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Instruction manual
Paper belt filter DPF300-700
Version:08/2018 Original language
© Mayfran 2018, Landgraaf All rights reserved
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Content 1 GENERAL ...................................................................................................................................... 4
1.1 ILLUSTRATIONS ........................................................................................................................... 4 1.2 SAFETY ...................................................................................................................................... 4 1.3 NAME PLATE ............................................................................................................................... 4
2 BASIC INFORMATION .................................................................................................................. 5 2.1 OPERATING INSTRUCTIONS .......................................................................................................... 5 2.2 IDENTIFICATION OF SAFETY NOTICES ............................................................................................ 5 2.3 STICKERS AND EXPLANATION OF SYMBOLS ................................................................................... 6 2.4 WARRANTY AND LIABILITY ............................................................................................................ 6
3 SAFETY ......................................................................................................................................... 7 3.1 SAFETY AND ORGANISATIONAL PRECAUTIONS ............................................................................... 7 3.2 OBLIGATIONS OF THE OPERATOR / QUALIFICATION OF THE STAFF ................................................... 7 3.3 HAZARDS WORKING WITH THE MACHINE ........................................................................................ 7 3.4 PERSONAL PROTECTIVE EQUIPMENT AND ORGANISATIONAL MEASURES .......................................... 7 3.5 INFORMATION ABOUT GENERAL HAZARDS ..................................................................................... 8
3.5.1 HAZARDS FROM ELECTRICAL ENERGY ................................................................................... 8 3.5.2 BEHAVIOUR IN CASE OF AN EMERGENCY ................................................................................ 8 3.5.3 FIRE .................................................................................................................................... 8 3.5.4 OIL, FAT AND OTHER CHEMICALS ........................................................................................... 8 3.5.5 NOISE EMISSION .................................................................................................................. 8
4 TRANSPORT STORAGE AND PUTTING OUT OF SERVICE ..................................................... 9 4.1 TRANSPORT ................................................................................................................................ 9 4.2 LIFTING INSTRUCTIONS ................................................................................................................ 9 4.3 STORAGE ON SITE IN PROPERY SPACES ...................................................................................... 10 4.4 PUTTING OUT OF SERVICE AND DISPOSAL ................................................................................... 10 4.5 PUTTING OUT OF SERVICE, STORAGE AND RECOMMISSIONING ...................................................... 10 4.6 PUTTING OUT OF SERVICE AND DISPOSAL ................................................................................... 10
5 SAFETY INSTRUCTION WHEN WORKING WITH THE MACHINE .......................................... 11 5.1 CHECKING THE SAFETY DEVICES ................................................................................................ 11 5.2 EXCHANGE OF MACHINE PARTS .................................................................................................. 11
6 MACHINE DESCRIPTION ........................................................................................................... 12 6.1 TASK OF THE MACHINE .............................................................................................................. 12 6.2 INTENDED USE OF THE MACHINE ................................................................................................. 12 6.3 FUNCTIONAL DESCRIPTION ........................................................................................................ 12
6.3.1 CONTROL SYSTEM - OPERATION MODES ............................................................................. 13 7 INSTALLATION ........................................................................................................................... 14
7.1 DELIVERY ................................................................................................................................. 14 7.2 TRANPORT DAMAGE .................................................................................................................. 14 7.3 SITE OF INSTALLATION ............................................................................................................... 14 7.4 CONNCTION TO THE LIFT PUMP................................................................................................... 15 7.5 ELECTRICAL CONNECTION ......................................................................................................... 15
8 OPERATION OF THE PAPER BELT FILTER DPF .................................................................... 16 8.1 INSTRUCTIONS FOR COMMISSIONING .......................................................................................... 16 8.2 SAFE USE ................................................................................................................................. 16 8.3 SWITCH ON AND OFF ................................................................................................................. 16 8.4 CHANGING THE FILTER PAPER ROL ............................................................................................. 17
9 MAINTENANCE AND REPAIR ................................................................................................... 21 9.1 MAINTENANCE PLAN .................................................................................................................. 21 9.2 CONDITION OF FILTER PAPER ..................................................................................................... 21 9.3 LEVEL SWITCH .......................................................................................................................... 22
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9.4 CHAIN AND CLEAT CLEANER ....................................................................................................... 22 9.5 CHAIN TENSION ......................................................................................................................... 22 9.6 ADJUST SENSOR OUT OF PAPER ................................................................................................. 23 9.7 DRIVE UNIT ............................................................................................................................... 25
10 TROUBLE SHOOTING ................................................................................................................ 26 11 TECHNICAL DATA SHEET ......................................................................................................... 27 12 SPARE PARTS ............................................................................................................................ 28
12.1 DPF300 ............................................................................................................................... 28 12.2 DPF400 ............................................................................................................................... 29 12.3 DPF500 ............................................................................................................................... 30 12.4 DPF700 ............................................................................................................................... 31
13 CONTACT .................................................................................................................................... 32
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1 GENERAL Before putting the machine into operation, read and observe the operating instructions and safety instructions. Commissioning of this machine is prohibited until it has been determined that the installation of the machine is in compliance with the provisions of the Machinery Directive, the harmonized standards, European standards or the corresponding national standards.
1.1 ILLUSTRATIONS The illustrations in this manual may represent similar machines and may differ from the delivered version. All instructions apply to all machines covered in this manual.
1.2 SAFETY The following pages describe the safety instructions and safety requirements.
It is essential that you read the instructions and also the safety instructions that follow in further chapters before commissioning the
machine. The responsible specialist must know these instructions.
1.3 NAME PLATE The nameplate contains the Mayfran identification number: P13.YYW1234.01 Please always include this identification number in your correspondence with Mayfran.
Figure 1 Mayfran nameplate
YY= Year of construction
NOTICE
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2 BASIC INFORMATION
2.1 OPERATING INSTRUCTIONS The operating instructions contain basic information that must be observed when installing, operating and maintaining the machine. Therefore, these operating instructions must be constantly available at the machine. In addition, local rules and regulations for accident prevention, inspection and maintenance work must be observed.
The operating instructions are to inform you and to avoid dangers during operation. The operating instructions provide information and instructions for maintenance, repair and assembly of the machine.
2.2 IDENTIFICATION OF SAFETY NOTICES
Indication of danger (mostly followed by a safety instruction).
DANGER This is a hazardous situation which, if not avoided, will result in death or serious injuries.
WARNING This is a hazardous situation which, if not avoided, could result in death or serious injuries.
ATTENTION This is a hazardous situation which, if not avoided, could result in minor or moderate injuries
NOTICE This is a situation which, if not avoided, could result in material and/or environmental damage.
NOTICE
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2.3 STICKERS AND EXPLANATION OF SYMBOLS No access for unauthorized persons
This prohibition sign indicates that access for unauthorized persons is prohibited. The area marked in this way may only be entered by persons who have an explicit assignment for this, e.g. work to be performed. All other persons are forbidden access.
Warning of a danger spot
This warning sign indicates that this danger spot requires special attention and caution! Before carrying out maintenance and repair work in this area, it must be ensured that the entire system is switched off.
Danger high voltage
Warning of dangerous electrical voltage means "stop" for hazardous areas containing live parts.
Warning of suspended load
In this area there is an increased risk of being hurt by suspended loads. Only stay for a short time in this area.
Mandatory sign hand protection
This sign indicates that it is essential to use hand protection.
2.4 WARRANTY AND LIABILITY The operator is liable for any installation, maintenance or operating errors. Unauthorized structural modifications to the machine voids the warranty.
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3 SAFETY
3.1 SAFETY AND ORGANISATIONAL PRECAUTIONS • Dangers and safety instructions on the machine must be observed • Dangers and safety instructions on the machine must be kept in readable condition. • The machine may only be operated in technically perfect condition • Protective devices must not be disabled at any time, e.g. by bridging limit switches, valves
and other control components. • All protective devices, e.g. safety covers and doors need to be closed during machining
process. • In the event of an emergency, error or other irregularities, the machine must be switched off
and the main switch must be secured against being switched on again • The uncontrolled access of non-authorized / unauthorized persons to the operating area of
the machine is prohibited
3.2 OBLIGATIONS OF THE OPERATOR / QUALIFICATION OF THE STAFF The operating instructions do not include the internal operating instructions that regulate the behavior during operation in order to avoid accidents, health and environmental hazards. The target group of this machine and the operating instructions is the commercial use. The operator needs to have specialized knowledge with regards to cooling lubricant systems. The operator is obliged to let qualified personnel only work on the machine. Qualified personnel are persons who - on the basis of their training, experience, instruction and knowledge of relevant standards and regulations, accident prevention regulations and operating conditions - have been authorized by the operator to carry out the required activities. The personnel have the appropriate training and expertise in the field of mechanical and / or plant engineering as well as in the fields of electric and pneumatic / hydraulic machinery and • have been instructed in the operation of the machine • have read and understood the operating instructions
3.3 HAZARDS WORKING WITH THE MACHINE The machine is built according to the state of the art and the required safety rules. Nevertheless, the use can endanger the body and life of the user or third parties or impair the machine. The machine is only to be used
• for the intended use • in safety-related perfect condition
Malfunctions that can impair safety must be corrected immediately.
3.4 PERSONAL PROTECTIVE EQUIPMENT AND ORGANISATIONAL MEASURES The applicable guidelines and requirements depending on the working environment must be strictly adhered to.
Wear the prescribed protective equipment. All existing security measures must be checked regularly.
Safety instructions at normal operation
Only operate the machine if all safety devices are fully functional. Avoid unsafe situations
Safety instructions in the context of special and maintenance activities
Inform operating personnel of special and maintenance work before starting to carry out the work. Appoint a supervisor.
Secure the maintenance area as far as necessary.
NOTICE
NOTICE
NOTICE
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3.5 INFORMATION ABOUT GENERAL HAZARDS
3.5.1 HAZARDS FROM ELECTRICAL ENERGY • The control cabinet must always be kept closed. Access is only allowed to authorized
personnel with keys or tools. • Work on the electrical supply must be carried out by a qualified electrician only. • Check the electrical equipment of the machine regularly. Exchange loose connections and
scorched or damaged cables immediately or put them in proper condition • If required, turn of parts of the plant that need inspection, maintenance or repair. Secure
these parts against being switched on again: o Secure the main or repair switch with a padlock o Attach a warning label to the main or repair switch
• Observe the special regulations if work on live parts is necessary. Danger due to electric energy.
3.5.2 BEHAVIOUR IN CASE OF AN EMERGENCY If there are leaks, immediately shut down the machine and depressurize the hydraulic system. Replace the defective parts immediately, or have them replaced immediately.
3.5.3 FIRE • Read and follow the instructions for fire detection and escape routes posted at the facility or
workplace • The use of unsuitable extinguishing agents for firefighting
o can produce toxic gases (vapours); o should be determined based on the electrical system and the risks; o may present a danger to life due to the risk of electric shock.
Consequently: o Never use water for firefighting! o Only use class ABC fire extinguishers o Only use fire extinguishers with CO2 filling for electric fires!
3.5.4 OIL, FAT AND OTHER CHEMICALS When working with oils, greases and other chemical substances, consult the product-specific safety regulations (such as the manufacturer's safety data sheets)!
3.5.5 NOISE EMISSION The noise emission is below 70 dB(A). The noise emission is determined in no-load operation, within a distance of 1m.
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4 TRANSPORT STORAGE AND PUTTING OUT OF SERVICE Observe the general safety instructions during transport.
4.1 TRANSPORT CAUTION
Risk of injury from heavy load falling down. Do not stay beneath floating load.
• Prior to transport, all used and generated energy (such as electricity, compressed air, etc.)
must be removed. • Only use suitable, standardized and tested lifting gear (forklift truck, mobile crane, bridge
crane) and lifting accessory (round slings, lifting slings, slinging ropes, chains) for transport. • When transporting the machine, pay attention to the weight, a stable centre of gravity and
sufficient manoeuvring distance. • Transporting the machine by forklift, hoist, etc. is only allowed at the intended lifting points.
For crane transport, a chain or wire rope slings with four hooks must be used. • Always make sure that the machine is transported without impact and shock. • Always secure loads to be transported against falling or tipping over!
4.2 LIFTING INSTRUCTIONS
Figure 2: Lifting instructions
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4.3 STORAGE ON SITE IN PROPERY SPACES The installation and storage location of the machine must be sufficiently stable. The machine needs to be set up on a levelled ground. The machine is built only for in rooms protected from the weather (+ 10 ° to 40 ° C). During Storage protect the machine from aggressive, humid environment or outdoors. For installation, observe the installation instructions in chapter ‘Installation site‘.
4.4 PUTTING OUT OF SERVICE AND DISPOSAL CAUTION
When putting out of service and (partially) dismantling the machine, please note that:
• Assembly / disassembly work may only be carried out by trained and instructed personnel with specialist knowledge. (see chapter obligations of the operator / qualification of the staff)
• For reasons of safety, do not disconnect any lines, connections and components while the system is under pressure. The machine must be switched off and secured against being switched on again. (see chapter Residual risks of the machine and safety).
4.5 PUTTING OUT OF SERVICE, STORAGE AND RECOMMISSIONING Depending on the storage times, necessary corrosion protection measures have to be carried out. When recommissioning, observe the instructions for installation and commissioning (see chapter Installation and chapter Commissioning).
4.6 PUTTING OUT OF SERVICE AND DISPOSAL The individual materials must be disposed of in accordance with the environmental conditions applicable at the place of use. Liquids need to be handled according to the instructions in the relevant safety data sheets
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5 SAFETY INSTRUCTION WHEN WORKING WITH THE MACHINE
Figure 3: Safety instruction on the machine
Risk of injury from reaching into the discharge opening when dirt bin has been removed.
Don’t reach into the discharge opening while the machine is in operation.
The system cannot be stopped in an emergency.
The system must be equipped with one or more emergency stop buttons. If emergency stop buttons are not part of the delivery, the system must be equipped with one or more emergency stop buttons (in line with the 2006/46/EC Machinery Directive and standard EN 60204).
5.1 CHECKING THE SAFETY DEVICES
Check the safety devices: - at the start of every shift - weekly, when operating continuously - after every maintenance or repair
Check: - the prescribed condition - the prescribed place - the safe connection - the prescribed function
5.2 EXCHANGE OF MACHINE PARTS Only the parts listed in the parts list may be replaced with new, identical and tested components in original quality. Components may only be disassembled for repair to the extent described in the component-specific operating instructions.
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6 MACHINE DESCRIPTION
6.1 TASK OF THE MACHINE The paper belt filter DPF filters metal swarf from coolant. The machine is only designed to operate with cooling lubricants (emulsion as well as neat oil). When using neat oil the filtration capacity will be reduced. The paper belt filter DPF can filter dirt as described below:
• Broken metal swarf (of limited suitability for aluminium swarf) • Metal sludge from grinding application
Floating dirt, as aluminium swarf or plastic material can only be filtered in limits.
6.2 INTENDED USE OF THE MACHINE The machine consists from the following components:
• Paper belt filter DPF including dirt bin. The machine may only be used under the intended operating conditions. These include the following:
• Ambient temperature Min./Max. +10°C to +35°C • Max. humidity (not-condensing) 85%
The machine may only be used to the extent described in chapter “Task of the machine”. Any other or further use does not correspond to the intended use. Intended use also includes:
• observing all instructions in the manual and the accompanying documents • complying to inspection and maintenance work
Mayfran is not liable for damage resulting from improper use of the machine.
6.3 FUNCTIONAL DESCRIPTION The coolant coming from the machining centre flows through the inlet into the paper belt filter DPF. The inlet pressure needs to be limited to 1.5 bar max. The coolant passes the filtration paper and flows into the clean tank. The filtration degree reaches 25µm nominal. Swarf accumulates on the filter paper. Periodically the coolant level rises and is detected by the level sensor. The filter paper is moved towards the dirt bin. The paper belt filter DPF moves the filter paper automatically. A paper reserve and an out-of-paper switch detect when the filter paper gets empty. In case of overflow the level switch acts as an emergency prompt. The gear motor and sensors need to be electrically connected and protected in the electrical cabinet on site. The paper belt filter DPF needs to be controlled from the electrical cabinet on site.
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6.3.1 CONTROL SYSTEM - OPERATION MODES The paper belt filter control needs to be installed as described below: Normal operation mode:
Component Delay Action Level Switch high – paper belt filter DPF
0.1-2.0 sec (Standard 0.5 sec)
None
Filter drive none ON, when level high active ON, when “paper forward manually” triggered
OFF, when level high not active with a delay of 1-5 sec (standard 1 sec) or when “paper forward manually” off.
0-80 hours after last activation (standard 4 hours) with delay of 1-5 sec (standard 1 sec)
Table 1: Normal operation mode Alarm messages Non critical alarms – action required at next available opportunity e.g. before machining next component Critical alarms – immediate action required
Component Delay Error Critical/ non critical
Action
Level Switch high – paper belt filter DPF
0-300 sec Standard:10 sec
Activated - Filter polluted, risk of overfow
Critical Alarm, machining cycle is interrupted, machining stops immediately
Filter drive None MCB* tripped Non critical
Pre-warning, machining cycle can be finished
Paper reserve None activated Non Critical
Pre-warning, machining cycle can be finished
Out of paper None Activated Critical Alarm, machining cycle is interrupted, machining stops immediately
Table 2: Alarm functions *MCB = motor circuit breaker
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7 INSTALLATION
7.1 DELIVERY
The delivered goods must be examined immediately upon receipt for any damage or defects. The customer has to report any damage or defects within 5 days in writing.
7.2 TRANPORT DAMAGE
If transport damage is discovered during machine inspection, the following procedure must be followed:
• Notify deliverer • Record damage report (include pictures, if possible) • Inform manufacturer
7.3 SITE OF INSTALLATION
Ensure the installation site is stable and safe for access, operation and maintenance, as well as the arrangement and installation of components and systems. The location of the machine must be sufficiently stable. The machine should be set up and operated on levelled surface. The machine has been built only for use in rooms protected from the weather (+ 10 ° C - 40 ° C). Only put the system in service after all electrical connections have been installed and all components are ready for use.
NOTICE
NOTICE
NOTICE
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7.4 CONNCTION TO THE LIFT PUMP
Figure 4: connection to the lift pump
Connect the lift pump to the filter inlet (1).
The inlet pressure may not exceed 1.5 bar.
7.5 ELECTRICAL CONNECTION
Only qualified personnel with electrical expertise may make the electrical connections. The electrical connection of the machine must be in accordance with the attached wiring diagram or terminal diagram. The connection is made in the terminal box of the machining center.
• Observe the direction of rotation arrow on the filter drive. • Check the function of the level switch and the sensors
Figure 5: Rotation direction of the drive
NOTICE
NOTICE
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8 OPERATION OF THE PAPER BELT FILTER DPF
8.1 INSTRUCTIONS FOR COMMISSIONING WARNING
It is essential to read and understand chapter Safety before using the machine for the first time. If you have problems commissioning the machine, please contact Mayfran customer service.
8.2 SAFE USE
WARNING
• Never reach into the discharge chute of the paper belt filter DPF, as long as the machine is live. The filter paper is moved also during rest period.
• Make sure that the power supply to the machine / system is interrupted (main switch off and secure) before maintenance, adjustment, lubrication, cleaning and repairs
• Do not remove covers or safety guards without first disconnecting the power supply!
• Eliminate defects before putting the machine back into operation.
• If defects occur during operation, switch off the machine immediately and eliminate them.
• After repairs, checks or servicing the machine first reinstall all mechanical and electrical parts that have been removed. Then carry out a visual inspection of the machine and its surroundings, to make sure no disturbance is to be expected during further operation.
• The prescribed maintenance intervals must be observed.
8.3 SWITCH ON AND OFF
The machine needs to be switched on and off via the machining center / the electrical control cabinet.
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8.4 CHANGING THE FILTER PAPER ROL
CAUTION
Risk of injury from being crushed Before changing the filter paper roll switch off the machine and protect the switch from being switched on unintentionally.
WARNING
Fire hazard The filter paper is made from synthetic resin and is easily burnable. Keep naked flames away from the machine.
If no filter paper rest is present:
Step 1: Unscrew the butterfly nuts and take them out (2). Take off the cover (1)
Step 2: Take out the empty roll (6).
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Step 3: Put in a new filter roll (3)
Step 4: If the new filter paper (7) is frayed, cut the filter paper with a sharp knife. Use the cutting rill (3) in the filter housing.
Step 5: Unroll approx. 1 meter of paper roll (3).
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Step 6: Remount the cover (1) and reinstall the butterfly nuts (2).
Step 7: Thread the filter paper (3) into the housing (see drawing)
Step 8: Switch on the machine. Press the button “paper forward manually” (4) to pull the filter paper (3) into the machine.
Step 9: Keep the button “paper forward manually“(4) pressed until the filter paper exits the discharge chute (5).
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If there is a rest of the old roll remaining: Proceed as described above with step 1 and 2.
Step 2b: If the remaining filter paper (7) is frayed, cut the filter paper with a sharp knife. Use the cutting rill (3) in the filter housing.
Go further with step 3-6.
Step 7b: Slide the new filter paper (7) over a length of about 10 cm underneath the remaining filter paper (3).
Go further with step 8 and 9.
10 cm
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9 MAINTENANCE AND REPAIR
WARNING It is essential to read and understand chapter Safety before every maintenance or repair. If you have problems with maintenance and repair of your machine, please contact customer service (see chapter Address)
CAUTION
Risk of injury from swarf and coolant During maintenance and repair always wear safety gloves.
9.1 MAINTENANCE PLAN
Activity Maintenance/inspection intervals
Empty dirt bin If necessary
Check condition of filter paper weekly
Clean level switch, if necessary clean monthly
Check chain and cleat cleaner, if necessary clean monthly
Check chain tension, if necessary adjust ½ yearly
Check oil in paper belt filter drive, if necessary fill up yearly Table 3: Maintenance plan
9.2 CONDITION OF FILTER PAPER
Check visually the filter paper. To do so, remove the inspection cover on top of the paper belt filter DPF. To replace damaged filter paper proceed as described in chapter “Changing the filter paper roll”.
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9.3 LEVEL SWITCH
Clean the level switch (1) if necessary. Replace damaged and defective parts.
9.4 CHAIN AND CLEAT CLEANER
Check the chain and cleat cleaner (3) for dirt, damage and wear. Clean if necessary and replace defective and worn parts.
9.5 CHAIN TENSION
Loosen the nut (4) a couple of turns. Loosen the bolt (3) one turn. Loosen the nut (5) one turn. Loosen the bolt (6) a couple of turns. Let the tensioner (7) rest at the chain. Use a torque wrench to tighten the bolt (3) with 1.0 – 1.5 Nm. Tighten the nut (4). Tighten the bolt (6). Tighten the nut (5).
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9.6 ADJUST SENSOR OUT OF PAPER
Unscrew the butterfly nuts and take them out (2). Take off the cover (1)
Remove the filter paper roll (3).
Loosen and remove the bolt (4).
Take out the paper tray (5).
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Loosen the nuts (7) one turn. Place the sensor (8) in a position that the distance to the filter paper (6) is at least 30 mm. Tighten the nuts (7).
Reinsert the paper tray(5).
Pull in the filter paper as described in chapter „Change filter paper roll“.
> 30 mm
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9.7 DRIVE UNIT
The gear units are intended for mounting in dry spaces. They are suited for all mounting positions. The gears are of shaft-mounted design and provided with a hollow shaft. A torque arm serves to secure the unit. It is designed with a special fixing structure provided with disk springs. Electrical connection: Check before starting: 1. The required power supply 2. If the required power supply is the same as the supplied power supply The motors are suitable for 200V (3pH) or 400V (3pH) at 50 or 60 Hz.
Figure 6 Gear motor connection
The gears are filled before delivery with a sufficient amount of lubricant and sealed so as to be oil-tight. For refilling the gears please refer to the lubrication chart below.
Gear Type Lubrication oil Gear oil quanity
Tsubaki CMFA 010-200H240VN6 Mobil 600 W Super Cylinder oil 0,45 L Tsubaki CMFA 020-230AH220VN6
Mobil 600 W Super Cylinder oil 0,45 L
Table 4 Lubrication table
To prevent fretting corrosion between motor bearing and the bore of the worm wheel, the motor bearing must be coated with a suitable lubricant when the unit is installed. Mayfran recommends the use of Klüber Microlube GL 261. The gearbox is to be regularly checked to detect leakage, contamination and suspicious noise in due time.
Figure 7: Lubrication point on gear motor
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10 TROUBLE SHOOTING
Problem Possible cause Possible solution The filter paper rips The filter paper is of poor quality /
incorrect specification Replace the filter paper by genuine Mayfran filter paper.
No or poor filtration quality Filter paper is damaged Transport the filter paper until the damage is moved.
Out of filter paper. .
Check the sensor for correct functioning. Replace if necessary. Install a new roll of filter paper.
No warning when out of filter paper
Sensor position incorrect Adjust the position of the "out of paper" sensor.
Overflow
Level switch not working
Check the level switch for correct functioning. Replace if necessary
Inlet volume is too high Reduce the inlet volume Overload of gear motor due to a clogged filter
Remove the blockage and clean the filter. Reset the thermal switch.
Filter paper is not carried out Check for a blockage. If applicable remove the blockage. Check if the genuine Mayfran filter paper is in use.
Leakage Side sealing is damaged or worn out.
Contact Mayfran.
Gear motor does not run, when turned on
no power supply to the motor Check all electric cables and electric connections. Replace and/or repair if necessary.
Gear motor defect Replace the defective gear motor.
Motor circuit breaker activates as soon as the motor is turned on
Motor circuit breaker – contacts defect
Replace motor circuit breaker
Cable connection loose or defect Tighten cables or replace
Settings of motor circuit breaker incorrect or to low
Adjust settings of motor circuit breaker
Table 5: Trouble shouting
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11 TECHNICAL DATA SHEET
Dimensions DPF-300D DPF-400D DPF-500D DPF-700D Length 902 mm 1272 mm 1300 mm 1300 mm Width 773 mm 1010 mm 1272 mm 1540 mm Height 882 mm 800 mm 875 mm 875 mm Weight 126 kg 145 kg
Electric motor DPF-300D DPF-400-700D Manufacturer Tsubaki Tsubaki Type CMFA-010-200H240VN6 CMFA020-230AH220VN6 Power 0,1 kW 0,2 kW Voltage at Frequency 200-240 / 345-415 V at 50 Hz 200-240 / 345-415 V at 50 Hz 200-280 / 345-480 V at 60 Hz 200-280 / 345-480 V at 60 Hz Phases 3 3 Protection degree IP55, Class F IP55, Class F Diameter hollow shaft 25 mm 25 mm Overload protection No No Drive torque 100 Nm bei 50 Hz
85 Nm bei 60 Hz 195 Nm bei 50 Hz 166 Nm bei 60 Hz
Belt speed 1.7 m/min bei 50 Hz 2.1 m/min bei 60 Hz
1.9 m/min bei 50 Hz 2.3 m/min bei 60 Hz
Standard Filter paper* DPF-300D DPF-400D DPF-500D DPF-700D
Quality 150 g/m2 150 g/m2 150 g/m2 150 g/m2 Width 500 mm 500 mm 700 mm 1000 mm Roll diameter (length) Max. 250 mm
(ca. 50 m) Max. 220 mm (ca. 50 m)
Max. 250 mm (ca. 50 m)
Max. 250 mm (ca. 50 m)
*The table shows the standard filter paper. The filter paper used in your application can differ from the standard filter paper. Consult the valid part list of your filter.
NOTICE Use genuine Mayfran filter media to ensure proper functioning of the machine. Other filter media can lead to malfunctioning or f the machine. When other filter media is required please consult Mayfran.
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12 SPARE PARTS
12.1 DPF300
Item Description Part Manufacturer Type Qty C/S/W
1 Drive shaft complete 634.2035 Mayfran T634.2035 (DPF-300D) 1 W 2 Bearing 657.5305 Mayfran 657.5305 1 W 3 Drive unit 1310666 Tsubaki CMFA010-200H240VN6 1 W 4 Photo-electric sensor E4346 Balluff BOS 18M-PA-RH22-S40180176 1 S 5 Filter paper* 8052059 Mayfran 150 g/m2, B=500 mm 50 m C 6 Limit switch E2281 IFM IF5904 IFK4004-CPKG/US 2 S 7 Chain tensioner 634.2004 Mayfran T634.2004 1 W 8 Chain assembly 634.1005 Mayfran T634.1005 1 S 9 Sensor E3323 Balluff BES M12MI-PSC40B-S04G-M01(0) 1 S
10 Chain & cleat cleaner 634.2011 Mayfran T634.2011 1 W *Standard filter paper. The filter paper used in your application can differ from the standard filter paper. Consult the valid part list of your filter. C Consumable S Spare part W Wear part
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12.2 DPF400
Item Description Part Manufacturer Type Qty C/S/W
1 Drive shaft complete 634.2053 Mayfran T634.2053 (DPF-400D) 1 W 2 Bearing 657.5305 Mayfran 657.5305 1 W 3 Drive unit 634.5171 Mayfran 634.5171 1 W 4 Drive unit 1310667 Tsubaki CMFA020-230AH220VN6 1 W 5 Photo-electric sensor E4346 Balluff BOS 18M-PA-RH22-S40180176 1 S 6 Filter paper* 8052059 Mayfran 150 g/m2, B=500 mm 50 m C 7 Limit switch E2281 IFM IF5904 IFK4004-CPKG/US 2 S 8 Chain tensioner 634.2004 Mayfran T634.2004 1 W 9 Chain assembly 634.1006 Mayfran T634.1006 1 S
10 Sensor E3323 Balluff BES M12MI-PSC40B-S04G-M01(0) 1 S 11 Chain & cleat cleaner 634.2011 Mayfran T634.2011 1 W *The standard filter paper. The filter paper used in your application can differ from the standard filter paper. Consult the valid part list of your filter. C Consumable S Spare part W Wear part
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12.3 DPF500
Item Description Part Manufacturer Type Qty. C/S/W
1 Drive shaft complete 634.2092 Mayfran T634.2092 (DPF-500D) 1 W 2 Bearing 657.5305 Mayfran 657.5305 1 W 3 Drive unit 634.5171 Mayfran 634.5171 1 W 4 Drive unit 1310667 Tsubaki CMFA020-230AH220VN6 1 W 5 Photo-electric sensor E4346 Balluff BOS 18M-PA-RH22-S40180176 1 S 6 Filter paper* 8052061 Mayfran 150 g/m2, B=700 mm 50 m C 7 Limit switch E2281 IFM IF 5904 IFK4004-CPKG/US 2 S 8 Chain tensioner 634.2004 Mayfran T634.2004 1 W 9 Chain assembly 634.1007 Mayfran T634.1007 1 S 10 Sensor E3323 Balluff BES M12MI-PSC40B-S04G-M01(0) 1 S 11 Chain & cleat cleaner 634.294 Mayfran T634.2094 1 W *Standard filter paper. The filter paper used in your application can differ from the standard filter paper. Consult the valid part list of your filter. C Consumable S Spare part W Wear part
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12.4 DPF700
Item Description Part Manufacturer Type Qty. C/S/W
1 Drive shaft complete 634.2066 Mayfran T634.2066 (DPF-700D) 1 W 2 Bearing 657.5305 Mayfran 657.5305 1 W 3 Drive unit 634.5171 Mayfran 634.5171 1 W 4 Drive unit 1310667 Tsubaki CMFA020-230AH220VN6 1 W 5 Photo-electric sensor E4346 Balluff BOS 18M-PA-RH22-S40180176 1 S 6 Filter paper* 8052060 Mayfran 150 g/m2, B=1000 mm 50 m C 7 Limit switch E2281 IFM IF 5904 IFK4004-CPKG/US 2 S 8 Chain tensioner 634.2004 Mayfran T634.2004 1 W 9 Chain assembly 634.1008 Mayfran T634.1008 1 S 10 Sensor E3323 Balluff BES M12MI-PSC40B-S04G-M01(0) 1 S 11 Chain & cleat cleaner 634.2064 Mayfran T634.2064 1 W *Standard filter paper. The filter paper used in your application can differ from the standard filter paper. Consult the valid part list of your filter. C Consumable S Spare part W Wear part
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13 CONTACT http://www.mayfran.com Mayfran International B.V. P.O. Box 31032 Edisonstraat 7/ 9 6370 AA Landgraaf 6372 AK Landgraaf The Netherlands +31 (0) 45 532 92 92 +31 (0) 45 532 93 00 (fax) [email protected] www.mayfran.nl
Mayfran GmbH Postfach 50 02 21 D-52086 Aachen Germany +49 (0) 241 93 87 20 +49 (0) 241 17 50 80 (fax) [email protected] www.mayfran.de
Niederlassung Süd Richthofenstraße 32 73312 Geislingen/Steige Germany +49 (0) 7331 95 53 0 +49 (0) 7331 95 53 55 (fax)
Mayfran UK Limited Unit 38 Bradley Fold Trading Estate Bradley Fold Road Radcliffe Bury BL2 6RT United Kingdom +44 12 04 36 64 69 +44 12 04 36 68 40 (fax) [email protected] www.mayfran.co.uk
Mayfran France S.A.R.L. Val de Fontenay Business Centre Le Périgares A 201 rue Carnot CS 80033 F-94127 Fontenay-sous-Bois Cedex France +33 (0) 1 73 43 43 99 +33 (0) 1 73 43 45 10 (fax) [email protected] www.mayfran.fr
Mayfran International, Inc. P.O.Box 43038 6650 Beta Drive Cleveland, OH 44143 USA +1 440 461-4100 +1 440 461-0147 (fax) [email protected] www.mayfran.com
