VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES. Follow these procedures to keep your Vyleater running smoothly.

Transcription

1 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES! WARNING! Failure t fllw these prcedures may cause an verlad cnditin that culd result in the Vyleater becming severely damaged. Fllw these prcedures t keep yur Vyleater running smthly. Daily Maintenance Prcedures Run the Vyleater anther 5 t 10 minutes after the last lad f the day Remve and clean the Tp separating screen befre each use Always replace the Screen Access Panel Weekly Maintenance Prcedures Remve and clean bth separating Screens Check bth Screens fr hles r tears Check and replace Screen Spring Clips as necessary Check and clean the inside f the Cnveyr Enclsure Mnthly Maintenance Prcedures Timing Belt Drive Inspectin Yearly Maintenance Prcedures Grease Crusher Bearings Lubricate Drive Chain As Required Maintenance Prcedures Blwer Drive Belt Replacement Cnveyr Drive Belt Replacement Hpper/Hpper Cver Remval Crusher Maintenance Rll Remval Crusher Seal Replacement Rll Replacement Full explanatins f each step fllw belw.

2 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES cntinued Page 2 f 10 Daily Maintenance Prcedures Run the Vyleater anther 5 t 10 minutes after the last lad f the day Once the vials are dne crushing they are still making their way dwn the vibratry screen. Allwing a few extra minutes helps mve this material ff the screen. Sme vial pieces will likely be left behind this is nrmal as vibratry cnveyrs like these wn t always cmpletely clean itself f material. Remve and clean the Tp separating screen befre use Access t the screens is gained as described in Operatinal Instructins fr the Vyleater. Keeping the screen clean increases the vlume f liquid that can be reclaimed. It als results in less material being left behind n the screen and prevents backups. Tip: It is usually easier t clean the screens after the waste fluid has dried. Clean the screens after it has sat idle fr an extended perid r pull the screens after the last run and allw them t air-dry vernight. Exceptin: If the waste fluid tends t cagulate and harden, it is best t clean the screens after the last use. Tp Screen Remval Always remve the tp screen first and then the bttm screen. Clean as much lse material frm the tp f the screens as pssible. Grip the Tp Screen frame with bth hands s that it slides ut f the guide tracks evenly. Tip the Screen ver a bx, garbage can r in a plastic garbage bag t cllect the vial remnants. Use a stiff brush (a plastic scrub brush r wire brush wrks well) t remve mst f the material imbedded in the screen mesh. Pull ut pieces that are stuck in the mesh being careful nt t distrt the mesh pening. If the screen mesh is clgged with dried fluid, use water and detergent r ther apprpriate cleaning agent t scrub this clean. Always replace the Screen Access Panel While the screen clips will usually keep the screen secure, the screens may vibrate ut f the cnveyr when the panel is remved. This can cause crushed pieces t fall int the drain pan and create liquid drain clgs. Tip: If the screens stick ut t far t prperly replace the Panel, the cnveyr u-channels (n the sides and the far end) must be cleaned f debris.

3 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES cntinued Page 3 f 10 Weekly Maintenance Prcedures Remve and clean bth separating Screens befre use Access t the screens is gained as described in Operatinal Instructins fr the Vyleater. Keeping the screen clean increases the vlume f liquid that can be reclaimed. It als results in less material being left behind n the screen and prevents backups. Tip: It is usually easier t clean the screens after the waste fluid has dried. Clean the screens after it has sat idle fr an extended perid r pull the screens after the last run and allw them t air-dry vernight. Exceptin: If the waste fluid tends t cagulate and harden, it is best t clean the screens after the last use. Tp Screen Remval Always remve the tp screen first and then the bttm screen. Clean as much lse material frm the tp f the screens as pssible. Grip the Tp Screen frame with bth hands s that it slides ut f the guide tracks evenly. Tip the Screen ver a bx, garbage can r in a plastic garbage bag t cllect the vial remnants. Use a stiff brush (a plastic scrub brush r wire brush wrks well) t remve mst f the material imbedded in the screen mesh. Pull ut pieces that are stuck in the mesh being careful nt t distrt the mesh pening. If the screen mesh is clgged with dried fluid, use water and detergent r ther apprpriate cleaning agent t scrub this clean. Bttm Screen Pull carefully s as t prevent crushed pieces frm falling int the drain pan area belw the screens Pull the bttm screen ut trying t avid drpping any debris int the lwer drain pan prtin f the Cnveyr husing. Clean as described abve. Tip: Yu may cnsider purchasing a secnd Primary (tp) Screen t allw the peratr t swap ut screens and begin prcessing vials immediately. The dirty screens can then be cleaned at a mre cnvenient time. Anther Secndary (bttm) Screen can als be purchased, althugh this usually desn t require as much time t clean. Part N Part N Primary (tp) Screen Secndary (bttm) Screen Check bth Screens fr hles r tears The screen mesh must be under tensin t functin prperly. If there are any hles, tears r separatins frm the frame, the entire screen must be replaced.

4 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES cntinued Page 4 f 10 Check and replace Screen Spring Clips as necessary If either Screen rattles inside the cnveyr enclsure, the shaking efficiency is dramatically decreased leading t material slwdwns r a material back-up. Tip: Pull the Screen Clips dwn t increase the hlding tensin f the clips. Replacement Screen Clips and rivets are available if any are missing r badly crrded. Part N Part N R Screen Spring Clips (10/screen) Stainless Steel Pp Rivets (10/screen) Check and clean the inside f the Cnveyr Enclsure Crushed material that falls ff the screens can lead t a clg f the liquid drain hse. Inspect the bttm drain pan area f the Cnveyr husing fr debris r accumulatins f fine shards. At a minimum, remve any large pieces t prevent a drain clg. Keep the screen u-channels free f vial remnants t allw the screens t seat prperly inside the cnveyr enclsure. A wet-dry vacuum wrks well fr this prcedure. If a clg is suspected, access the drain frm the Cleanut Panel n the crusher end f the cnveyr. (Oppsite end frm the screen access.) Fr access t the inlet end f the cnveyr (the liquid drain end), a remvable Clean-ut Panel is lcated n the left-hand end f the cnveyr. (Refer t Dwg #VL-90200, item 22.) Lsen the quick-release thumbscrews n the left exterir end panel (refer t Dwg #VL , item 25) and swing dwn t pen. The Cleanut Panel inside is secured with 2 r 4 thumbscrews (Refer t Dwg #VL-90200, item 23.) Lsen these and remve the panel. Replace the panel befre running any vials thrugh the Vyleater. Inspect the discharge chute leading dwn frm the crusher and int the cnveyr. Remve any debris that has built up arund this pening. Remve any pieces that may have fallen int the Pan area befre replacing the screens. Each screen is replaced (first the BOTTOM & then the TOP screen) by feeding them int their respective guide tracks (refer t Dwg #VL-90200, item 19) using even pressure n bth sides f the frame.

5 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES cntinued Page 5 f 10 Mnthly Maintenance Prcedures Timing Belt Inspectin (discnnect & lck-ut pwer befre replacing belts) Accessing the Belt Drives Access t the tw Belt Drives is btained frm the right hand end f the Vyleater. Lsen the three thumbscrews n the Screen Access Skin Panel and swing dwn. Remve the 1/8-inch hex Allen head screws hlding the fixed skin panel abve the right hand end access dr. Remve the panel. The Blwer Belt drive runs frm the mtr t the Blwer shaft. The Cnveyr Drive Belt runs frm the mtr t the eccentric shaft. Optinal: Discnnect the Blwer Hse by lsening the radiatr hse clamp at the blwer utlet flange using a flathead screwdriver r 5/16-nut driver wrench and slide it ff the blwer flange. T remve the Hse entirely lsen the clamp n the ppsite end f the hse at the internal flange just underneath the tp skin panel f the Vyleater. Inspectin f the intact Drive Belts Turn ver each belt and lk at the rectangular ridges n the belt. These shuld be squared ff and well defined. Check the sides f each belt t see if it is frayed. Check that everything is square and that the pulleys are aligned with ne anther. Check belt tensin s that there is n mre than a 1/16-inch deflectin when gently pressed with a finger. Inspectin f the Fur Drive Sheaves Inspect each f the fur Drive Sheaves. Cnfirm each sheave is tight n the shaft. If required, tighten the scket-head setscrews using the apprpriate sized allen-wrench key. If replacement is required If either belt requires replacement, fllw the prcedures fund under AS Required Maintenance in the fllwing sectin. If any f the fur drive sheaves seems wbbly r badly wrn, replacements can be btained frm S&G.

6 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES cntinued Page 6 f 10 Yearly Maintenance Prcedures Grease Crusher Bearings The crusher unit has 4 bearings that shuld be checked and lubricated every 100 hurs r nce a year with ne sht f industrial grease. T gain access t the bearings, remve the rear panel by lsening the screws with an 1/8- inch Allen scket wrench. The crusher is lcated underneath the lading hpper. All ther bearings n the Vyleater are grease-less.! CAUTION! DO NOT OVER-GREASE Lubricate Drive Chain The crusher drive chain shuld be lubricated with a lightweight chain lubricant every 100 hurs f peratin. TENSION: D nt tensin the chain unless an bvius rattling is present. Lsen the drive by lsening the utside jam nut n the spring side f the munting assembly. Tighten the jam nut that is butted up against the spring, cmpressing the spring and tightening the chain. Retighten the secnd jam nut t lck the setting in place. NOTICE This shuld be dne with the rlls in the CLOSED psitin.

7 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES cntinued Page 7 f 10 As Required Maintenance Prcedures Blwer Drive Belt Replacement (discnnect & lck-ut pwer befre replacing belts) Replacement belts can be btained frm S&G Enterprises. Part N Blwer Drive Timing Belt (250XL) Remve the Blwer Assembly Discnnect the Blwer Hse by lsening the radiatr hse clamp at the blwer utlet flange using a flathead screwdriver r 5/16-nut driver wrench and slide it ff the blwer flange. T remve the Hse entirely, lsen the clamp n the ppsite end f the hse at the internal flange just underneath the tp skin panel f the Vyleater. Remve the tw hex nuts (9/16-wrench) hlding the Blwer munt u-bracket t the tp f the machine frame. Set the Blwer Assembly n a table and remve the tw hex nuts and blts (9/16- wrench) hlding the utside bearing t the u-bracket. Lsen the scket-head setscrew (allen-wrench key required) in the cllar f this utside bearing. This setscrew secures the bearing t blwer drive shaft. Slide the bearing ff the shaft t expse the versize hle in the side f the u-bracket. Insert the new belt thrugh the hle, lping it ver the end f the shaft. Replace the bearing and re-tighten the cllar setscrew. Replacement f the Blwer Assembly Replace the Blwer Assembly and lsely tighten the tw nuts that fasten the u-bracket t the machine frame. Slide the blwer belt ver bth drive sheaves. Push the Blwer Assembly back t tighten the belt. Cnfirm the Assembly is square in relatin t the belt and tighten dwn the tw bracket munting nuts. The belt shuld be centrally lcated n each sheave. Check belt tensin s that there is n mre than a 1/16-inch deflectin when gently pressed with a finger. Tip: Run the Vyleater (being careful nt t get t clse t the Belt drives) and cnfirm Blwer Belt is riding dwn the center f bth drive sheaves. If nt, turn ff the Vyleater and re-align the Blwer Assembly as required.

8 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES cntinued Page 8 f 10 Cnveyr Drive Belt Replacement (discnnect & lck-ut pwer befre replacing belts) Replacement belts can be btained frm S&G Enterprises. Part N Cnveyr Drive Timing Belt (230XL) Lp the new Drive Belt ver the small sheave lcated n the mtr shaft. Slide the new belt ver the large drive sheave n the cnveyr drive shaft. Rtate the mtr shaft t help pull the belt nt the sheave. Check belt tensin s that there is n mre than a 1/16-inch deflectin when gently pressed with a finger. Tip: If necessary, the mtr munt can be lsened t make it easier t install the new Belt. Hwever, after ding s, re-tensin the Blwer Belt as explained in the previus sectin. Tip: Run the Vyleater (being careful nt t get t clse t the Belt drives) and cnfirm Cnveyr Belt is riding dwn the center f bth drive sheaves. If nt, turn ff the Vyleater and re-align the Mtr and/r Blwer Assembly as required. Hpper/Hpper Cver Remval! WARNING! Under n cnditins shuld the Hpper be remved withut first discnnecting & lcking ut electrical pwer! Full access will be gained t the Crushing Rlls when the Hpper Cver is remved and any accidental peratin f the Crusher culd be extremely hazardus r fatal! On tp f the Vyleater (left end) remve the screws lcated at the utside edge f the stainless steel flange that surrunds three sides f the hpper. D nt remve the screws lcated clsest t the vertical Hpper walls. Once the screws have been remved, the Hpper Cver may be swung up and t the right n a built in hinge. Inspect the interir f the Hpper fr accumulatins f material, cracks r damage. Inspect the Hpper wash jet (if prvided.) Clean as needed. Inspect the interir f the Crusher. Remve accumulatins f residue. Examine the crushing rlls fr visible signs f damage. Inspect the fam Gasket. Gently clean the surface t remve any vial remnants r dirt. Replacement gasket material is available frm S&G. Swing the Hpper Cver back dwn ver the crusher, replace and tighten all the screws remved earlier.

9 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES cntinued Page 9 f 10 Crusher Maintenance Rll Remval The heart f the Vyleater Vial Crusher is the rller mill mechanism lcated n the left-hand end, belw the hpper and behind the lading track assembly. The mill is made up f tw case hardened, tl steel rlls, machined with a curse V-shaped crrugatin pattern alng the surface. One rll serves as the main drive, cupling with the 3-hp mtr and 20:1 gearbx. The ther is adjustable, capable f mving frm a virtual clsed setting with the drive rll, t as much as 3/4 inch gap fr crushing larger glass cntainers. Occasinally, the rlls r the crusher seals may need replacing due t wear. These peratins are dne with nly partial disassembly f the equipment being necessary.! WARNING! DISCONNECT POWER TO THE VYLEATER TO PREVENT ACCIDENTAL STARTUP OF THE MACHINE. T prevent injury, thrughly clean ut the interir f the crusher husing f any vial remnants. Open the rll spacing t an apprximate 1/4-inch gap. Making nte f the apprximate spring tensin, lsen the chain tensiner by lsening the tw hex nuts n the eyeblt where the die spring is lcated. Remve the drive chain. Lsen the setscrew n bth sprckets and pull the sprckets ff the shafts. Lsen and remve the eccentric lcking cllars lcated n the utside f bth glide bearings and n fixed flange bearings. Munted n the machine frame behind the crusher is an aluminum rd. This is a handle intended t make remving the rlls easier. Lsen and remve the handle and screws. Rtate the rll until tw threaded hles cme int view. Clean ut the hles and thread the tw handle blts int the rll. Rtate again until the handle is resting n tp f the crusher frame. Lsen cunter-clckwise and remve the large hex blt lcated n the end f the adjustable rll shaft. Prevent the rll frm rtating by bracing it with the handle against the crusher frame. Having ne persn hld the rll handle perpendicular t the crusher frame, pull bth shafts straight ut t disengage the shafts frm the rll itself. Lift the rll ut. Repeat the abve steps fr the secnd statinary rll. The drive cupling n the statinary rll may have t be slid back ut f the way.

10 VYLEATER DAILY HOUSEKEEPING & PREVENTATIVE MAINTENANCE PROCEDURES cntinued Page 10 f 10 Crusher Seal Replacement. If nt replacing the seals, skip this sectin and refer t ROLL REPLACEMENT. Remve the rll shafts by sliding them int the crusher frame. Remval f the drive cupling n the statinary rll will be necessary. Nte the exact shaft lcatins fr replacement. Statinary Rll Seals: Remve the plates (2) screwed int the inside frame wall n bth sides f the crusher. Adjustable Rll Seals: On the utside f the crusher frame, lcated behind bth take-up bearings is a frmed wire clip. Pull this clip back twards the backside f the machine and remve. This will disengage the (2) seal husings. The cmplete replacement assemblies include: QTY PART N. ITEM Crusher Vitn Wiper Seal Statinary Rll Vitn O-ring Adjustment Rll Vitn O-ring Statinary Rll TFE Bushing Adjustment Rll TFE Bushing Replace the seal husings and the fur shafts. Rll Replacement Using the handle again, lwer either rll back int place and push the shafts back int the rll. Rethread the large hex blt and tighten dwn firmly. Center the rll in the crusher frame and reset the eccentric lcking cllars. Repeat the abve steps fr the secnd remaining rll. Replace the sprckets (file any high spts n the shafts) making sure they line up with the tw idler sprckets and replace the drive chain. Tensin the chain by tightening the die spring t the same lcatin as nted befre. If excessive chain jumping results with pliable plastic vials, tighten the spring until this is minimized. Flip the Hpper/Hpper Cver dwn and refasten the screws. Engage the agitatr drive bar. VMANUAL\Maintenance\Std-Maint.dc Rev 11/05