BART/60 Pneumatic conveyor unit Updated 01/01/2017 Integrated Air Control OPERATING MANUAL AIR-TEC SYSTEM S.r.l. via del Cerchio 3/2 40012 Calderara di Reno BOLOGNA Tel. +39 051 725128 Fax. +39 051 725146 e-mail: airtec@air-tec.it
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INTRODUCTION The purpose of this manual is to provide the basic information necessary for using and maintaining the equipment. It is important to remember that the machine is designed and built to work exclusively with certain materials and in specific conditions. The performance you will obtain from the machine will depend on how well You have understood the contents of this manual. Improper use may cause the warranty to lapse. We strongly recommend that you carefully study this manual, the information regarding the individual components, drawings and all other documentation provided. If you diligently follow the instructions contained, we are sure you will be among the growing number of satisfied owners of Air-Tec pneumatic conveyance systems. We are committed to helping you get the most from this machine in order to enhance all your production. This manual, written by the manufacturer, is an integral part of the machine kit; It must therefore follow the car until its dismantling and be readily available for easy reference by the operators concerned and the work site. In case of change of ownership of the machine the manual must be handed over to the new owner who supplied the machine. Before doing any work with or on the machine staff concerned must absolutely and necessarily having read carefully this manual. If the manual is lost, crumpled and that they are not completely readable, you must request a new copy from manual Air-Tec System Ltd. (AIRTEC), verify that the modification date is prior to the purchase of the machine and, if not it is, go directly to AIRTEC. This manual provides warnings and indications concerning the safety regulations for the prevention of occupational accidents. Ranging however, and in any case, observed most scrupulously by the various operators safety standards laid against them by current regulations. Any modification of the safety standards that were to take place over time will have to be delivered and implemented. «CAUTION» Always keep it handy! Always observe the information! The information and illustrations in this manual were up to date edition. Pag. 3 di 36
AIRTEC is committed to continuous product improvement. Therefore changes in the components or the machine itself will be made without prior notice to third parties. All technical information contained herein are the exclusive property of AIRTEC. and should be considered confidential. Therefore it is prohibited its reproduction and dissemination also part without written permission. Also it is prohibited to use this manual for purposes other than those set out above. In order to detail for greater impact and clarity the operation, maintenance or other, some pictures may show the machine without protective equipment. «WARNING» IT S FORBIDDEN, LIKE STD 2014/68/UE DIRECTIVE, UTILIZE THE MACHINE WITH FLUID GROUP 1 Pag. 4 di 36
INDEX INTRODUCTION 3 CONVENTIONAL PNEUMATIC CONVEYANCE 7 BART INSTALLATION DIRECTIONS 8 DIMENSIONAL DRAWING 11 LAY OUT BART COMPONENTS 12 PNEUMATIC DIAGRAM SHOWING APPLICATION WITHOUT VENTING SYSTEM 13 STARTING UP AND OPERATION 14 CHECK LIST 14 BART FLUIDISATION SETTING 15 ROUTINE MAINTENANCE 16 RECOMMENDED SPARE PARTS 16 BUTTERFLY VALVE - SPARE PARTS 18 EXTRAORDINARY MAINTENANCE 20 REPLACING THE GASKET OF THE BUTTERFLY LOADING VALVE 20 IMPORTANT NOTES FOR THE COMMISSIONING 21 WORKING PRESSURE OF BART VESSEL: MAX 1,9BAR 21 NOTES TO THE PROPER INSTALLATION OF PRESSURE VESSELS 21 VESSEL CLASS A 21 VESSEL CLASS B 21 VESSEL CLASS C 21 WARRING. 21 CHANGING THE BART VENTING SYSTEM 22 BART LOADING SYSTEM VENT 22 PNEUMATIC DIAGRAM SHOWING APPLICATION WITH VENTING SYSTEM 23 ATTACHED: TECHNICAL DATA SHEET FOR INSTRUMET ON BOARD MACHINE 24 Pag. 5 di 36
1. RELIEF VALVE 24 2. PRESSURE SWITCH 26 3. LEVEL INDICATOR STANDARD VERSION 27 4. AIR VALVE 28 5. LOADING BUTTERFLY VALVE 30 Pag. 6 di 36
CONVENTIONAL PNEUMATIC CONVEYANCE The conventional pneumatic conveyance system relies on high pressure. In this specific case the pressure will be 2 bars. It is mainly recommended for conveying fine powders and granules, as well as fragile products like ceramic powder, over medium-short distances (15-30 metres max). It can also be used over longer distances but the efficiency (air/ product ratio) declines proportionally. This is a non-continuous conveyance system driven by a blow conveyor (BART). The operating cycle begins with the opening of a butterfly valve located on the top part of the BART; this allows the material to start dropping into the blow conveyor. Filling stops when the level sensor indicates that the BART has been filled to the maximum level. At this point the butterfly valve will close. When these conditions have been reached, a conveying blow valve will open to start building up the pressure inside the BART. A pressure sensor will determine when the pressure ( PS1 ) necessary for conveying the material has been reached inside the blow conveyor. The same pressure sensor also serves to close the air delivery line at the end of the conveyance cycle and allow the residual air to clean out the line. The fundamental features of this conveyance system are a high air flow at the start and end of each cycle and a lower air flow during the cycle itself. The BART pneumatic blow conveyor can convey many different kinds of materials. Both the physical characteristics of the materials and the distance they are to be conveyed have a direct influence on the machine s performance in terms of compressed air consumption and hourly capacity. Pag. 7 di 36
BART INSTALLATION DIRECTIONS Product inlet Product piping Connect Control Board and junction box Connect Power Supply Pag. 8 di 36
Supply Air actuator Connect air supply Set Convey pressure Set Fluidizing Pag. 9 di 36
1. It is recommended to use a compressed air storage tank with a capacity of at least 200 litres. 2. The conveyor tube, made of flexible spiral tubing or metal, must be bent into broad curves 3. The tube supplying compressed air to the pressure reducer, the pressure reducer and tube connecting the pressure reducer to the compressed air control unit must all have a diameter of 1 inch. 4. The pressure reducer must be set between 0.1 and 2 Bars 5. The maximum conveying distance is 30 metres 6. The receiving hopper must be provided with an efficient venting system to prevent the build up of counter-pressure while material is being conveyed 7. Avoid long lines with material conveyed downward 8. Use compressed air that has been dehumidified, with hygroscopic material in particular 9. The compressed air supply to the loading valve actuator and vibra-jets (where present) must be drawn upstream from the pressure reducer and must have a pressure of at least 4.5 bars to ensure that the equipment will work efficiently. The recommended value is 6 bars SIZE WEIGHT SUPPLY VOLTAGE INSTALLED POWER COMPRESSED AIR CONSUMPTION NOISE LEVEL 800x350x900 50kg 230V 50/60Hz 200VA MAX 60Nm³/h <70dBA Pag. 10 di 36
DIMENSIONAL DRAWING Pag. 11 di 36
AIR-TEC system BOLOGNA - ITALY Vessel LAY OUT BART COMPONENTS Pag. 12 di 36
PNEUMATIC DIAGRAM SHOWING APPLICATION WITHOUT VENTING SYSTEM Pag. 13 di 36
CHECK LIST STARTING UP AND OPERATION ensure scrupulous compliance with the specifications provided in the drawings of electrical and mechanical components; make sure that the mechanical components have been properly installed; compressed air supply requirements: o supply line section 1 o supply line pressure 6 bars o pressure reducer set at 0.1-2 bars electricity supply requirements: check the wiring and voltage; check the stability of the equipment; ambient conditions suitable for operation; check and/or reset the system control parameters recorded on the display; Be sure that the characteristics of the material to be handled are compatible with the operating conditions of the and with the parameter settings. Check the correct operating of instruments on machine: o Pressure switch o Level indicator o Switch and solenoid valve For the correct functioning of level switch, it can be required a calibration procedure, to do at the start-up of machine. See the operating instruction of instruments, attached to this manual. Pag. 14 di 36
BART FLUIDISATION SETTING The BART blow conveyor builds up pressure by introducing compressed air through a feed manifold and through a fluidising filter located in the lower part of the conveyor. A gate valve allows the stream of compressed air to be divided between the fluidising filter and the feed manifold. The characteristics of the material will determine how the compressed air stream should be divided for optimal conveyance Powder-like materials: it is recommended to direct 75% through the fluidising filter and 25% through the compressed air feed manifold. Granular materials: a 50-50 division is recommended. 100% FLUIDISING FILTER 50% FLUIDISING FILTER 50% FEED MANIFOLD Pag. 15 di 36
ROUTINE MAINTENANCE 1. Check the efficiency of the bottom part fitted with the fluidising filter and replace it if necessary. 2. Check the condition of the butterfly loading valve: check for wear on the gasket and disk. RECOMMENDED SPARE PARTS CODICE / CODE DESCRIZIONE / DESCIPTION 1 KB60_LIV1 KIT LEVEL STANDARD 2 KB60_LIA1 KIT LEVEL ATEX 2A KB60_LIV2 LEVEL INDICATOR HIGT TEMPERATURE 3 KBT1_PRES PRESSURE SWITCH KIT 4 KBT1_EVXX KIT SOLENOID VALVE STANDARD 5 6E0200180 SOLENOID VALVE ATEX 22 6 6E0200101 SOLENOID VALVE ATEX 21 7 6E0500080 RELIEF VALVE 8 KBT1_GRNA SEAT PLUS REPAIR KIT. BLACK GASKET 9 KBT1_GRND SEAT PLUS REPAIR KIT. WHITE GASKET 10 6K1500108 SEAT CLAMP 11 KBT1_NAM1 KIT NAMUR STANDARD 12 KBTA_NA22 KIT NAMUR ATEX 22 13 KBTA_NA21 KIT NAMUR ATEX 21 14 5B0000000 OPERATOR KEYPAD 15 KBT1_BAL1 OPERATING BLOCK 16 6F0800811 CARBON STEEL DISC 17 6F0800812 STAINLESS STEEL DISC AISI 316 18 KBT1_VA3V THREE WAYS VENT VALVE 19 6F0100072 BUTTERFLY INLET VALVE, BLACK SEAT + ACTUATOR 20 6F0100074 BUTTERFLY INLET VALVE, WHITE SEAT + ACTUATOR 21 6E0800330 PRESSURE GAUGE 22 6F0300750 EXIT VALVE IN BRASS 23 6F0300770 EXIT VALVE IN AISI 316 24 6F0800731 HINGES KIT DN 150 25 6F0800610 LIMIT SWITCH 26 6F0100077 BUTTERFLY INLET VALVE BODY CARBON STEEL 27 6F0100078 BUTTERFLY INLET VALVE BODY STAINLESS STEEL 28 KBT1_VNN1 BUTTERFLY VALVE IN CARBON STEEL WITH NAMUR VALVE 29 KBT1_VBN1 BUTTERFLY VALVE IN STAINLESS STEEK WITH NAMUR VALVE 30 6E0500080C RELIEF VALVE atex22 Pag. 16 di 36
31 6E0500080D RELIEF VALVE atex21 Pag. 17 di 36
BUTTERFLY VALVE - SPARE PARTS Pag. 18 di 36
DN 150 6F0100070 6F0100071 6F0100072 6F0100073 6F0100074 6F0100075 6F0100076 6F0100077 6F0100078 6F0100079 CORPO, A105+SILICONE, ATTUATORE NO F/C BODY VALVE,A105+SILICON GASKET, ACTUATOR NO LIMIT SWITCH CORPO, A105+NBR, ATTUATORE+F/C BODY VALVE,A105+BLACK GASKET, ACTUATOR+LIMIT SWITCH CORPO, A105+NBR, ATTUATORE NO F/C BODY VALVE,A105+BLACK GASKET, ACTUATOR NO LIMIT SWITCH CORPO, AISI 316+G. NAT., ATTUATORE+F/C BODY VALVE,AISI 316+WHITE GASKET, ACTUATOR+LIMIT SWITCH CORPO, AISI 316+G. NAT., ATTUATORE NO F/C BODY VALVE,AISI 316+WHITE GASKET, ACTUATOR NO LIMIT SWITCH CORPO, AISI 316+SILICONE, ATTUATORE NO F/C BODY VALVE,AISI 316+SILICON GASKET, ACTUATOR NO LIMIT SWITCH CORPO, A105+CARBOSSILATO, ATTUATORE NO F/C BODY VALVE,A105+CARBOSSILATO GASKET, ACTUATOR NO LIMIT SWITCH CORPO, A105+NBR BODY VALVE,A105+BLACK GASKET CORPO, AISI 316+G. NATURALE BODY VALVE,AISI 316+WHITE GASKET CORPO, A105+CARBOSSILATO BODY VALVE,A105+CARBOSSILATO GASKET Pag. 19 di 36
EXTRAORDINARY MAINTENANCE REPLACING THE GASKET OF THE BUTTERFLY LOADING VALVE To replace the gasket correctly, carefully follow the directions below: First of all, make sure that the compressed air supply is DISABLEDAND DECOMPRESSED and that the power supply is OFF before performing any maintenance work. 1. remove the butterfly valve from the Bart blow conveyor and remove the actuator; 2. loosen and take out the screw situated on the side opposite the actuator; 3. screw an M6 bolt into the threaded hole to extract the spindle; 4. Remove the snap ring and extract the other spindle using suitable pliers. Now the disk is free and can be removed; 5. pry out the gasket by inserting a tool with a pointed tip and round edge, e.g. a screwdriver, between the gasket and the metal body of the valve; WARNING: DO NOT INSERT THE TOOL CLOSE TO THE POINT WHERE THE SHAFT PASSES THROUGH BECAUSE THIS COULD CAUSE DAMAGE TO THE SEAT DO NOT DAMAGE THE GASKET SEAT!! 6. now fit the new gasket in place, taking care to thoroughly lubricate the valve body for a smoother insertion. 7. also grease the spindles before replacing the other valve components. WARNING: BEFORE CONNECTING THE POWER SUPPLYAND INTRODUCING COMPRESSED AIR, MAKE SURE THERE ARE NO FOREIGN BODIES IN THE DISK CLOSING AREA. KEEPYOUR HANDS FAR AWAY FROM THE AREA INSIDE THE GASKET BECAUSE THE DISK MAY ROTATE SUDDENLY WHEN COMPRESSED AIR IS INTRO Pag. 20 di 36
IMPORTANT NOTES FOR THE COMMISSIONING WORKING PRESSURE OF BART VESSEL: MAX 1,9BAR SUPPLY MAY 'BE PROVIDED THE PRESSURE REGULATOR AT THE ENTRANCE OF THE VESSEL. NOTES TO THE PROPER INSTALLATION OF PRESSURE VESSELS VESSEL CLASS A BELONG TO THIS CATEGORY ALL CONTAINERS WITH THE PRODUCT OF VOLUME (LITRE) PRESSURE (NOT MORE THAN 12 ATE) NOT EXCEEDING 8000. THESE CONTAINERS USED INDIVIDUALLY NOT ECESSITANO VERIFICATION OF THE FIRST AND PERIODIC SYSTEM BY ORGANIZATIONS VESSEL CLASS B BELONG TO THIS CATEGORY TWO OR MORE CONTAINERS OF A CLASS SYSTEM INSTALLED IN THE SAME. THEY ARE SUBJECT ONLY TO VERIFICATION OF ORIGINAL EQUIPMENT TO BE CALLED A INAIL (EX ISPESL) OF TERRITORIAL JURISDICTION. IF YOU ARE INSTALLED WITH DEVICES CLASS C MUST BE SUBJECT TO PERIODIC CHECKS IN THIS CATEGORY. VESSEL CLASS C BELONG TO THIS CATEGORY ALL CONTAINERS WITH THE PRODUCT OF VOLUME (LITRE) PRESSURE (ATE) MORE THAN 8000 OR PRESSURE THAN 12 ATE. THEY ARE SUBJECT TO VERIFICATION OF ORIGINAL EQUIPMENT TO BE CALLED A INAIL (EX ISPESL) TERRITORIAL JURISDICTION OF THE ANNUAL AND PERIODIC CHECKS BY REGIONAL ARPA. WARRING. IN ITALY THE LAW PROVIDES THE OBLIGATION OF COMPLAINT TO BODIES IN CHARGE OF PLANTS THE SUCCESSFUL INSTALLATION CATEGORY "B" AND "C". ALSO MUST KEEP THE CERTIFICATES OF ORIGIN OF SAFETY VALVE AND THE FUEL TANK ATTACHED HERE BECAUSE' IF YOU ARE MISSING THE POSSIBILITY OF USE OF THESE IS NOT MORE AUTHORIZED BY THE AUTHORITIES RESPONSIBLE, AND BECOMES THE MANDATORY REPLACEMENT Pag. 21 di 36
CHANGING THE BART VENTING SYSTEM 3-way ball valve with actuator and rapid couplings for Rilsan ø8 x 1/8 Qty. 2 1 nipple Qty. 1 1 x 40 mm threaded stub pipe with 1 ring nut and 2 gaskets 1 elbow Qty. 1 1 standard gas fittings for spiral rubber tubing, outside diameter 25 mm Qty. 2 Aluminium under-base of solenoid valve complete with 2 rapid couplings for Rilsan ø8 x 1/8 ; 2 OR, outside diameter 21 mm, thickness 2 mm Bolts M5 x TCCE Qty. 2 Spiral tubing, inside diameter 25 mm L=1000 mm and 2 clamps Rilsan tube ø8 x 1500 mm -¾ flexible tubing, 600 mm 0240269 BART LOADING SYSTEM VENT 1. remove the 3-piece union from the Bart 2. screw in the 3-way valve directly with a nipple and with the arrow turned toward the Bart; 3. fit the 3-piece union in the valve 4. replace the lower flexible tube with a new one 5. drill a hole in the hopper body and install the elbow with a fitting for rubber tubing 6. remove the pneumatic control valve situated above the loading valve actuator 7. place the manifold between the loading valve and the actuator with the OR turned down in contact with the body of the actuator 8. install the control valve situated above the manifold, taking care not to turn it by 180, in which case the opposite effect would be obtained 9. using the ø8 Rilsan tube provided, connect the manifold to the 3-way valve; make sure that when the loading valve is open, the inside of the Bart is connected by means of the 3-way valve and the spiral tubing is connected to the bag-emptying hopper. If this is not the case, invert the Rilsan tubes. Pag. 22 di 36
PNEUMATIC DIAGRAM SHOWING APPLICATION WITH VENTING SYSTEM Pag. 23 di 36
ATTACHED: TECHNICAL DATA SHEET FOR INSTRUMET ON BOARD MACHINE 1. RELIEF VALVE Pag. 24 di 36
Pag. 25 di 36 Vessel
2. PRESSURE SWITCH Pag. 26 di 36
3. LEVEL INDICATOR STANDARD VERSION Pag. 27 di 36
4. AIR VALVE Pag. 28 di 36
Pag. 29 di 36 Vessel
5. LOADING BUTTERFLY VALVE Pag. 30 di 36
Pag. 31 di 36 Vessel
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Pag. 33 di 36 Vessel
NOTE: Pag. 34 di 36
Pag. 35 di 36 Vessel
Via del Cerchio 3/2 40012 Calderara di Reno BOLOGNA ITALY Tel.+39 51 725128 Fax +39 51 725146 http://www.air-tec.it e-mail: airtec@air-tec.it Cod. Fisc. e Part. IVA 04202180370 C.C.I.A.A. 353394 - Iscrizione Tribunale BO 63997 Pag. 36 di 36