DISAB P 210/ ADR

Transcription

1 DISAB P 210/ ADR P 210/ ADR shown above is equipped with options. This vacuum loader is designed and built in compliance with applicable ADR regulations and handles material of a consistency that can pass through a DN200 hose. Such material being for instance stone, gravel, sand, chemicals, sludge and liquids. A cargo space containing 12 m³ takes care of the pneumatically separated material. The vacuum loader is designed and adapted for mounting onto a four-axle truck chassis with either two front axles or three rear axles. A power pack firmly mounted onto a support frame and a tilting tank constitutes the main parts of the vacuum loader. The power pack consists of a vacuum pump that also can be used as a blower powered by the truck engine via a separate gearbox. The tank has a filter compartment as well as a debris tank for excavated material. Emptying of the tank is either by tilting the tank with open tailgate or pneumatically by using a DN150 hose. POWER PACK The power pack is manufactured by hollow beams and sheet steel except the doors which are made of stainless steel. Roof, walls, doors and hatches/covers are insulated with mineral wool and covered with a perforated plate. Easily removable wall elements on both rear and front side as well as two doors on each side facilitate servicing and maintenance work. The power pack consists of vacuum pump, belt drive/transmission and constructions for sound absorption, cooling air and safety filter as well as a separate control board. The vacuum pump is mounted on a frame separated from the other framework by vibration absorbers. TECHNICAL DESCRIPTION P 210/ ADR 1/8

2 VACUUM PUMP Roots type rotary 3-lobe machine with pre-inlet cooler. It is also used as pressure source to empty the tank. Make Max vacuum Air volume Air volume Operating speed Power required Max overpressure Lubrication Cooling Transmission Kaeser Omega 83 PV -950 mbar 8100 m³/h (unloaded) 7300 m³/h (-500 mbar) rpm 240 kw mbar ( rpm) Oil pan Air Truck engine, V-belt TRANSMISSION A gearbox in the transmission line between truck engine and drive shaft is operated from the driver s cab by a cylinder. A cardan shaft is transferring the power to the pump belt transmission. The belt tension is adjusted by a grooved spring-loaded tension roller. Make OMSI Model PFT-PCV/3000 Direct Drive Max continuous moment Nm Max intermittent moment Nm Max permitted engine rpm rpm Gear ratio 1:1.275 Sound silencer A silencer of the absorption type including two separate units reduces the noise from the vacuum pump exhaust flange. The sound silencers have easily exchangeable linings. Furthermore there is a combined spark extinguisher/flame damper (ADR requirement) preventing sparks or flames from igniting the air going out from the pump. Safety valves Two spring-loaded release valves under the vacuum pump reduce the pressure at max mbar. Cooling system A combined sound silencer and filter housing is placed in front of the power pack. The filter consists of a cartridge, easily accessible and simple to dismantle. If the cooling system is blocked due to jammed filters, temperature will rise in the exhaust air of the pump. A temperature guard is immediately activated to relieve the vacuum loader, which also is indicated with a lamp on the control panel. TECHNICAL DESCRIPTION P 210/ ADR 2/8

3 Safety filter Two filter cartridges will protect the vacuum pump at a possible leak in the main filter system. The cartridges are easily accessible for inspection or exchange. Filter area: 34 m² Furthermore there is a combined spark extinguisher/flame damper (ADR requirement) to prevent sparks or flames from the pump to ignite the air going into the pump. Cooling air valve In the safety filter housing there is a valve that opens if the air temperature in the pump gets too high. The valve admits extra cooling air to the pump without unloading, which means the machine can continue the suction work. Should, however, the temperature rise further, the power unit will unload. Exhaust emission from vacuum pump Residual dust in outlet air from the Vacuum pump is max 1.3 mg/m³. Sound level The sound level of a vacuum loader depends on several items such as diesel engine, vacuum pump, load factor, type of material, amount of material in the suction line and distance to the suction nozzle. The sound level on a P 210 vacuum loader has been measured in a free open area at 10 different spots and all at 7 meters distance from the unit. The ambient sound level was recorded to 78 dba. The vacuum loader had a maximum load factor during the test, but the noise from handled material is deducted. Instruments and Control panel All necessary gauges and control instruments are assembled inside a water-splashproof control panel of stainless steel and located at the left-hand side of the power pack. Speed control Vacuum/pressure/unloading Filter hatch Level guard by-pass The hydraulic valves can also be manually controlled with a control lever Speed counter hour counter Level guard Pump temperature Vacuum meter Pressure gauge Remote Control box with 20 meter cable Safety functions The unloading valve opens at following malfunctions: Too high temperature in exhaust air from the vacuum pump As soon as the emergency stop is engaged, the truck engine stops automatically. TECHNICAL DESCRIPTION P 210/ ADR 3/8

4 DEBRIS TANK The tank is mounted to the support frame behind the power pack. The front of the tank rests on two supports, whereas the rear part is anchored to the support frame via tipping shaft hinges. When the tank is resting on the support frame it is hydraulically secured by a special lock in compliance with ADR requirements. The tank is dimensioned for a calculated pressure of 3 bar (ADR requirement) and absolute vacuum. It is pressurized and tested at 4 bar (ADR requirement) and a vacuum of -950 mbar. The tank is produced in acid-resistant stainless steel quality in 6 mm thickness of plate, front and rear end as well as filter neck in 8 mm plates. All parts not in direct contact with handled material (bars, u-profiles, plates, flanges) are produced in sheet steel. Diameter of tank: 2100 mm. On the inside a partition wall divides the tank. Front part builds the filter compartment see below. The rear section is a pre-separator or debris tank, see below. The rear gate is opened for emptying the collected material. Debris tank Here most of the excavated material is handled. Only the finest particles are allowed into the filter compartment. Gross volume: 12 m³ Level guards Separate level guards for dry and wet materials. Filter compartment In the partition wall to the debris tank there is a pneumatically operated hatch letting out dust as the tank is being tipped/emptied. The filter system comprises 15 filter bags on cassettes, which in turn are installed and locked onto a removable frame. The roof of the filter compartment is based on a pressure vessel end attached to the filter neck by 12 bolts. At inspection/filter change the bolts are eased off and the hatch lifted about 50 mm by means of a small jack and moved to the side. Atmospheric air impacts allowed through the relieve valve take care of the filter cleaning. Effective filter area: 33 m² Filter cleaning The timing for cleaning intervals and duration is preset from factory. With a switch on the switch panel filter cleaning is on/off. Filter cleaning is also activated each time the unloading valve is opened. Relieve valve To equalize pressure in filter compartment and debris tank. A pneumatically operated butterfly valve opens automatically as the unit is shut-off or for cleaning of the main filter. The relieve valve is a very important safety function, which also can be operated by the operator either from the switch panel or by the radio remote control (option). TECHNICAL DESCRIPTION P 210/ ADR 4/8

5 Tailgate The tailgate is suspended with two heavy-duty hinges and opened/closed by means of two hydraulic cylinders. Six hydraulically operated cylinders are locking the gate. The gate is provided with an integrated fluidizing system for pneumatic unloading designed for maximum extraction of as many kinds of materials as possible. The mixture air/material is controlled by three valves and a mixing valve. A non-return valve prevents the material from rushing backwards to the pump. The material outlet is regulated by a ball valve DN 150 mm. On top of the gate is an inlet DN 200 for connection of suction hose. The inlet is provided with a manually operated ball valve, which is closed as the tank is to be pressurized. Tank equipment Walkway on lefthand side along the tank Manhole on lefthand side of the tank top Emptying chute in stainless steel diverting dumped material Revolving beacon (1 pc) Working light (2 pcs) Advertising sign boards in stainless steel on both sides Fire extinguisher CONTROL SYSTEM Hydraulic system Consisting of oil tank, hydraulic pump and necessary pilot valves and overflow valves for the various hydraulic functions. All valves are fitted to the support frame. The tank is tipped by a single-acting front cylinder. An auxiliary (slave) cylinder between frame and tank helps stabilizing the tipping movement. One cylinder is operating the tank lock closing the tank to the frame. The tailgate is opened/closed by six cylinders and raised/lowered by another two cylinders. One cylinder is operating a hook shutting the tailgate prior to being locked. Please note that the truck chassis has to be provided with a power take off suitable for the hydraulic pump, preferably an engine power take off. Hydraulic pump Parker F1-40 Mobile valve package Danfoss PVG32 Oil tank volume 130 l Pneumatic system The pneumatic system of the vacuum loader is connected to the truck system, safety valve and drain valve included. Compressed air is used to handle the unloading valve, to operate suck/blow functions and the filter hatch cylinder. Electric system Via a separate main circuit-breaker the system of the vacuum loader is connected to the truck system. TECHNICAL DESCRIPTION P 210/ ADR 5/8

6 Truck chassis A four-axle truck chassis with two front axles or alternatively a four-axle truck chassis with one front axle and three rear axles. Suitable wheelbase with sleeper cab is mm. The truck must be equipped with power take off, preferably a so called engine PTO for hydraulic pump connection, and a module for data communication i.e. BBM (Body Builder Module). Support frame The frame bolted onto the truck chassis is mainly in cold-formed u-profiles dimensioned 200x80x6 mm. The tipping axle, diameter 100 mm, is welded onto the frame. Equipment truck chassis The truck chassis comes with the following standard equipment: Divided and adjustable rear underride protection complying with the authorities requirements on structural strength (as well as ADR requirements) Side underride protection, if required Rear lighting set Surface conditioning Inside and outside grit blasting Ground coating with Primer Finishing coat with a two-component paint in one RAL colour Please note that painting of the truck is not included! Technical documentation Instruction Manual and Spare Parts List, 2 set of each, are included in the scope of supply. Final inspection According to separate agreement with our workshop in Eslöv. Mounting to truck Free delivery of the truck to DISAB for mounting of the vacuum loader. The truck supplied must have the approval of the DISAB Technical Department. On delivery it should be ready for installation, with a naked frame and with a correct wheelbase and PTO. All additional adjustments will be charged separately. Weight and dimensions The weight depends on the equipment of the vacuum loader. The weight stated below is a calculated net weight based on: Complete vacuum unit without any options Total length (truck chassis excluded) Total width Height on top of truck chassis without hose boom Height on top of truck chassis with hose boom kg 8800 mm 2500 mm 2800 mm 2860 mm TECHNICAL DESCRIPTION P 210/ ADR 6/8

7 DISAB P 210/ ADR OPTIONS Side/telescopic hose boom A DN200 hose boom at the righthand side of the tank. The hose boom can be turned/rotated 180º, raised 80º and lowered 30º. Lengthwise it can be telescopically adjusted 1.5 m. All operation is via hydraulic cylinders. A DN200 or DN150 suction hose can be connected. In standard configuration the hose boom is controlled by the cable remote control box. As option it can also be controlled by radio. Remote control by radio EX classed Radio with 12 channels for remote control of diesel engine rpm, unloading valve (vacuum), tailgate, tipping of the tank and telescopic hose boom, if installed. Compressor A hydraulically operated 2 bar compressor used for pneumatic unloading of powder material. Make and model Max pressure Max airflow Power requirement Gardner Denver Wittig RTL80 2 bar 480 m³/h (at 2 bar) 28 kw Jetting unit A hydraulically operated jetting unit located in the power pack. Max pressure Max flow Water tank volume 200 bar 30 l/min 260 l (hose kit included) Liquid pump A hydraulically operated separate pump mounted on the truck chassis. A suction hose and an unloading hose DN100 are connected directly to the pump. The unloading hose can be connected to the debris tank of the vacuum loader or to another suitable container. Make and model Max. unloading pressure Power requirement Jurop VL7 6 bar 20 kw Mudguards Plastic mudguards covering the 2 nd and rear axles (8X4) or 2 nd and 3 rd axles (6X4). Long mudguards Mudguards in stainless steel covering all axles except for the front axle and ending at the power pack. The mudguards are provided with hooks for anchoring of tubes or hoses. TECHNICAL DESCRIPTION P 210/ ADR 7/8

8 Other options - detailed information upon request Toolbox Extra outlet on the tailgate for draining fluid, DN100 valve Pneumatic vibrators underneath the tank Fuel consumption meter Load pressure meter for air spring suspension Alarm indicating closed tailgate, lowered tank and hose boom Level guard in filter compartment Oil cooler for split-shaft gearbox Additional flashing light Additional working light Tipping function operated from the driver s cab Hose support brackets Sound-signal for high pump temperature Light signal for high pump temperature 2 bar adaptor Light console on driver s cab with flashing lights Foldable safety rail for the tank Rear light console in stainless steel TECHNICAL DESCRIPTION P 210/ ADR 8/8