Operating instructions

Transcription

1 Operating instructions Plug diverter MAYH Original operating instructions

2 Table of contents 1 Important information Scope of validity Contact Address Personnel qualifications Mechanics Electrician Welders Presentation conventions Explanation of warnings Safety Intended use Misuse Technical condition ATEX labeling Personnel qualifications Securing the machine against unexpected startup Safety devices Safety markings Safe working environment Slipping and tripping hazards Technical data Ambient conditions Performance characteristics Operating pressures Pneumatic drive torque Operating materials Compressed air Consumption data Air consumption Airborne noise emission Measured values Weights Gray iron (GG) Stainless steel (RF) Dimensions MAYH-N MAYH-ZZ Electrical specifications Proximity switch (inductive) Pulse valve Pneumatic system Operating pressure Compressed air quality Table of contents

3 4 Description Identification Nameplate Type key ATEX designation for use in Ex zone ATEX designation without approval for use in potentially explosive zones Overview Mode of operation Automatic operation Protection devices Transport Packaging symbols Checking delivery Temporary storage Lifting instructions Installation Preparing installation location Installation Installing plug diverter Laying diverter drive, distribution diverter Plug diverter as collection unit Installing product connections Connecting the utilities Electrical systems Compressed air Commissioning Setting limit position of rotary slide valve Checking commissioning Conformity Checking EC conformity Test run Checking the running behavior Checking function with system control Operation Operating modes Automatic operation Emergency manual actuator for solenoid valve Starting and stopping Emergency rotary slide valve movement Trouble-shooting Error messages Maintenance Cleaning Cleaning schedule Maintenance Maintenance schedule Checking shoulder screws Table of contents 3

4 11 Repair Dismantling plug diverter Assembling plug diverter Decommissioning Dismantle Disposing of machine Spare parts Spare Parts Spare part identification Ordering instructions Spare parts lists Table of contents

5 1 Important information 1.1 Scope of validity The machine differs in terms of the following features: Nominal diameter Material (gray iron housing and ductile gray iron rotary slide valve or both parts rust-resistant) Design adapted to the products to be conveyed Type MAYH-GG-N MAYH-GG-ZZ MAYH-RF-N MAYH-RF-ZZ Designation For flour, powdery and granular products (standard design) For sugar and slightly sticky products For corrosive or damp products For corrosive and sticky products The machine can be used in pneumatic conveyor systems with the following diameters: DN50 DN65 DN80 DN100 DN120 DN140 DN170 DN200 For aggressive products, diverter parts that come into contact with the product are also available in cast stainless steel. 1.2 Contact Should you have any questions, please contact the manufacturer's regional subsidiary. Have the operating manual handy Address Customer Service Grain Processing CH-9240 Uzwil, Switzerland Phone: Chapter 1 Important information 5

6 Fax: Personnel qualifications Mechanics Individuals who work on mechanical equipment must be technically trained or have attended and passed the manufacturer's training Electrician Individuals who work on electrical equipment must be technically trained or have attended and passed the manufacturer's training Welders Personnel who weld on the equipment must have specialized training. 1.4 Presentation conventions Explanation of warnings DANGER Type and source of danger The danger will result in death or severe injuries. Precautionary measures to mitigate the danger. WARNING Type and source of danger The danger can result in death or severe injury. Precautionary measures to mitigate the danger. CAUTION Type and source of danger The danger can result in injuries. Precautionary measures to mitigate the danger. NOTICE Type and source of danger The danger can cause material damage. Precautionary measures to prevent material damage 6 Chapter 1 Important information

7 2 Safety 2.1 Intended use The machine is intended to distribute the product flow in pneumatic conveyor systems. Powdery and granular products from the grain and animal feed industries are conveyed. Use the machine only as intended. Only operate the machine in accordance with the instructions in this operating manual. 2.2 Misuse Machine wear. Do not use the machine with highly abrasive products. 2.3 Technical condition If the machine is in poor technical condition, safety, proper operation and availability are compromised. Operate the machine only when it is in faultless technical condition. Comply with the maintenance schedule. Use only genuine replacement parts as listed in the spare parts catalog. If the performance characteristics of the machine change, check the machine for malfunctions. Correct malfunctions immediately. The machine must not be modified or altered without approval from the manufacturer. 2.4 ATEX labeling The ATEX designation indicates the conditions under which the machine may be used in a potentially explosive zone or connected to a potentially explosive zone. Note the type plate. Chapter 2 Safety 7

8 2.5 Personnel qualifications Unqualified personnel cannot recognize risks and are thus exposed to greater danger. Allow only technically qualified personnel to perform the activities described in these operating instructions. Ensure that personnel comply with local laws and regulations for safe and hazard-conscious work. Define and communicate work responsibilities. Only give keys and passwords to appointed staff. 2.6 Securing the machine against unexpected startup If the machine starts up unexpectedly, individuals working on the machine could be injured severely. Set the safety switch to 0 and lock it. Remove the key and keep it with you. 2.7 Safety devices If safety devices are not functioning effectively, people are at risk. Before operating the machine, ensure that all safety devices are functioning effectively. 2.8 Safety markings If safety markings are not noticeable, people are at risk. Replace unreadable safety markings. Do not remove or cover safety markings. 2.9 Safe working environment Slipping and tripping hazards Slippery surfaces and tripping hazards may result in serious accidents. Keep aisles, handles, steps, ladders, platforms and handrails free of grease, oil and other types of dirt. Do not use the machine as a climbing aid or storage area. Use only the steps and platforms provided. Wear anti-slip safety shoes. 8 Chapter 2 Safety

9 3 Technical data 3.1 Ambient conditions Description Value Unit Ambient temperature with impulse valve C Product temperature C 3.2 Performance characteristics Operating pressures Description Positive operating pressure for pressure conveying (max.) Negative operating pressure for suction conveying (max.) Value Unit +1.5 bar 0.5 bar Pneumatic drive torque Operating pressure: 6 bar Type Nominal diameter DN Unit N ZZ Nm 3.3 Operating materials Only use lubricants with FDA approval USDA H Compressed air Description Value Unit Solids < 5 μm Pressure dew point +2 C Oil content < 5 mg/m 3 Chapter 3 Technical data 9

10 3.4 Consumption data Air consumption Type Nominal diameter DN Unit N Standard liters ZZ Airborne noise emission Measured values The measured values do not take ambient effects into account. Description Equivalent workplace emission level L p Value Unit < 70 db (A) 3.6 Weights Gray iron (GG) Type Nominal diameter DN Unit GG-N GG-ZZ kg Stainless steel (RF) Type Nominal diameter DN Unit RF-N RF-ZZ kg 10 Chapter 3 Technical data

11 3.7 Dimensions MAYH-N Fig. 3.1 DN A B C D E F G H J K L M M M M M16 4 M DN M N O P Q R S T U V max Chapter 3 Technical data 11

12 3.7.2 MAYH-ZZ Fig. 3.2 DN A B C D E F G H J K L M M M M M16 4 M DN M N O P Q R S T U V max Electrical specifications Proximity switch (inductive) Description Voltage Current load (long-term) Current load (short-term) Voltage drop Value Unit V DC 100 ma 100 ma < 2.5 V 12 Chapter 3 Technical data

13 Description Value Unit Current consumption < 15 ma Ambient temperature C Type of protection IP67 Protection class III Pulse valve 5/2-way pulse valve. Switching duration of rotary slide valve can be set using adjustable throttle silencer. Description Voltage Current Type of protection Value Unit V AC / V DC 10 A IP Pneumatic system Operating pressure Description Operating pressure Value Unit 5 6 bar Compressed air quality Description Dust-free, anhydrous, oil-free, dried; according to DIN ISO (UAS sheets 1 + 2) Solids Water Oil Value Unit 3 Class 4 Class 4 Class Chapter 3 Technical data 13

14 4 Description 4.1 Identification Nameplate (1) Model: Serial No.: Manufactured: * (2) (3) (4) (6) Fig. 4.1 (5) Nameplate (1) Manufacturer (4) Year of construction (2) Place of manufacture (5) Machine number (3) Machine type (6) ATEX designation Position Fig Type key MAYH-N-50 RF-Ex MAYH N Machine code Type: N = Flour diverter ZZ = Sugar diverter 50 Nominal diameter DN [mm] 14 Chapter 4 Description

15 MAYH-N-50 RF-Ex RF Ex Material: RF = housing/rotary slide valve RF GG = housing GG/rotary slide valve GGG Approval for potentially explosive zone ATEX designation for use in Ex zone 22 The ATEX designation indicates the conditions under which the machine may be used in a potentially explosive zone or connected to a potentially explosive zone. II */3D T=115 C T A 60 C X Explanation of symbols: II ATEX symbol Device group */ Internal category: Does not have its own internal source of ignition /3 External category 3 D T Dust atmosphere Maximum expected surface temperature in C in normal operation at full load and at an ambient temperature T A T A Increased ambient temperature in C X Information provided in the operating instructions on compliance with potential explosion protection is identified by an X symbol ATEX designation without approval for use in potentially explosive zones II */-D Explanation of symbols: ATEX symbol II Device group */ Internal category: Does not have its own internal source of ignition /- Not approved for use in potentially explosive zones D Dust atmosphere Chapter 4 Description 15

16 4.2 Overview Fig. 4.3 (1) Housing (10) Setscrew (2) Rotary slide valve (11) Retaining bolts for bearing ring (3) Shoulder screw (12) Bearing ring 16 Chapter 4 Description

17 (4) Inductive proximity switch (13) Pipe flange (5) Gear wheel (14) Sealing ring for pipe flange (6) Retaining bolts for gear wheel (15) Shank screw for limit switch actuation (7) Drive housing (16) Valve construction (8) Shoulder screws for fastening (17) Solenoid valve drive housing (9) Sealing pack (O ring, Teflon (18) Pneumatic cylinder with rack seal) 4.3 Mode of operation The plug diverter is used as a two-way distributing unit in pneumatic conveying systems. The rotary slide valve guides the conveyance air product mixture one outlet or the other. The plug diverter consists of the housing, rotary slide valve and pneumatic drive. In the product stream, the rotary slide valve has a metal-to-metal seal relative to the housing. The shape of the rotary slide valve is designed in such a way that the sealing effect increases with increasing conveying pressure. The conveying chamber is sealed to the outside by means of special sealing packs (PTFE ring and O ring). If fitted in tight spots, the diverter drive can be moved to the opposite side. An inductive proximity switch reports the limit positions of the rotary slide valve to the system control unit. If necessary, the rotary slide valve can be actuated manually using an openend wrench or with the manual actuator on the solenoid valve. Fig Automatic operation The control air actuates the pneumatic cylinder's piston. The piston movement is transferred to the gear wheel on the rotary slide valve with a rack. The rotary slide valve guides the product to the straight or deflected outlet. Chapter 4 Description 17

18 4.4 Protection devices A cover sheet is installed above the inductive proximity switch. 18 Chapter 4 Description

19 5 Transport 5.1 Packaging symbols (1) (2) (3) (4) (5) Fig. 5.1 Packaging symbols (1) Top (4) Fragile (2) Protect against moisture (5) Attach here (3) Center of gravity Note packaging symbols. 5.2 Checking delivery Check for completeness of delivery according to the delivery note. Report any missing parts or transport damage. See chapter 1.2 Contact. 5.3 Temporary storage Observe packaging symbols. Leave the machine and machine parts in the original packaging until starting assembly work. Store the machine in a dry room. Protect the machine from the effects of weather. Avoid temperature fluctuations. Temperature fluctuations cause corrosion due to condensation. If the machine is stored for long periods, protect the inside and outside of the housing with an anti-corrosive preservative and close the connection flange. 5.4 Lifting instructions Important Never place machine on limit switch. Do not suspend machine from pneumatic cylinder. 1. Suspend machine from the forged eye bolts provided or through the product opening. 2. Transport the machine. Chapter 5 Transport 19

20 6 Installation 6.1 Preparing installation location Space requirements, floor openings, support surfaces and floor loadings in accordance with separate planning documents. Cordon off the installation area so that no unauthorized persons have access to it. Secure the working area (e.g. prevent tripping hazards etc.). Keep enough space free for installation and adjustment work. 6.2 Installation The plug diverter can be installed in any position. If the plug diverter is treated with a preservative, remove this before assembly. The top of the housing is fitted with 2 or 4 threads, depending on size, for fastening the plug diverter. If space is tight, move the drive to the opposite side of the plug diverter. See chapter Laying diverter drive, distribution diverter. 6.3 Installing plug diverter Fig. 6.1 (1) Conveyor pipe (5) Diverter suspension (2) Pipe flange (6) Screws (3) Sealing rings (7) Pipe lock (4) Diverter 20 Chapter 6 Installation

21 Important If the housing is distorted, the rotary slide valve jams. Do not distort diverter with flanges and conveyor pipes when installing. Note thermal expansion of conveyor pipes. Never weld pipe flanges onto conveyor pipes. 1. Connect diverter to the conveyor pipes with the pipe flanges and sealing rings provided. 2. Evenly tighten pipe flange screws. When operating, the conveyor pipes are 0.5 mm away from the diverter all the way round. 3. Separately secure conveyor pipes so that they are aligned with the housing openings. The pipe locks must absorb axial force from the conveyor pressure. 4. If conveying product at risk of explosion, secure conveyor pipes with pressure surge-resistant assembly set Laying diverter drive, distribution diverter The diverter drive is fitted on the right as standard. Second outlet down when viewed in the direction of throughflow. If required by the local installation situation, the diverter drive can be fitted on the left. After modification, swap function of limit switches. Chapter 6 Installation 21

22 Fig. 6.2 (1) Limit switch I (2) Limit switch II A Drive on right (standard) Piston extended Conveyance straight Limit switch I actuated B Drive on left Piston retracted Conveyance straight Limit switch II actuated 1. Remove diverter drive and rotary slide valve. See chapter 11.1 Dismantling plug diverter. 2. Mark gear wheel position on rotary slide valve. 22 Chapter 6 Installation

23 3. If present, unscrew setscrew (1) and screw in again on opposite side and secure with Loctite. 4. Turn rotary slide valve 180 and install in diverter housing again. 5. Install sealing pack and bearing rings. See chapter 11.2 Assembling plug diverter. 6. Secure gear wheel turned 120 counter-clockwise away from its original position. 7. Install and set diverter. See chapter 7.1 Setting limit position of rotary slide valve. 6.4 Plug diverter as collection unit 1. If the plug diverter is used as a collection unit, check the two limit positions of the rotary slide valve prior to installation in the pipelines. 2. If the rotary slide valve protrudes in relation to the housing when viewed in conveyor direction, reset the limit positions. See chapter 7.1 Setting limit position of rotary slide valve. 6.5 Installing product connections For the pipe connections, See chapter 6.3 Installing plug diverter. 6.6 Connecting the utilities Electrical systems Earthing To secure the electric connection cables, use the threaded holes in the diverter housing opposite the drive housing or drill new threaded holes in an appropriate place. Earthing in the piping is ensured by earthing the system. Ensure conductivity for screwed/bolted connections with contact washers or copper strands. Chapter 6 Installation 23

24 Fig. 6.3 (1) Screw M8 (5) Machine (2) Lock edge washer (spring washer) (6) Contact disk (only for powder-coated version) (3) Earthing slot with tag (yellow/ green) (7) Locknut (4) Machine earthing sign Check: The contact washer must pierce through the coating to ensure electrical conductivity. Inspect the screw unions. Resistance across butt joints may not exceed 10 ohms. If resistance exceeds 10 ohms, restore electrical conductivity. Solenoid valve and inductive proximity switch Connect solenoid valve and inductive proximity switch according to nameplate for elements Compressed air Connect compressed air supply (hose connection diameter 6/8 mm). See chapter Compressed air. See chapter Air consumption. 24 Chapter 6 Installation

25 7 Commissioning 7.1 Setting limit position of rotary slide valve The diverter drive is removed from the housing for a better view. The diverter drive is not removed when setting the diverter. 1. Switch off control air supply. 2. Disconnect air hose from solenoid valve. 3. Secure rotary slide valve so it does not fall. 4. Label proximity switch on drive housing before removing. 5. Unscrew plug connector on solenoid valve. All electric cables remain connected. 6. Remove diverter from conveyor pipes. 7. With piston rod retracted, use screw (1) to set deflection position. 8. Check: Piston rod is fully retracted and rotary slide valve is in correct position. 9. With piston rod extended, use adjusting screw (2) to set the straightahead position. Chapter 7 Commissioning 25

26 10. Viewed in the direction of product conveyance, the housing is flush with the rotary slide valve. (1) Diverter set well, housing flush. (2) Diverter set badly, protruding section. 11. Install diverter in conveyor line. 12. Connect air hose and plug connector to solenoid valve. 7.2 Checking commissioning No. Check 1 All transport aids and assembly fixings have been removed. 2 Electrical installation has been carried out and checked by an authorized, qualified electrician. 3 All electrical terminal boxes and plug sockets are closed. 4 Machine is earthed. 5 Rotary slide valve position correct. 6 All control elements, safety devices and warning systems are working properly. 7 A lockable safety switch is present, and personnel have a matching padlock. 8 All screwed/bolted connections have been properly tightened. 9 There are no foreign objects in the machine. 10 All connections for the lines are leak tight. 26 Chapter 7 Commissioning

27 7.3 Conformity Checking EC conformity Operate the machine in the European Union only if EC conformity has been checked and confirmed using the following checklist. Checklist No. Check 1 The operator has been informed that the operating instructions must be accessible to the personnel at all times. 2 The operator is responsible for instructing the personnel. 3 Assembly and installation have been carried out in accordance with the operating instructions. 4 Warnings and signs are attached so they are clearly visible. 5 Electric cable on and to the deflectors connected properly in accordance with the installation diagram and secured in accordance with local safety regulations against electrical shocks and short circuits. 6 The compressed air supply can be blocked and the system vented for service work. 7 The design of the pipe diverter is such that it is earthed via the suspension and piping. 8 The MAYH pipe diverter is positioned such that the position sensors are not subject to impact loading or impact protection is fitted. 7.4 Test run CAUTION Moving diverter. Cuts. Do not reach into diverter opening. Chapter 7 Commissioning 27

28 7.4.1 Checking the running behavior Fig. 7.1 (1) Manual actuator, red push-button switch (2) Waste air regulation screws 1. Guide control air to solenoid valve. 2. Check overpressure. 5 6 bar 3. Use manual actuator to move rotary slide valve. 4. Check rotary slide valve movement. Rotary slide valve moves smoothly to new limit position within 1.5 seconds. Rotary slide valve does not impact too hard in cylinder. 5. If the rotary slide valve movement does not match these requirements, use the waste air regulating screws on the solenoid valve to adjust the movement. 6. After the check, reset manual actuator to Checking function with system control 1. Individually energize both coils on solenoid valve. Check function of plug diverter. 2. Check response of the inductive proximity switches. 28 Chapter 7 Commissioning

29 8 Operation 8.1 Operating modes WARNING Mobile diverter. Risk of cuts or severing extremities. Do not reach into diverter. Do not force clamping or pressurized diverters to turn further. Only move diverter by hand if the supply of control air is interrupted and the air has left the cylinder Automatic operation Before switching the diverter over, purge the conveying line. The solenoid valve for the plug diverter is a pulse valve. The solenoid valve coil is energized (control voltage) until the new limit position is signaled or until 10 seconds have passed. If the new limit position is not reached in this time, the system control reports a fault. Conveyance must not be approved Emergency manual actuator for solenoid valve If necessary, the rotary slide valve is moved with control air using the emergency manual actuator. To switch over, press the red push-button switch on the solenoid valve. Only ever actuate one side at a time. The second side must be at 0. After actuation, set the key button to Starting and stopping The machine is started and stopped using a superordinate system control unit. The EMERGENCY STOP button is integrated in the system control unit. The machine is stopped as soon as the EMERGENCY STOP button is triggered. Chapter 8 Operation 29

30 8.3 Emergency rotary slide valve movement Fig. 8.1 NOTICE Jamming plug diverter. Material damage. Do not manually actuate jammed and pressurized plug diverter with a tool. Interrupt supply of control air before actuating plug diverter with a tool. If the plug diverter becomes jammed, establish why this is happening before actuating. 1. Interrupt control air supply. 2. Loosen hose from solenoid valve. 3. Move rotary slide valve with open-end wrench. 30 Chapter 8 Operation

31 9 Trouble-shooting 9.1 Error messages Fault Cause Remedy No feedback on limit position. Proximity switch not responding. Check proximity switch and switching spacing. 9.2 Faults Fault Cause Remedy Diverter does not switch. Rotary slide valve jamming. Operating pressure too low or no control air. Correctly set manual actuator button on solenoid valve. Clean restrictor screws on solenoid valve. Check solenoid valve, replace if necessary. Check electrical connections. Housing is distorted. Loosen flanges of pipe connections and reconnect pipes. See chapter 6.3 Installing plug diverter. Thermal expansion of conveyor pipes compresses housing. Deposits on housing and rotary slide valve. Rotary slide valve or housing is corroded. The bearing rings are jammed in the housing. Shorten conveyor pipes by the amount of thermal expansion and reinstall. See chapter 6.3 Installing plug diverter. Do not switch the diverter position during operation or in the air current. Allow enough time for purging the conveying line before switching to the other position. Remove parts and remove any rust with fine abrasive paper. Apply a light coat of oil to parts and install. Protect parts from condensation or water ingress. If necessary, install a stainless plug diverter. Remove any chafing marks with fine abrasive paper. Replace defective bearing rings. Chapter 9 Trouble-shooting 31

32 Fault Cause Remedy Operating pressure too low. Uneven rotary movements with fine powder products. Diverter is not sealed to shut-off conveyor pipe. Correctly set position of rotary slide valve. See chapter 7.1 Setting limit position of rotary slide valve. The exterior of the diverter is leaking. Replace defective sealing packs or sealing rings. Dust in the bearing points. Clean bearing rings, sealing packs and rotary slide valve. 32 Chapter 9 Trouble-shooting

33 10 Maintenance WARNING Moveable rotary slide valve. Risk of severe injuries. Do not reach into holes in the plug diverter. NOTICE Jamming plug diverter. Material damage. Do not manually actuate jammed and pressurized plug diverter with a tool. Interrupt supply of control air before actuating plug diverter with a tool. If the plug diverter becomes jammed, establish why this is happening before actuating. Important Before maintenance and cleaning work, undertake the following: 1. Set safety switch to 0 and lock it. 2. Remove key and keep it with you. 3. Interrupt control air supply and vent diverter drive Cleaning Cleaning schedule Interval Machine part Duration 6,000 h / once a year Surface Inside of rotary slide valve housing Gear wheel and rack Measure : Clean with a brush or cloth. : Check and clean. Apply a little grease. Chapter 10 Maintenance 33

34 10.2 Maintenance Maintenance schedule Interval Machine part Duration 6,000 h / once a year Measure Plug diverter : Check and maintain. Gear wheel fastening Bearing ring fastening Limit switch fastening Drive housing fastening shoulder screws : Check for tightness. Check for abrasion. : It must be possible for the drive housing to move with a little play on the shoulder screws. Teflon seal : If grooves on the circumference are no longer visible, replace the seals Checking shoulder screws Fig Check shoulder screws are secure. The drive housing can be moved with a little play. 34 Chapter 10 Maintenance

35 11 Repair WARNING Mobile diverter. Risk of cuts or severing extremities. Do not reach into diverter. Do not force clamping or pressurized diverters to turn further. Only move diverter by hand if the supply of control air is interrupted and the air has left the cylinder Dismantling plug diverter Fig (1) Teflon seal (3) Bearing ring (2) Rotary slide valve (4) O ring 1. Switch off control air supply. 2. Disconnect air hose from solenoid valve. 3. Secure plug diverter so it does not fall. 4. Label proximity switch on drive housing before removing. 5. Release plug connector on solenoid valve. All electric cables remain connected. 6. Remove diverter from conveyor pipes. 7. Release shoulder screws and remove diverter drive. 8. Remove bearing ring with O ring and Teflon seal. Depending on the size of the diverter, remove the gear wheel in order to remove the bearing ring. Once the gear wheel is removed, mark the position of the stud on the rotary slide valve. Chapter 11 Repair 35

36 9. Pull rotary slide valve out of housing Assembling plug diverter 1. Clean all parts. 2. Check sealing packs and bearing rings. Replace if necessary. 3. Slide rotary slide valve into diverter housing and align evenly between drive side and rear. 4. Use food-safe grease to lubricate both sides of Teflon seal (1) and insert in diverter housing. 5. Place O ring (2) on bearing rings (3). 6. Attach bearing rings with O rings on sides of rotary slide valve and screw down on both sides of rotary slide valve with screws and washers. 7. Evenly tighten bearing ring screws crosswise. To check: Place open-end wrench on rear of rotary slide valve and turn valve this way and that a couple of times. 8. Install gear wheel on rotary slide valve. Ensure shank screw is in correct position. 9. Set rotary slide valve in housing to deflection. Cylinder piston rod must be retracted. 10. Attach drive housing and tighten with three shoulder screws. Attach diverter drive in parallel to diverter housing. 11. Check diverter position. If the settings on the cylinder haven't been changed, the positions of the rotary slide valve are correct in relation to the gear wheel. If the rack engages with the gear wheel in the wrong place, remove drive housing and refit one or more teeth further on/back. 12. Connect diverter to conveyor pipes. 13. Attach plug connector to solenoid valve. 14. Attach air hose to solenoid valve. 15. Switch on control air supply. 36 Chapter 11 Repair

37 12 Decommissioning 12.1 Dismantle Once work with the machine is complete (inspection, removal or disposal), the machine is disassembled in reverse order to the assembly process. Before starting the disassembly process, the person who is responsible must obtain instructions from the manufacturer for safe disassembly. The machine may only be disassembled in accordance with all accident prevention measures and only by instructed personnel. This personnel must be familiar with the safety precautions Disposing of machine 1. Dismantle machine into its components. 2. Sort components according to materials and dispose of them in compliance with local applicable laws and regulations. Chapter 12 Decommissioning 37

38 13 Spare parts 13.1 Spare Parts Keeping a ready supply of spare parts and wearing parts plays an important role in ensuring the availability and correct operation of the machine. Only use original spare parts listed in the spare parts catalogue. Parts obtained from third-party suppliers may have an adverse effect on the operating behavior of the machine and can compromise its safety Spare part identification Code [C] Description V1 E1 E2 E3 Wear part Parts which wear during normal operation. Parts which have to be replaced once or several times a year. Very critical spare part Parts, which in the event of their failure or defectiveness, can result in complete failure of the machine. Parts that are relevant to safety. Problematic spare part Parts, which in the event of their failure or defectiveness, can result in severely limited functionality of the machine. The machine can continue to be operated for a short time. Normal spare part Parts, which in the event of their failure or defectiveness, can result in minor limited functionality of the machine. The machine can continue to be operated for a longer time Ordering instructions Incorrect parts may be shipped if the information in spare parts orders is incomplete. In case of any doubt, please enclose a dimensional drawing with a description. A spare parts order must contain the following information: Machine number Component assembly number or part number Designation Quantity Motors: manufacturer and motor number Gearboxes: manufacturer and gearbox number 38 Chapter 13 Spare parts

39 13.4 Spare parts lists (4) (5) (6) (7) (8) (9) (3) (2) (10) (11) (11) X X (1) (14) (13) (12) (15) (16) (5) (17) (18) (19) (20) (21) (22) Fig Chapter 13 Spare parts 39

40 Item Parts no. C Designation Quantity 1 Housing 2 Rotary slide valve 3 Deep groove ball bearing for rack 4 Shoulder screw 5 Inductive proximity switch 6 Gear wheel 7 Deep groove ball bearing for housing 8 Retaining bolts for gear wheel 9 Drive housing 10 Shoulder screw for fastening the drive housing 11 Sealing pack (O ring and Teflon seal) 12 Setscrew 13 Fastening screw for bearing ring 14 Bearing ring 15 Pipe flange 16 Sealing ring for pipe flange 17 Shank screw with limit switch actuation 18 Cable socket 19 Valve construction 20 Solenoid valve 21 Magnet coil 22 Pneumatic cylinder with rack 40 Chapter 13 Spare parts

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42 CH-9240 Uzwil, Schweiz