BETJENINGSINSTRUKTION OPERATION MANUAL BEDIENUNGSANLEITUNG INSTRUCCIONES DE OPERACIÒN
VACUUM COATER TYPE:
ID. NO.:
ORDER NO.:
ITEM NO.:
Customer: Adress:
Andritz Feed & Biofuel, Glentevej 5-7 DK-6705 Esbjerg Ø Denmark Tel. +45 72 16 03 00 Fax +45 72 16 03 01
18 04 2010. Rev.nr: 4
IMPORTANT! IMPORTANT! IMPORTANT! TO AVOID PERSONAL INJURY OR DAMAGE TO THE MACHINE, ANDRITZ FEED & BIOFUEL URGE EVERYBODY IN CONTACT WITH THE MACHINE TO READ THIS OPERATING MANUAL. WARNINGS SIGNS MUST BE OBSERVED!
▓3213
Ö 425
▓ 2800
DIMENSIONED SKETCH VAC1000
▓3410
▓300
▓4135
DIMENSIONED SKETCH VAC1500
CONTENTS INTRODUCTION
.............................................................................................................. 1
1.
GENERAL DESCRIPTION ...................................................................................... 2 SAFETY.............................................................................................................. 3 FUNCTIONAL DESCRIPTION ......................................................................... 4 FLOW DIAGRAM .............................................................................................. 5
2.
DELIVERY AND INSTALLATION ........................................................................... 6 HANDLING......................................................................................................... 6 SUPPORT .......................................................................................................... 8 MOUNTING SEQUENCE .................................................................................. 9 Inlet valve .............................................................................................. 10 Bottom valve ......................................................................................... 10 Vacuum connection .............................................................................. 11 Vacuum compensation ......................................................................... 12 Spray system ........................................................................................ 13 Nozzles ................................................................................................. 14 Mounting of adapters with nozzles in nozzle plates ............................. 15 Loadcells ............................................................................................... 16
3.
CONNECTIONS ....................................................................................................... 17 ELECTRICAL CONNECTIONS ......................................................................... 17 COMPRESSED AIR CONNECTIONS .............................................................. 18 Compressed air diagram ...................................................................... 18 Compressed air consumption............................................................... 18 LIQUID CONNECTIONS ................................................................................... 19 Description ............................................................................................ 19 Dimensions ........................................................................................... 19 Pipe materials ....................................................................................... 19
4.
STARTING-UP ......................................................................................................... 20 STARTING-UP, GENERAL .............................................................................. 20 FIRST-TIME START-UP.................................................................................... 20
5.
OPERATION ........................................................................................................... 21 CHARGE SIZE................................................................................................... 21 PROCESS DESCRIPTION................................................................................ 21 Taring of weigher .................................................................................. 22 Filling ..................................................................................................... 22 Evacuation ............................................................................................ 23 Coating.................................................................................................. 23 Vacuum compensation ......................................................................... 23 Emptying ............................................................................................... 23
6.
MAINTENANCE ....................................................................................................... 24 NOZZLE CHECKING......................................................................................... 24 CHECKING OF ANY MATERIAL DEPOSITS .................................................. 25 CHECK OF MIXER SCREW ............................................................................. 26 ADJUSTMENT OF MIXER SCREW.................................................................. 27 CHECK OF BOTTOM VALVE SEAL.................................................................29
7
SPARE PARTS REPLACEMENT .......................................................................... 30 NOZZLE REPLACEMENT ................................................................................ 30 BOTTEM VALVE SEAL REPLACEMENT......................................................... 30 SCREW SHAFT SEAL REPLACEMENT .......................................................... 33
8.
RISK ASSESSMENT ............................................................................................... 37 VIBRATION RISK .............................................................................................. 37 NOISE RISK....................................................................................................... 37 DUST RISK ........................................................................................................ 37 ELECTRICAL RISK............................................................................................ 38 OPERATIONAL RISK ........................................................................................ 38
9.
SCRAPPING ............................................................................................................ 39
1
INTRODUCTION Please follow the instructions of this manual carefully. ANDRITZ FEED & BIOFUEL has paid great attention to design and production to make our products as safe and reliable as possible. Should you however, get problems with your ANDRITZ FEED & BIOFUEL product, we kindly ask you to contact your supplier or ANDRITZ FEED & BIOFUEL. Should you have any remarks regarding our equipment and/or this manual please contact us at the below address. ANDRITZ FEED & BIOFUEL A/S Glentevej 5-7 P.O.Box 2050 DK-6705 Esbjerg Tlf.: +45 7216 0300 Fax.: +45 7216 0301 E-mail:
[email protected]
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1. GENERAL DESCRIPTION The ANDRITZ FEED & BIOFUEL vacuum coaters are manufactured completely of low carbon steel or parts in touch with materials may be made of stainless steel. The coater is designed to coat fish feed pellets, pet food and similar products by means of vacuum. The machine distinguishes itself by producing a uniform product with addition of both small and large liquid quantities and by gentle treatment of the product. The vacuum coater designed as a conical vertical mixer with a convex top and with the mixing screw placed vertically in the coater centre line is resting on 3 loadcells in the frame (1). The material intake goes on via a dosing slide through the flexible connection (2) and the inlet valve (3). The vacuum build-up takes place through the vacuum connection (4) with the vacuum pump (not shown). 5 7
8 2 3
4
1
6
The mixer screw operated by a frequency controlled geared motor (5) ensures optimum circulation of the product from the bottom valve slide (6) up to the spray systems 7). These systems allow addition of up to 5 different liquids, or addition of large quantities in very short time through a combination of systems. Vacuum compensation (8) is adjusted by means of valves. Inside the coater, the vacuum is compensated through the mixer screw shaft and through shaft holes both at the top and bottom of the coater. The bottom valve is opened for emptying of the coater and the products passes through a flexible connection on through the process line.
3
SAFETY The vacuum coater is designed with a view to the largest possible safety for the operator during operation. All moving parts are carefully screened and when installed and connected according to the instructions there is no risk of personal injury when the coater is used as intended.
IMPORTANT! THE INSPECTION DOOR MUST BE CLOSED AND BOLTED DURING OPERATION. (THE COATER DOES NOT WORK WITH OPEN DOOR.)
IMPORTANT! THE MOTOR MUST ALWAYS BE DISCONNECTED WHILE WORK IS GOING ON ON THE INNER PARTS OF THE COATER TO PREVENT IT FROM BEING STARTED INADVERTENTLY..
IMPORTANT! REMEMBER TO SECURE THE BOTTOM VALVE AGAINST UNINTENTIONAL OPERATION WHEN THE FLEXIBLE CONNECTION UNDER THE VALVE IS DEMOUNTED AND WHILE WORK IS GOING ON ON THE VALVE.
IMPORTANT! THE MIXER SCREW CAN BE TURNED BY HAND. THEREFORE DO NOT HOLD FINGERS BETWEEN THE SCREW FLIGHTS AND THE SCREW HOUSING.
4
FUNCTIONAL DESCRIPTION This description implies normal integration of the vacuum coater in a process line. 1.
The weigher is tared by the weigher computer and signals ready to receive a charge. (The bottom valve is closed and the buffer bin filled up).
2.
The inlet valve opens.
3.
The dosing slide opens.
4.
The dosing slide closes half when that when the majority of the charge is reached. (Is checked by the pre-bin level indicator.)
5.
The dosing slide closes completely.
6.
The inlet valve closes.
7.
The charge weight is checked and registered.
8.
The vacuum valve opens, and evacuation starts. (The vacuum pump has already been started) .
9.
The vacuum valve closes, when the desired vacuum level has been reached.
10. The mixer screw starts at low speed and is quickly accellerated to normal speed (50 Hz). 11. The liquid pump starts and the oil valve opens. (Choice of valves and nozzles depends on desired liquid quantity.) 12. The liquid valve closes, when the quantity has been reached (registered by the mass flowmeter). 13. The mixer screw frequency is reduced to 40 Hz. 14. Vacuum compensation starts and is regulated by means of the belonging valve. 15. The bottom valve opens, when the evacuation is finished, and the mixing screw is stopped. 16. The mixing screw is reversed, when the weigher computer registers stable weight (ensures complete emptying of screw flights). 17. The weigher computer signals empty and the bottom valve closes.
5
FLOW DIAGRAM
Buffer bin
Cyclone separator Dosing slide
Vacuum evacuation Vacuum filter
Inlet valve
Vacuum pump
Vacuum valve Liquid valve
Liquid pump
Mixer screw
Vacuum coater
Bottom valve
6
2. DELIVERY AND INSTALLATION The vacuum coater is supplied separated for transport. The coater itself is delivered in a special wooden frame (saddle) and various valves, connections and spray systems packed separately. The frame is supplied as a separate unit. Immediately upon receipt the delivery is checked for transport damage and shortshipments. Any damage and shortshipments are reported at once to ANDRITZ FEED & BIOFUEL. From receipt until installlation the coater most be stored in a suitable store to avoid damage from precipitation and anything else which may damage the coater. HANDLING
IMPORTANT! THE TRANSPORT FITTING AT THE BOTTEM END OF THE MIXING SCREW MUST NOT BE REMOVED UNTIL THE COATER HAS BEEN PLACED IN ITS NORMAL POSITION IN THE FRAME.
7
The vacuum coater is lifted by means of the 4 lifting eyes placed on the top of the coater.
IMPORTANT! ANY KIND OF HOISTING MUST TAKE PLACE BY MEANS OF STRAPS IN ALL 4 LIFTING EYES. IT IS IMPORTANT TO USE SUFFICIENTLY LONG STRAPS TO PREVENT THE COATER FROM BEING DAMAGED.
In case of insufficient free height a lifting yoke must be used.
NOTICE: THE POINT OF GRAVITY MAY BE DISPLACED.
8
SUPPORT The frame with the coater is placed on a even foundation of concrete or steel (steel beams) whether it is a frame with or without legs. When a frame without legs is used it is recommended to place the supports under each loadcell. The load on the foundation is shown in the below illustration and the loads, statically and with batch (pellets and oil): VAC1000
VAC1500
3*800 kg statical 3*1400 kg dynamical (maximum)
3*1250 kg statical 3*2100 kg dynamical (maximum)
ø
ø
Opening in floor of ø600mm for frame of standard height
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MOUNTING SEQUENCE 1. 2. 3. 4. 5. 6.
The frame is placed on an even surface. The transport fittings are mounted on the frame. (According to the marks). The coater is lifted into the frame and fastened to the transport fittings. The coater and frame can now be lifted to its final position. The valves for inlet and outlet respectively, flexible connections, connections and spray systems are mounted next. Finally, the loadcells with vibration dampers and protection irons are mounted.
IMPORTANT! ALWAYS USE THE TRANSPORT FITTINGS AT INSTALLATION OF THE COATER AND DO NOT MOUNT THE LOADCELLS UNTIL ALL OTHER PARTS ARE MOUNTED.
Transport fittings
IMPORTANT! THE FRAME IS NOT ALIGNED UNTIL THE COATER IS PLACED IN THE FRAME AND THE LOADCELLS ARE MOUNTED. THE FLANGES BETWEEN THE CONE AND THE COVER MUST BE HORIZONTAL.
10
Inlet valve The inlet valve is placed on the inlet flange and the belonging mounting set is used to bolt it to the flexible connection for the inlet. The actuator is oriented as shown in the below picture, but it can be oriented in other directions, if required. Be aware, however, not to block the access to the nozzles.
Actuator
Bottom valve The bottom valve and the flexible connection is mounted with the belonging mounting set. Remember the packing between the cone bottom flange and the valve. It is recommended to orient the valve as shown above (opposite the geared motor), but the orientation may be different according to requirement.
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Vacuum connection The vacuum connection is mounted on the flange on top of the coater and is oriented suitably in relation to the piping to the vacuum pump. It is recommended, however, to orient the connection 180° opposite the inlet flange. The individual components MUST be placed in the order shown below. The distance between the components may be varied with the pipe delivered , if necessary.
Vacuum valve Cyclone separator Compensator
Manometer
Transmitter
Vacuum pipe
Vacuum filter
IMPORTANT! Must be supported!
Level control
Manual drain
IMPORTANT! REMEMBER TO SUPPORT THE FLANGE ON THE COMPENSATOR NEXT TO THE CYCLONE SEPARATOR TO THE FRAME OR THE BUILDING.
12
Vacuum compensation To mount the vacuum compensation the rotating union is placed on top of the mixing screw shaft. (Remember to lock the union on the shaft with two pointed screws.) The fitting preventing unintentional rotation of pipes and valves is mounted with 2 bolts on top of the gear. The most suitable orientation is selected, it is, however, recommended to orient it in the same direction as the vacuum connection. Take care not to hinder opening of the inspection door. Geared motor
Rotary couping Compensation pipe
Compensator valve
Fittings
IMPORTANT! REMEMBER TO SUPPORT THE VALVE TO THE FRAME OR THE BUILDING.
13
Spray system The spray systems are mounted in the appropriate fittings distributed evenly on the ring of the frame. The flanges for connection of liquids are oriented suitably. It is, however, recommended to place the liquid pipes so that the flanges placed between the recommended position of the vacuum connection and the position of the geared motor and so that the individual hoses are placed opposite each nozzle plate. Notice: The liquid pipe flanges must be turned alternately to different sides to get space for the valves. (See also the dimensioned sketch at the front of the manual).
IMPORTANT! THE MANIFOLDS AND THE HOSES ARE PLACED SO, THAT THERE ARE DROP FROM THE MANIFOLDS TOWARDS THE NOZZLES TO OBTAIN THE BEST POSSIBLE EMTYING AT OIL CHANGE.
Spray system 2
Spray system 1
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Nozzles The nozzles are mounted in the following way: The thin sealing ring (1) is pulled down over the nozzle (2) to the nozzle collar. The nozzle is placed in the adapter (3). (The nozzle size depends on the liquid amount to be added by the individual spray system).
5 3
2
6 4 1
IMPORTANT!
The thread is packed with Teflon Tape
THE NOZZLE MUST FIT TIGHTLY INTO THE ADAPTOR GROOVE.
The other sealing ring (4) is placed on top of the die and the nipple muff part is screwed into the adapter. The male quick-acting clutch is screwed onto the nipple muff.
The assembled unit together with the belonging O-ring is placed in the nozzle plate on top of the coater in the row for the topical spray system (see next page).
15
Mounting of adapters with nozzles in nozzle plates
IMPORTANT! THE SIX ADAPTERS WITH NOZZLES FOR EACH LIQUID SYSTEM MUST BE PLACED IN THE SAME HOLE IN THE INDIVIDUAL NOZZLE PLATES TO GET THE MOST OPTIMUM SPRAY PATTERN.
IMPORTANT! IT IS RECOMMENDED TO PLACE THE ADAPTERS WITH THE SMALLEST NOZZLES FOR THE SMALL LIQUID QUANTITIES CLOSER TO THE CENTRE OF THE COATER TO GET THE BEST DISTRIBUTION OF THE LIQUID ON THE PELLETS. The remaining spaces in the nozzle plate are closed with O-ring and “blind” adaptors. The adaptors are finally fastened to the star-shaped fitting.
The hoses are mounted to the nozzles by means of the quick-acting couplings.
IMPORTANT! IF TWO SPRAY SYSTEMS ARE TO BE USED SIMULTANEOUSLY, THE NOZZLES MUST NOT BE PLACED IN THE SAME ROW, AS THEY WILL DISTURB EACH OTHER’S SPRAY PATTERN.
16
Loadcells The loadcells are the last components to be mounted on the coater and they are placed as shown below. The cables to the loadcells are lead to the inside of the frame ring and trough the mounted pipes to a central point where they are joined in the junction box.
Vibration damper
Protection iron
Loadcell
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3. CONNECTIONS ELECTRICAL CONNECTIONS
IMPORTANT! IT IS THE RESPONSIBILITY OF THE PURCHASER/MAIN CONTRACTOR THAT AN APPROVED REPAIR SWITCH IS CONNECTED TO THE VACUUM COATER, SO THAT THE MECHANIC/OPERATOR IS ABLE TO DISCONNECT AND KEEP THE COATER DISCONNECTED WHILE WORK IS GOING ON ON THE INNER PARTS OF THE MACHINE, OR WHILE THE GUARDS ARE REMOVED. The coater motor and electrical parts are connected by an electrician according to the EU Council directive, (the Low Voltage Directive). The joint box for internal electrical connections to the loadcells (supplied by SPROUTMATADOR A/S) are placed appropriately on the frame. The coater is connected according to the topical electrical diagrams. ANDRITZ FEED & BIOFUEL A/S recommends the use of safety relays make PILZ. Relay for monitoring of safety circuit: PILZ type PNOZ8. Relay for monitoring electric motor rotor: PILZ type PSWZ.
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COMPRESSED AIR CONNECTION Compressed air connections are made according to the diagram below. For the sake of the comparatively large compressed air consumption on the inlet valve and the bottom valve, respectively, the compressed air must be lead in minimum ½” pipes as close to the valves as appropriate. Compressed air diagram Compressed air 6 bar
Bottom valve
Vacuum valve
Inlet valve
Valve spray system 1
Valve spray system 2
To vacuum equalizing valve (max 5 bar) Compressed air consumption Valves
Inlet valve Bottom valve Vacuum valve Liquid valve Vacuun compensation valve
Compressed air consumption/ double strokes at 6 bar Nl 14,3 184,8 1,97 0,3
Minimum pressure bar
Maximum pressure bar
Connection hose Ø mm
4 4 4 4
6 6 6 6
8 12 8 8
0,3
4
6
8
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LIQUID CONNECTION Description The liquid supply from the pumps is connected to the spray system flanges. A ball valve is mounted for each spray system.
Connection spray system 2 Connection spray system 1
Dimension The dimension of the liquid connection is DN40, TN16 (Ø48.3mm). Pipe material The pipe material must be AISI 304 or better.
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4. STARTING-UP STARTING-UP - GENERAL Before starting-up, the vacuum coater is checked for any leaks from damaged seals and leakages at assemblies/mounting of coater, vacuum system and spray systems. The vacuum pump is started and the coater is evacuated to maximum vacuum level. The vacuum valve is closed and any pressure rise in the coater is observed for 5 minutes on the manometer. If the pressure rises above 0,15 bar, all assemblies and seals should be checked and tightened/retightened, if required. This procedure also applies after any repairs/replacements of worn or damaged parts which includes seals of any kind. FIRST-TIME START-UP Before the first-time start-up the following is checked: Check the vacuum coater inside for foreign matters. Check that the inspection door is correctly fastened. Check that the bottom valve opens and closes according to the control signals. Check that the vacuum valve opens and colses according to the control signals. Check that the liquid valves open and close according tot he control signals. Check that all liquid hoses (quick-acting couplings) arre mounted. Check that the mixer screw rotates (clock-wise seen from above) according to the control signal.
IMPORTANT! FOR FUNCTIONAL REASONS THE NUMBER OF REVOLUTIONS SHOULD NOT EXCEED 175 RPM. (65 Hz).
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5. OPERATION CHARGE SIZE The coater is dimensioned for a maximum charge size of dry material of a density of 0.55 kg/dm³ as indicated in the below table. The table also shows that minimum filling of the coater is 400 kgs. Minimum filling is intended to ensure optimum coater function with regard to spraying of liquids on all the material.
MODEL VAC1000 VAC1500
Maximum Minimum Maximum Minimum
FILLING Litres Dimensioning 2000 700 3500 800
γ = 0.55 kg/dm³ kg 1100 385 1925 440
PROCESS DESCRIPTION The vacuum coater is designed to operate with charges and is therefore typically installed in a process line. The process consequently depends on a normal process line flow and that the external conditions are available (sufficient amount of material in the pre-bin, the vacuum pump is running etc.). The process consists of the following sequences (see also the functional description of this manual): The description and duration of the individual process sequences is guiding. In practice variations may occur depending on material and the result desired from the process. The individual parameters controlling and monitoring the process are determined according to the topical formula and may be varied to achieve the optimum result of the process.
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Sequence time [secs] 0
50
100
150
200
250
300
350
400
The weigher is tared Inlet valve/filling Dosing slide item 1 The weight is registered Vacuum valve/evacuation Mixing screw 50 Hz Liquid valve/coating Liquid pump Mixing screw 40 Hz Compensator vave Bottom valve/emptying The weigher checks whether the coater is empty Mixing screw is reversed The mixer screw signal empty
The weigher is tared Before starting the process the weigher computer checks whether the coater is empty and the weigher is tared (reset). Taring lasts approx. 5 secs. Filling The vacuum coater is filled from the pre-bin through the inlet valve at the top of the coater via a dosing slide and the filling is checked by the pre-bin level control which closes the slide partly when most of the preset charge has run into the coater. The slide is closed entirely when the charge reaches the preset value. During filling the mixing screw is rotating (at reduced rpm. – approx. 40 Hz) to distribute the charge evenly in the coater. Upon filling the inlet valve closes, the mixing screw stops that the exact weight of the charge is registered by the weigher computer. Filling lasts approx. 30 secs.
23
Evacuation The pipe system vacuum valve between the coater and the vacuum pump opens, and the coater evacuates to the desired vacuum, whereafter the valve closes again. The vacuum pump does not stop. Evacuation lasts 30 –60 secs. Coating The mixing screw is started and the frequency is increased to 50 Hz, whereafter liquid addition starts. The liquid is sprayed onto the material by the six nozzles in the spray system chosen for the topical quantity of liquid. The liquid quantity is registered by the mass flowmeter and addition is disconnected when the quantity has been reach. Upon finished coating the mixing screw frequency is reduced to approx. 40 Hz. Coating lasts 30 – 80 secs. Vacuum compensation Vacuum compensation in the coater is an important part of the entire process and is consequently controlled and regulated accurately by the control and valve. During the addition of liquid the pressure has risen a little in the coater and the vacuum level for start of compensation is not the same as the level at evacuation. If the pressure rises too much during the liquid addition it is possible to reevacuate the coater to a lower level before the compensation is started. The compensation takes place via the bleeder valve and the coupling at the end of the mixing screw shaft (above the geared motor), through the hollow shaft and through holes in the wall of the shaft into the coater. These holes allow compensation both through the top and the bottom of the coater. Upon finished compensation the mixing screw stops. The compensation process is formula related and can vary between approx. 90 secs. and 220 secs. Emptying At first emptying of the coater takes place with stopped mixing screw until the weigher computer registers stable weight (approx. 50 kgs). Then the mixing screw is reversed at normal frequency and the last material is flung off the mixing screw. The reversing ensures complete emptying of the coater. The mixing screw is stopped after approx. 10 seconds and emptying is finished. The bottom valve closes and the process can be started again. Emptying lasts approx. 30 seconds.
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6. MAINTENANCE NOZZLES CHECK If the result of coating is not satisfactory, or if coating lasts too long time, it may be due to one or more blocked nozzles in the spray system, which can be checked in the following way: The liquid hoses of the topical spray system are demounted one by one by releasing the quick-acting couplings. Check whether the nozzles are blocked by looking through the fixed part of the quickacting coupling on the coater. If a nozzle is blocked it must be cleaned as description in the section REPLACEMENT OF NOZZLES. Upon finished checking/cleaning, the hoses are mounted again.
IMPORTANT! REMEMBER TO HOLD THE END OF THE HOSE HIGH WHILE CHECKING THE NOZZLE TO AVOID SPILLING THE LIQUID.
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CHECKING FOR ANY MATERIAL DEPOSITS IN THE COATER Material deposits inside the coater may occur a.o. around the housing between the material level and the empty space above and on the flights of the mixing screw next to the central pipe. Any deposits may disturb the coater function if not removed. Therefore the coater must be checked inside at regular intervals by opening the inspection door and removing deposits with a suitable instrument. The bottom valve may be opened first and the bottom part of the flexible connection under the valve is replaced by a tray or a place to prevent the deposits from falling into the system when scraped out. The screw can also be reversed for emptying.
IMPORTANT! THE MOTOR MUST ALWAYS BE DISCONNECTED WHILE WORKING ON THE INNER PARTS OF THE COATER TO PREVENT IT FROM BEING STARTED INADVERTENTLY.
IMPORTANT! REMEMBER TO PROTECT THE BOTTOM VALVE AGAINST UNINTENTIONAL OPERATED WHILE WORKING WITH THE FLEXIBLE CONNECTION UNDER THE VALVE.
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CHECK OF MIXING SCREW The mixing screw is checked for unintentional wear and any damage from foreign matters at regular intervals. The replaceable part of the mixing screw (next to the bottom valve) is also checked for any damage and wear and whether it has loosened. Checks for damage and wear are made through the inspection door and up through the bottom valve (after demounting the flexible conenciton under the valve).
IMPORTANT! THE MOTOR MUST ALWAYS BE DISCONNECTED WHILE WORK IS GOING ON THE INNER PARTS OF THE COATER, TO PREVENT IT FROM BEING STARTED INADVERTENTLY.
IMPORTANT! REMEMBER TO SECURE THE BOTTOM VALVE AGAINST UNINTENTIONAL OPERATION WHILE THE FLEXIBLE CONNECTION UNDER THE VALVE IS DEMOUNTED AND WHILE WORK IS GOING ON ON THE VALVE. Check the replaceable parts of the mixing screw up through the bottom valve (after demounting the flexible connection under the valve). The bottom valve may also be demounted to gain better access. Check wither the replaceable part har loosened by checking whether there are wear marks on the bottom of it or whether it can be turned in relation to the actual mixing screw. Retighten, if necessary, by tightening the bolts of the tightening element. The tightening moment is: 38 Nm.
Tightening element
27
ADJUSTMENT OF MIXING SCREW Check the distance from the screw to the bottom valve slide in the following way: The bottom valve is opened and secured against unintentional operation. Hold a straight piece of steel (400mm long) up under the bottom valve sealing ring. Measure the distance from the steel piece to the end of the screw. The distance must be between 4-6 mm also under the screw flight.
If the distance deviates from the above the tightening element is loosened and the replaceable screw part is raised or lowered to get the correct distance. After adjustment the parts are refastened as described above. If it is not possible to have sufficient distance be raising the replaceable part, the entire mixing screw is raised in the following way: The replaceable part of the screw is fastened. Demount the vacuum compensation and the rotating coupling at the end of the screw shaft. (Remember to loosen the pointed screws.) Rotary couping
28
Mount the adjustning/lifint fitting delivered with the coater at the end of the gear shaft and fasten the nut against the fitting.
Loosen the shrunk-on ring at the top of the gear by loosening the bolts ¼ - ½ turn one by one all the way round and so on until the shaft has been loosened inside the shrunk-on ring.
Raise the screw by fastening the nut of the adjustment fitting and simultaneously check the distance between the lower end of the screw and the bottom valve slide as described above. Refasten the shaft in the new position by tightening the shrunk-on ring bolts ¼ -½ turn one by one all the way round and so on, until the specificed tightening moment (see picture) has been reached.
IMPORTANT! ALWAYS USE A TORQUE WRENCH FOR TIGHTENING OF THE SHRINK DISK. THE MOMENT (59 Nm) IS INDICATED ON THE TYPE SIGN ON THE SHRINK DISK. ALSO SEE THE OPERATION AND MAINTENANCE MANUAL FOR THE GEAR.
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CHECKING THE BOTTOM VALVE SEAL If reevacuation of the vacuum coater occurs repeatedly during the process, or if an inappropriate pressure increase in the coater is noted it may be due to damage or wear on the bottom valve sealing ring.
IMPORTANT! THE MOTOR MUST ALWAYS BE DISCONNECTED WHILE WORK IS GOING ON ON THE INNER PARTS OF THE COATER TO PREVENT IT FROM BEING STARTED INADVERTENTLY.
IMPORTANT! REMEMBER TO SECURE THE BOTTOM VALVE AGAINST UNINTENTIONAL OPERATION, WHILE THE FLEXIBLE CONNECTION UNDER THE VALVE IS DEMOUNTED AND WHILE WORK IS GOING ON ON THE VALVE. The sealing ring is checked in the following way: Open the bottom valve slide.
Demount the flexible connection under the bottom valve. Check the sealing ring visually for deposits and any damage (clean with paper or cloth to see better). If damage or wear is found on the sealing ring, it is replaced as described in the next chapter.
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7. REPLACEMENT OF SPARE PARTS REPLACEMENT OF NOZZLES
If other nozzles are wanted for one or more of the spray systems, the description under NOZZLES in the chapter DELIVERY AND ASSEMBLY is followed in opposite order to demount the “old” nozzles. REPLACEMENT OF BOTTOM VALVE SEAL If the bottom valve seal has to be replaced the following procedure is followed:
IMPORTANT! THE MOTOR MUST ALWAYS BE DISCONNECTED, WHILE WORK IS GOING ON ON THE INNER PARTS OF THE COATER, TO PREVENT IT FROM BEING STARTED INADVERTENTLY.
IMPORTANT! REMEMBER TO SECURE THE BOTTOM VALVE AGAINST UNINTENTIONAL OPERATION WHILE THE VALVE IS DEMOUNTED AND WHILE WORK IS GOING ON ON THE VALVE. Demount the flexible connection under the bottom valve.
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Spindle
The bolts fastening the bottom valve to the cone flange are demounted. The valve is now suspended in the service fitting. The spindle is turned by means of a wrench until the bottom valve is lowered 100125mm.
NOTICE! THE BOTTOM VALVE WEIGHS APPROX. CA. 150 KGS. THEREFORE DO NOT SCRHEW THE SPINDLE FURTHER DOWN THAN NECESSARY TO SWING THE VALVE TO THE SIDE! THE VALVE MAY FALL OUT, AS THE SPINDLE IS NOT LIMITED AND CAN BE COMPLETELY UNSCREWED FROM THE FIXED PART!
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Swing the valve to the side, so that it is possible to knock out the supporting ring holding the sealing ring with a mallet.
Sealing
Supporting ring
Remove the supporting ring when loosened. Remove the old sealing ring and mount a new. Place the supporting ring and knock it carefully into place (mind the sealing). After replacing the sealing ring and mounting the bottom valve and flexible connection, they are checked for any leakages as described in the section STARTING-UP GENERAL of this manual.
33
REPLACEMENT OF SCREW SHAFT SEAL At the top of the coater – in the flange under the gear – is placed 3 sealing rings around the mixer screw shaft.
Flange
IMPORTANT! THE MOTOR MUST ALWAYS BE DISCONNECTED WHILE WORK IS GOING ON ON THE INNER PARTS OF THE COATER TO PREVENT IT FROM BEING STARTED INADVERTENTLY.
IMPORTANT! REMEMBER TO SECURE THE BOTTOM VALVE AGAINST UNINTENTIONAL OPERATED WHILE THE FLEXIBLE CONNECTION UNDER THE VALVE IS REMOVED AND WHILE WORK IS GOING ON ON THE VALVE. For replacement of these sealing rings due to wear or damage the following procedure is used: Demount the vacuum compensating system at the end of the screw shaft. Rotary couping
34
Demount the flexible connection under the bottom valve and place a thick plate on top of the surge bin flange. Open the bottom valve, or lower it and swing it to the side. Mount the inner part of the adjustment/lifting fitting delivered with the coater.
Fasten tackle No. 1 (600 kgs) to a fixed point vertically over the screw shaft and to the lifting eye on the fitting. A strap of approx. 750mm is used between the tackle and the lifting eye. (It must not be thicker than 60mm, as there must be space for it inside the hollow shaft of the gear). Tighten the strap towards the tackle. The shrunk-on ring of the gear is loosened as described in the section ADJUSTMENT OF MIXING SCREW. Slowly lower the screw until it rests against the plate. Remove the strap from tackle No. 1. Fasten tackle No. 2 (300 kgs) to straps on the gear and to a fixed point above the gear.
8 pcs M16 bolts
Marks
Demount the 8 bolts (M16) from the adjusting flange of the gear. Carefully lift the gear free of the screw shaft. (MARK HOW THE FLANGES ARE PLACED OPPOSITE EACH OTHER BEFORE LIFTING THE GEAR.)
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Demount the ole sealing rings and mount new ones. (THE LIP IS TURNED UPWARDS.)
Lift the screw (place the strap through the hollow shaft of the gear), so that the shaft wear ring has passed through the top sealing ring. Take care that the rings are not lifted up with the screw. Lower the gear back in place and mount the bolts. Adjust the height of the screw as described in the section ADJUSTMENT OF MIXING SCREW and fasten the shrunk-on ring. Remove tackles and straps. Check that the screw centers in the bottom valve hole by rotating it manually. If necessary, it is adjusted with the adjustment screws on the gear flange.
Fasten the gear and the adjusting screw lock nuts. Start the geared motor at the lower frequency and increase the rpm. slowly. If the screw knocks against the edge bottom valve hole, the gear flange bolts are readjusted and the geared motor is restarted.
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IMPORTANT! TAKE CARE THAT NOBODY IS NEAR THE BOTTOM VALVE WHEN THE SCREW IS STARTED. Mount the flexible connection under the bottom valve, when the screw is running correctly. Mount the vacuum compensating system. Finally, check whether there are any leaks as described in the section STARTING-UP GENERAL.
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8. RISK ASSESSMENT Below the risks which may occur during normal operation are assessed. Further, it is described how the occurance of these risks may be prevented. VIBRATION RISK Under normal circumstances the vacuum coater does not emit any noticeable vibrations. If any vibrations occur during operation the coater is checked for: - Deposits on the mixing screw - Wedged in foreign matters - Defective bearings - Defective gear - Imbalance in norm motor - Too high rpm. of the mixing screw (above 65 Hz) NOISE RISK According to the Machine Directive, EU Council Directive No. 89/392 information on the airborne noise from the coater must be stated hear. Under normal operation conditions will not make more noise than permitted by the Directive. If the noise exceeds the permissible, the noise may be caused by the following reasons: - Foreign matters in the coater - Friction between the mixing screw and housing - Defective bearings - Defective gear DUST RISK There is no dust risk in connection with normal operation of the vacuum coater, as it is designed as a closed unit and will not function as intented with open connections or leaks.
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ELECTRICAL RISK When the lectrical installations have been made by an authorized elektrician and in accordance with the Low-Voltage Directive, there should not be any electrical danger. OPERATIONAL RISK If the precautions described in the section SAFETY are observed there should be no risk involved in normal operation of the vacuum coater.
WARNING SIGNS MUST BE OBSERVED!!!
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9. SCRAPPING At demounting the vacuum coater is handled according to the guidelines described in chapter 2. When the vaccum coater is resold to another party than ANDRITZ FEED & BIOFUEL, it is the responsibility of the seller, that this operation manual accompanies the coater to its future owner. For scrapping the gear is demounted and emptied of oil. The oil is chemically destructed. Sealings and other plastic materials are removed and combusted. The remaining parts are made of steel and can be scrapped right away.
