply.

Turn the control on.

Adjust the load time. see “ADJUSTING THE LOAD TIME.” SECTION 4

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OPERATION 4-1UGC011/0902 TLM Loaders

●● How it works . . . . . . . . . . . . . . .4-2●● Using the motor hold-down

swing clips . . . . . . . . . . . . . . . . .4-3●● Adjusting the load time . . . . . . .4-4●● Vacuum modes . . . . . . . . . . . . .4-5●● Operation and adjustment of the

optional blowback . . . . . . . . . .4-5●● Feed tube adjustments . . . . . . .4-7

OPERATION

HOW IT WORKS

TLM Loaders UGC011/09024-2 OPERATION

Once the loader is turned on, the start of the loading func-tion is triggered by the demand switch, integrated into thegravity discharge valve on the bottom of the loader.When the flapper swings closed by the weight of its owncounterweight, it is an indication that the loader 'sees' nomaterial below it and must provide material by starting aload cycle.

The demand switch, located on the loader flange, is a"reed" type that magnetically reacts with a small magnet,located on the flapper weldment. As the flapper closes andthe magnet gets close to the reed switch, the reeds of theswitch close, providing a demand signal to the loader con-trol. From that point, the loader control's timed vacuumfunction takes over, providing an automated, timed loadcycle.

Upon completion of the timed loading cycle, the vacuummotor will stop and the loaded material will dischargefrom the loader into the receiving bin, or glass chamberbelow the loader.

After discharging material into the receiving hopperbelow the loader, the cycle may repeat or the dischargeflapper may be held open with the material that was dis-charged from the loader. If the flapper closes, the cyclewill repeat. If the flapper is held open by the material, it isan indication that there is no need for another load cycleand the loader will wait until the material level falls, theflapper closes, the magnet comes close to the reed switchand triggers another load cycle.

To access to the motor and filter area follow these simplesteps:

Unplug the motor from the control.

To release the clamps, press in orpull on the rubber pads on eachclamp in the direction shown in fig-ure 2.

Lift the motor housing straight up andaway from the loader body. See figure 3.

The motor housing can stay attached tothe clamps and tilted to a 90 degree angle,to completely expose the filter inside theloader body. See figure 4.

When necessary, the motor housing can becompletely removed (for instance when ser-vicing the brushes) by lifting it out of theopenings in the clamps. See figure 5.

To re-install, repeat the above procedures inthe reverse order. Use care to align thegrooves in the motor unit’s blowback pipewith the swing clamps.

USING THEMOTORHOLD-DOWNSWING CLAMPS

UGC011/0902 TLM Loaders OPERATION 4-3

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Load time can be adjusted through the adjustable potentiome-ter located inside the control box.

To adjust the load time:

Loosen one screw and pull the lid off the control box. Locate the adjustable potentiometer insidethe control box.

Use a small screw driver to adjust the potentiometer. Clockwise increases the duration of thevacuum motor’s cycle and counterclockwise decreases it.

How to determine where to set your load time:

Load time should be set with enough seconds to “just fill”the vacuum loader. 'Just full' is indicated by an audible risein the pitch of the vacuum motor and/or material no longerflowing in the material conveying line.

Too much load time will prematurely wear out the vacuummotor, pack material in the conveying line, prematurelyblind the filter and possibly cause material shortages byclogging up the system by attempting to fill a loader that isalready full.

Too few seconds set on the control may starve yourprocess with numerous on and off cycles that yield too lit-tle material transfer.

Load time may be best adjusted by trial and error, to pro-vide sufficient vacuum-on time to "just fill" the loaderbefore the motor shuts off.


ADJUSTING THELOAD TIME

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How the optional blowback works:

When equipped, the blowback function of your TLM Loaderis comprised of a compressed air solenoid and timer, connect-ed to the blowback chamber above the internal cartridge filterof the loader, below the vacuum motor. The solenoid is wiredto be energized whenever the loader is turned on. A smalltimer on the solenoid's electrical connector provides periodicpulses of compressed air, to clean the filter of collected mater-ial fines and dust.

To adjust the blowback pulses:

The blowback pulses may be adjusted to provide more thor-ough filter cleaning (more pulses) or to conserve compressedair (fewer pulses) by adjusting one of the dual timers locatedon the blowback solenoid's electrical connector.

The mini-screwdriver adjustable “ON" timer provides theduration of the filter cleaning burst of air and should be facto-ry set correctly to minimum. Only about ½ second burst ofcompressed air should provide an optimized pulse of filtercleaning action.

The "OFF" setting establishes the length of time betweeneach burst of air. This setting should be factory set to about a50 second time-length, so that a ½ second filter cleaning burstof air will occur every 50 seconds.

Changes may be made to the blowback timer's “OFF” settingto increase the number of pulses (counter-clockwise turns, forless pause between pulses). Or the number of pulses may bedecreased (clockwise turns, for more pause time between puls-es) by adjusting the “OFF” time setting.


OPERATION ANDADJUSTMENT OFTHE OPTIONALBLOWBACK

NOTE: The filter cleaningblowback action, will occur asset whenever the loader isturned on, regardless of howlittle or how much the loaderis being used. Blowbackbursts are likely to occur dur-ing vacuum loading, whichmay momentarily alter load-ing performance. This is nor-mal.

The blowback will also occurwhen the loader is not beingused for any period of time,but yet remains turned on,since the blowback functionruns on its own timer. This isalso normal. If this is unde-sirable, the loader shouldsimply be turned off, whichwill halt the blowback functionas well as any loading.

IMPORTANT: The “ON” time setting should not bechanged from its ½ second setting.


Feed tubes may be provided in a variety of styles made tomatch the needs for your production. Whether they are hori-zontal types like distribution boxes (take off boxes) or hori-zontal bin tubes, or vertical types like wands that are made tobe hand inserted into material bins, they need to be adjustedfor their air to material ratio. Conair offers a vertical feed tubethat provides a fixed amount of material entry with an adjust-ment provision for air flow. Horizontal types are also avail-able, that feature fixed air flow and adjustments for regulatingmaterial entry.

Smooth material flow is controlled by opening or closing theholes at the top of the feed tube.

Insert the feed tube into the material supplyand observe its conveying action.

If the material surges ("gulps") as it is con-veyed, clear the line by lifting the feed tube out of thematerial supply and allow the line to clear.

Cover holes on the feed tube and retest untilthe material conveys smoothly. Use flex hose connected to the feed tube or strong tape(duct tape is commonly used) to cover the holes.

Test several cycles. Cover and uncover the feed tube holes to achieve thedesired results.

Once conveying is fine tuned, the feed tube should be twisted in its conveying hose toplace the open feed tube holes up, so that material cannotfall out of the holes when conveying stops.

VERTICAL FEEDTUBEADJUSTMENTS

TIP: Covering all holes con-veys the maximum amount ofmaterial with minimal air, pro-ducing the highest volume ofmaterial flow but at the slow-est possible conveying speed(a low air to material ratio).This can make conveyingover longer distances orthrough bends more difficult.With holes uncovered, a 'thin-ner' flow of material isachieved and the greatestconveying speeds are real-ized. This is a high air tomaterial ratio and can createundesirable material fractur-ing in the loader, "angle hair"in the conveying lines andmaterial dust.

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TYPES OF FEEDTUBES

Close off material flow to the loader. Loosen the thumb screw next to the adjustable air inlettube and push it all the way in to close off material flowand allow 100% air to flow through to the loader.

Adjust the air tube to achieve optimum conveying. Over the course of several cycles, pull the air tube outslowly until optimum conveying is achieved with minimalsurging (gulping).

If surging does occur, clear the conveying line by pushing the air inlet tube allthe way in until the line clears and then trial and error set-tings may be attempted again.

Once optimum settings are achieved,the air inlet position may be locked into position with the thumb screw.


HORIZONTALFEED TUBEADJUSTMENTS

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NOTE: As described in"Types of Feed Tubes"different types of feedtubes feed materialmixed with air in differentways. Conair horizontalfeed tubes (distributionboxes, etc) provideadjustments for materialflow with a fixed amountof conveying air for opti-mum material flow.Competitive units maynot work in the samemanner.

MAINTENANCE 5-1UGC011/0902 TLM Loaders

●● Preventative maintenanceschedule . . . . . . . . . . . . . . . . . .5-2

●● Removing the filter and cleaning . . . . . . . . . . . . .5-3

●● Inspecting and cleaningthe filter . . . . . . . . . . . . . . . . .5-4

●● Cleaning the optional filter . . . .5-5●● Motor bush inspection and

replacement . . . . . . . . . . . . . . . .5-5

MAINTENANCE

Normal maintenance of the TLM Loader consists of cleaningthe filter and motor brush replacement.

●● Daily❒❒ Clean the filter.

If you are running a dusty material or regrind you mayneed to check and clean the filter more often. If theloader seems to be straining to run, or material flow iserratic or sluggish, check the filter. The filter alsoshould be cleaned whenever you change materials.

●● Weekly, or as needed.❒❒ Drain the compressed air filter trap (if equipped).

Depending on your compressed air system, you may see moisture or oil in the compressed air filter trap. Open the petcock on the bottom of the trap to drain. If you see oil we recommend installing a coalescing type filter ahead of the standard moisture removing filter.

●● Monthly, or as needed❒❒ Check the motor brushes.

See “Motor Brush Inspection and Replacement.”

●● Semi-annually or as needed ❒❒ Examine the bolts.

Examine the bolts or clips holding the loader to thesurface. Make sure the bolts or clips are tight.

PREVENTATIVEMAINTENANCESCHEDULE

TLM Loaders UGC011/09025-2 MAINTENANCE

The filter of your TLM Loader is designed to protect the vacu-um motor from damage by plastic pellets, regrinds, and finesthat are drawn to the loader by the vacuum action of themotor. The cartridge filter, situated below the vacuum motor,in the body of the loader, separates vacuum conveying airfrom the loaded material and can become caked with materialdust as material is loaded.

The blowback function (if your Tube Loader is equipped withit), does a good job of cleaning the filter, but occasionally thefilter will need manual cleaning, or eventual replacement, tostay effective. The schedule of cleaning will depend upon howmuch material and how clean the material being conveyed is(dusty regrind causes rapid filter blinding).

Disconnect power to the loader.

Remove the filter. Expose the filter by releasing and tilting the motor unit offof the top of the loader body. see “USING THE MOTORHOLD-DOWN SWING CLAMPS .” SECTION 4

UGC011/0902 TLM Loaders MAINTENANCE 5-3

REMOVINGTHE FILTER FORCLEANING

CAUTION: Wear eye protectionWe recommend that you use vacuum air for cleaningfilters and other parts of this equipment. If you usecompressed air to clean the equipment, you mustwear eye protection and observe all OSHA and othersafety regulations pertaining to the use of compressedair.

WARNING: Disconnect power and airsources. Always disconnect the main power sourceand compressed air source before removing the filterThis prevents the loader from starting during servic-ing, which could cause personal injury from flyingdebris or moving parts.

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With the filter removed, it may cleaned with either com-pressed air, blowing down through from the motor side, orwith a vacuum cleaner sucking against the outside filtermedia.

Inspect the filter carefully. Check for holes that could allow the passage of fines ordust to the loader motor. Replace the filter if it is damaged,excessively worn or too clogged with fines and dust toclean. Be sure to discard and replace any filter that hasbecome hopelessly clogged with material dust. Do notattempt to repair a damaged filter. Replace the entire filterif the rubber seal is damaged or excessively worn.

Vacuum or use compressed air to remove particulate from the filter. We recommend that you vacuum the filter surfaces. If youuse compressed air, you must wear eye protection and fol-low all safety regulations pertaining to cleaning equipmentwith compressed air. The cartridge filter may be cleanedby blowing with compressed air from the inside out.

Wash the filter.Wash the cartridge with low water pressure (about 40 psi)from the inside outward.

Dry the filter.Let the cartridge dry for about 72 hours or until the filtermedia is completely dry. IMPORTANT: The cartridgemust be 100% dry before returning it to normal operation.

INSPECTINGTHE FILTER


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IMPORTANT: Do not excessively bang the filtercartridge on a hard surface to clean material fromthe filter. This could damage the filter, create holesthat will allow dust through the filter, or distort theflat sealing surface of the cartridge.

NOTE: Make sure you clean the filter in a dry loca-tion using dry air. If moisture is added to the filtermedium, the collected fines can solidify intoclumps that will be very difficult to remove.

If moisture is accidentally introduced, set the filteraside and allow it to thoroughly air dry before vacu-uming, or replace it with a new filter.

CAUTION: Weareye protection

We recommend that youuse vacuum air for cleaningfilters and other parts of thisequipment. If you use com-pressed air to clean theequipment, you must weareye protection and observeall OSHA and other safetyregulations pertaining to theuse of compressed air.

CLEANING/WASHING THEFILTER

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Install/Re-install the filter.

You can add a moisture trap to the compressed air supply ofyour loader. A moisture trap can prevent troublesome mois-ture, contained in the air, from entering the loader.

The filter bowl of this moisture trap must be emptied regularlyto drain the water from the air system. Follow the instructionslisted on the filter bowl itself, which usually requires openinga port at the base of the bowl and letting the water in the bowlblow out in a stream of compressed air. Creating a path forthis blowout of moisture is usually a good idea, to prevent astream of moisture-soaked air from contaminating machinesor people.

It is also a good idea to inspect the bowl periodically with thecompressed air supply turned off, to clean or replace the filterelement if need be or to remove contaminant accumulation, ifit is present.

CLEANINGTHECOMPRESSEDAIR FILTER(OPTIONAL)


4 CLEANING/WASHING THEFILTER(CONTINUED)

NOTE: The filter in your Conair Tube Loader performsdouble-duty as an effective seal between the hopperbody and the lid of the loader. Be sure to examine theintegrity of the rubber seal at the top so that the motorunit will seal effectively when clamped. Make sure toreplace the entire filter if the rubber seal is damaged orexcessively worn.

MOTOR BRUSHINSPECTIONANDREPLACEMENT

The vacuum motor on your Tube Loader is powered by abrush type, high RPM motor that requires maintenance tothe brushes on a regular basis. Inspect brushes regularly. Worn brushes can damage the motor and should bereplaced.

Disconnect the power. Lock out/tag out according to your plant's safety guide-lines.

If provided, disconnect the compressed air lineto the blowback solenoid. (This will be necessary to fully release the motor unit fromthe loader. )

Release the motor unit from the loader. “USINGTHE MOTOR HOLD-DOWN SWING CLAMPS .” SECTION 4.Once the motor unit is removed from the loader it may betaken to a work area for disassembly and inspection of thebrushes.

Remove the motor.The motor is located within a cylindrical shroud. Toremove the motor, place the motor upside down on itsblack plastic top, remove the bolt on the side of the motorhousing and twist the exposed blowback chamber clock-wise to release it from the two slots in the motor shroud.Once released the blowback chamber can be set aside.

Release the motor's power cablefrom the shroud by carefully pulling up on the cable andits grommet until it slips out of its slot in the shroud.

The motor may now be gently pulled straight out of theshroud, along with its cable for brush inspection. Take careto avoid catching the electrical wires on any metal detailsinside the shroud as the motor is pulled out.


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WARNING: Disconnect power and airsources. Always disconnect the loader from the mainpower source and compressed air source before ser-vice. This prevents the loader from starting duringservicing, which could cause personal injury from fly-ing debris or moving parts.

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continued on the next page...

Free the brushes and their holders by removingthe screws.Once the motor has been removed from the shroud, themotor brush covers will be visible on each side of themotor, held in place with two phillips-headed screws.

Examine the brushes carefully.Check to see if the brush is still intact and not disintegrat-

ed from use. The brush should be at least 1/4" long (asmeasured from the motor end to the brush holder) to bereturned to service. If either brush is not, discard bothbrushes and holders and replace both immediately.

Reassemble the loader. Once motor brush maintenance is completed, place themotor back into the shroud carefully, being careful not topinch any wires by lining up the motor’s power cable withits cord grip slot slot on the motor shroud. Reroute themotor wire's grommet through the slot in the motor shroudand re-install the blowback chamber, making sure thatthe small hole in the center of the blowback pipe is visi-ble and will be directed toward the filter, once the motorunit is re-installed on the loader. Twist the blowback cham-ber back into its locked position below the motor by rotat-ing counter-clockwise until it clicks into position in themotor shroud. Grooves in the blowback pipe facilitateproper positioning.

Re-install and tighten the locking bolt on the side of themotor shroud. This bolt should line up with a threadedboss on the side of the blowback chamber. If the boss is onthe opposite side of the blowback chamber, simply removethe chamber, rotate it and re-install so that the bolt may beinstalled securely.

Reconnect the motor unit with the swing clamps on theloader by pushing the blowback pipe back through theopenings in the clamps. The motor unit may now beplaced in position and fastened back down on the loaderwith the swing clamps.


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WARNING: Do notoperate the loaderwithout the lockingbolt in place andtightened securely.If the locking bolt isnot in place and tight-ened securely themotor assemblycould come looseduring operation ormaintenance andcause personal injury.

MOTOR BRUSHINSPECTIONANDREPLACEMENT(CONTINUED)

UGC011/0902 TLM Loaders TROUBLESHOOTING 6-1

●● Conveying problems and solutions . . . . . . . . . . . 6-2

TROUBLESHOOTING

TLM Loaders UGC011/09026-2 TROUBLESHOOTING

Problem

Low or nomaterial flow.

CONVEYINGPROBLEMS

Possible causeDoes the filter need to be cleaned?

Is there an overload onthe circuit breaker(s)?

Are there kinks in theflex hose?

Are there holes or cracksin any of the materiallines?

Are hose connections too loose?

Are material to air adjust-ments at the materialpickup device correct?

Do you have enough material at the source?

Are the motor brushesworn?

Solution

Check the filter and clean if itis clogged with dust or fines. Clean the filter. See Section 5, CLEANING THE

FILTER.Reset the circuit breaker if it is tripped. Check for reason.

Check the material flex hoseline for loops and “S” curves.Remove any loops and “S”curves in the flex hose. Try tokeep the hose as straight aspossible.

Check the material line for holes,cracks or other signs or excessivewear. Replace worn flex hose.

Check the material line hoseconnections for leaks. Hoseclamps should be secured nearthe end of the hose connec-tions.

Check the material to airadjustments at the feed tube ordistribution box to make surethey are properly adjusted See Section 4, FEED TUBEADJUSTMENTS.Replace/refill the material con-tainer or reposition the feed tube.

Check the motor brushes. If anybrush is too short, replace bothbrushes. See Section 5, MOTORBRUSH INSPECTION ANDREPLACEMENT.

WARNING: Disconnect power and air sources.Always disconnect the loader from its main powersource and compressed air source before servicing.This prevents the loader from starting during servicing,which could cause personal injury.

Problem

Low or nomaterial flow(continued).

Motor speedsounds like it variesas it operates.

Loader will notcycle.

Possible causeHas material plugged thetubing or flexible hose?

Motor brushes are usedup. Increased arcing iscreating uneven motorspeeds.

Is there a vacuum air leak?

Are all electricalconnections correct?

Is the flapper on the bottom of the loaderblocked preventing ademand signal?

Solution

Remove the conveying line fromthe material and check for vacu-um. If necessary, uncouple thelines, remove blockages andreassemble the lines. Readjust forproper material flow See Section4, FEED TUBE ADJUSTMENTS.

Check and/or replace brushes. Section 5, MOTOR BRUSHINSPECTION AND REPLACEMENT

Check o-rings and gaskets fordamage or leaks.

If the blowback option is installed,make sure the compressed air lineis connected at the lid.

Check to make sure loader con-trol is plugged into a powersource.

Unblock the flapper and determine the reason for theobstructed flapper motion. Ariser may be required for hop-per loading installations.See Section 3, Installing theHopper Loading Version.

CONVEYINGPROBLEMS

UGC011/0902 TLM Loaders TROUBLESHOOTING 6-3

WARNING: Disconnect power and air sources.Always disconnect the loader from its main powersource and compressed air source before servicing.This prevents the pump from starting during servicing,which could cause personal injury from flying debris ormoving parts.

SERVICE INFORMATION APPENDIX A1

We’re Here to He lpConair has made the largest investment in customer support in the plasticsindustry. Our service experts are available to help with any problem youmight have installing and operating your equipment. Your Conair salesrepresentative also can help analyze the nature of your problem, assuringthat it did not result from misapplication or improper use.

How to Contac t Cus tomer Ser v iceTo contact Customer Service personnel, call:

You can commission Conair service personnel to provide on-site service bycontacting the Customer Service Department.

Before You Ca l l . . .If you do have a problem, please complete the following checklistbefore calling Conair:

� Make sure you have all model, control type and serial numbers from theserial tag, and parts list numbers for your particular equipment. Servicepersonnel will need this information to assist you.

� Make sure power is supplied to the equipment.

� Make sure that all connectors and wires within and between controlsystems and related components have been installed correctly.

� Check the troubleshooting guide of this manual for a solution.

� Thoroughly examine the instruction manual(s) for associated equipment,especially controls. Each manual may have its own troubleshooting guideto help you.

� Check that the equipment has been operated as described in this manual.

� Check accompanying schematic drawings for information on specialconsiderations.

Additional manuals and prints foryour Conair equipment may beordered through the CustomerService or Parts Department for a nominal fee. Most manuals canbe downloaded free of chargefrom the product section of theConair website. www.conairgroup.com

NOTE: Normal operating hours are 8:00 am - 5:00 pm (EST). After hours emergency

service is available at the same phone number.

�

warrantY InforMatIona2 appendIx

Equ ipment Guaran teeConair guarantees the machinery and equipment on this order, for a period as defined in thequotation from date of shipment, against defects in material and workmanship under the nor-mal use and service for which it was recommended (except for parts that are typicallyreplaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limitedto replacing, at our option, the part or parts determined by us to be defective after examina-tion. The customer assumes the cost of transportation of the part or parts to and from thefactory.

Per fo rmance War ran tyConair warrants that this equipment will perform at or above the ratings stated in specificquotations covering the equipment or as detailed in engineering specifications, provided theequipment is applied, installed, operated and maintained in the recommended manner as out-lined in our quotation or specifications.

Should performance not meet warranted levels, Conair at its discretion will exercise one of the following options:

• Inspect the equipment and perform alterations or adjustments to satisfyperformance claims. (Charges for such inspections and corrections will be waived unlessfailure to meet warranty is due to misapplication, improperinstallation, poor maintenance practices or improper operation.)

• Replace the original equipment with other Conair equipment that will meetoriginal performance claims at no extra cost to the customer.

• Refund the invoiced cost to the customer. Credit is subject to prior notice by the customerat which time a Return Goods Authorization Number (RGA) will be issued by Conair’sService Department. Returned equipment must be well crated and in proper operating con-dition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and provide a customer receipt andother evidence that a claim is being made.

Warran ty L imi ta t ionsExcept for the Equipment Guarantee and Performance Warranty stated above, Conairdisclaims all other warranties with respect to the equipment, express or implied, aris-ing by operation of law, course of dealing, usage of trade or otherwise, including butnot limited to the implied warranties of merchantability and fitness for a particularpurpose.

APPENDIX B-1

The blowback option (120VAC, PN#101-795-03-01; and220VAC, PN#101-795-03-02) may be added to TLM tubeLoader. The blowback assembly can be located on either sideof the vacuum motor. The blowback solenoid is connected tothe to the blowback tube (located in the base of the motormodule) and is wired to the loader control.

Select which side you wish to locate the blow-back assembly.Make the selection based on the location of your com-pressed air supply in relation to the loader. Keep in mindthat the motor unit (with the blowback assembly) will betilted back, and/or removed frequently for filter and brushmaintenance.

Remove the pipe plug from either side of theblowback tube located in the motor unit of the loader.Carefully remove all residue thread sealant.

Install the compressed air solenoid into theblowback tube. Make sure that the solenoid's air flowis directed into the blowback tube. Required fittings areincluded with the solenoid valve. Use thread sealant tosecure the fit and to prevent leaks, but take care to avoidexcess that could end up trapped in the blowback pipe orfilter element. Make sure all fittings are tight and cannotvibrate loose or leak.

A quick disconnect fitting may be supplied atthe inlet of the solenoid valve, if desired. (see note). Air supply may not exceed 125 psi, the limit ofthe solenoid. If it does, an air regulator (not supplied)must be installed to limit air pressure to 125 psi.

ADDING THEOPTIONALBLOWBACK

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NOTE: A non-restrictive quick disconnect fitting (notsupplied) may be used to allow full disconnection of theair supply line when performing maintenance on theloader.

NOTE: Wet or lubricated compressed air will foul the fil-ter operation and cause premature filter blinding. Acompressed air filter (available from Conair) is recom-mended when using compressed air blowback, toassure a clean supply of dry air to the filter during blow-back. The compressed air filter should be mounted asclose as possible to the loader, but should be connect-ed to your air line or header, not the loader.



APPENDIX B-2

Wire the solenoid to the loader control. The solenoid's coil connector is equipped with a compacttimer element. The wire for the solenoid comes out of thatconnector and must be wired into the loader control. OnConair's optional "MLC6" control, with a matching termi-nal box (referred to as a "UTB"), the termination of thatsolenoid wire is already equipped with a green plastic con-nector that may be readily plugged into the receptaclemarked "BLOBAK" on the UTB and your installation iscomplete. On the standard "MLC2" control, the solenoidcable must be installed inside the control enclosure. Thecable is supplied with a cord grip that may be used forpassage through the control enclosure in place of one ofthe hole plugs installed in the enclosure.

Firmly connect the terminals.The individual conductors of the cable, green (ground),white (neutral) and brown (hot) are equipped with insulat-ed "spade lug" terminations that may be readily connectedto mating white, green and brown terminals located insidethe control. Make sure the terminals are pushed togetherfirmly, closing off any exposed conductor. Refer toBlowback Connections chart below for proper connectionsof 120 or 220 volt loaders.

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ADDING THEOPTIONALBLOWBACK(CONTINUED)

IMPORTANT: The blowback unit can now be connectedto the compressed air supply and operated, along withthe loader. Refer to instructions in the TLM loader man-ual for operational details.

120 VAC

220 VAC

Blowback Connections

Blowback ControlCable Connectors

Green to Green GroundWhite to White NeutralBrown to Brown Hot

Green to Green\Yellow GroundWhite to Blue NeutralBrown to Brown Hot


APPENDIX B-3

The optional remote On/Off switch (120VAC, PN#107-620-08-01; and 220VAC, PN#107-620-08-02) may be added toTLM Tube Loader.

The TLM loader, equipped with the standard MLC2 control,may be equipped with an optional remote on/off switch toallow the loader to be turned on and off from a remote loca-tion up to 15 feet away. The parts provided for this optionconsist of a switch and 15 foot wire assembly, terminated withspade lug connections that may be easily wired inside theMLC2 control. The switch is recommended to be bolted to afirm surface within the length of the cable provided. A bolthole for a 1/4 inch bolt is provided on the switch.

Disconnect all power to the TLM Loader.Make sure to unplug the power cord and locking out/tag-ging out according to your site's regulations.

Insert the remote on/off cable and its’ cord gripinto the appropriate hold. Remove the hole plug located just above the power cablein the control enclosure and insert the remote on/off cablewith its accompanying cord grip. The grip should providesuitable strain relief and insulation at the control box entrypoint.

Terminate the ground wire at the ground screwinside the box. The ground wire is equipped with a circular connector forperforming this connection.

Connect the remote on/off switch wires.Inside the control, the power wire connecting the incomingpower wire to the combination circuit breaker/switch isequipped with a coupled spade lug connection that may beseparated to allow connection of the remote on/off switchwires. The remote on/off switch is equipped with matingconnectors see the wiring guide labeled Figure 1 on thenext page for proper connection of 120 or 220 volt load-ers.

ADDING THEOPTIONALREMOTEON/OFFSWITCH

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NOTE: The remote on/off switch will interrupt the elec-trical path from the incoming power cable to the rest ofthe control by making the power travel through theremote switch before it reaches any components insidethe control.

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WARNING: Improperinstallation, operationor servicing may resultin equipment damageor personal injury.

This equipment should beinstalled, adjusted, and ser-viced by qualified technicalpersonnel who are familiarwith the construction, opera-tion and potential hazards ofthis type of machine.

All wiring, disconnects andfuses should be installed byqualified electrical techniciansin accordance with electricalcodes in your region. Alwaysmaintain a safe ground.



APPENDIX B-4

Match the mating connectors.Push the connectors together fully, to completely cover any exposed conductor. Electrical connections are nowcomplete.

Route the remote on/off switch cable from theloader control to the desired location within the15 foot cable length. Make sure the cable routing provides enough slack at thecontrol/loader for maintenance, removal, etc and makesure the cable will not come in contact with hot surfacesor moving parts that may damage the cable in operation.

Mount the switch assembly. The switch assembly can be mounted to any firm surfaceusing the accompanying bolt hole. Be sure to locate theswitch so that it will not be accidentally turned on or off..

ADDING THEOPTIONALREMOTEON/OFFSWITCH

NOTE: In operation, the remote on/off switch willenable the loader's operation in a similar fashion as theloader's circuit breaker /lighted switch, located on thecontrol. However, when the remote on/off switch is inthe off position, the light on the circuit breaker will notbe on, indicating the loader is not enabled and cannotoperate. If the circuit breaker is turned off, the light willbe off and the loader cannot operate, regardless of theposition of the remote on/off switch.

120 VAC

220 VAC

Remote On/Off Control Switch Cable Connectors

Green to Green ground screw GroundWhite w/male to Black w/female HotBlack w/female to Black w/male Hot

Green/Yellow to Green/Yellow ground screw GroundBlue w/male to Brown w/female HotBrown w/female to Brown w/male Hot

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Figure 1

WARNING: Improperinstallation, operationor servicing may resultin equipment damageor personal injury.

Before returning this equip-ment to service make surethat all wire connections, dis-connections and adjustmentswere made by a qualifiedelectrical technicians in accor-dance with electrical codes inyour region. Always maintaina safe ground.


USER GUIDE UGC011-0902 TLM Model Tube Loaders

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