Rapidmix400CW A1A Iveco - RanQuist.netIntroduction 2 International Ltd Ra pidmix 400 Maintenance Manual SAFETY PRECAUTIONS • Before commencing any repair or maintenance on any piece

A1

RAPIDMIX 400CW

A1A

CUSTOMER:

SITE:

MODEL No: 400CW

SERIAL No.:

CONTENTS PAGE

Section Page no.

Introduction 1 Safety Precautions 2 General 3 Bearings 3 Lubrication 3 Grease 3 Retention 4 Trouble Shooting 4 Conveyor Belt 5 Belt Care And Maintenance 5 Correct Belt Alignment 5 Belt Travel 6 Belt Troughing 7 Load Conditions 7 Belt Scrapers 7 Skirt Boards 8 Belt Care 8 Belt Covers 8 Conveyor Rollers 8 Loading Conveyor 9 Images 9 Parts Lists 10 Out Loading Conveyor Drum 11 Maintenance And Oil Details 12-13 Wiring Diagram 14 Parts List 15 Troubleshooting 16 Water Tank 17 Parts Lists & Pump Details 18 Silo 19 Parts List & Images 19 Cement Weighing System 20 Rotary Valve 21 General Instructions 21 Rotors 21 Bearings 21 Drive 22 General Maintenance 22 Sprockets And Chain 23 Rotor Centralisation 23 Air Purged Glands 24 Rotary Valve Parts 26-27 Oil Lubrication 28 Motor And Gearbox 29-31

Troubleshooting 32 Pressure Relief Valve 33 Maintenance 33 Replacement Of Wear Parts 33 Dismantling And Disposal 33 Fault Finding 34-36 Parts List 37-38 Silo Filter 39 Description 39 Handling 39 Positioning Of Insert able Filter 41 Pneumatic Connection 44 Electrical Controller 46 Maintenance Checks 50-51 Removal Of Filter Elements 52 Position Of Seals 52 Fault Finding 53 Aggregate Bins And Drag Out Conveyor 55 Parts List 56 Drive 57 Gearbox 57 Lubrication 57 Sprockets, Chain And Tensioner 58 Weighed Feeder 59 Mixer 60 Preventative Maintenance and Lubrication 60 Images 61 Parts List 62 Oil Bath 63 Images & Parts List 63 Conveyor Under Mixer 64 Images & Parts List 64 Compressor 65 Operation 68 Airdryer 74 Operation And Maintenance 76 Trouble Shooting 83 Generator Set 88 Start Procedure 88 Stop Procedure 89 Hydraulics System 90 Oil Type 90 Components List 90 Recommended Spares 90 Schematic Diagram 91 Maintenance Points 94 Fault Tracing And Rectification 95 Genset & Compressor Part Numbers 99 Maintenance Schedule 100

Introduction 1

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Rapidmix 400 Maintenance Manual

INTRODUCTION

Enclosed are the maintenance instructions for your RAPIDMIX 400 CONTINUOUS MIXING PLANT (WEIGHED MODEL). Paying regular attention to the maintenance requirements, and following the individual instructions will help to assist in the smooth operation of your plant and maintain its long life span. Pneumatic and hydraulic power has been utilised for the plant operation, and it is essential that the maintenance requirements detailed in the pneumatics and hydraulics sections are adhered to at all times. As a general rule all moving parts should be maintained free from dirt, foreign particles and lubricated when and where necessary. These manuals must be studied carefully before commencing any maintenance on the equipment. Conveyors where fitted, comprise of belts, gearboxes, bearings and electric motors - refer to different sections on the respective components. General details that apply to all conveyors are listed in the section ‘conveyors’. Silo components include the filter, pressure relief valve and rotary valve. Replacement parts may be obtained from Rapid International Ltd. Head Office if and when required at the address shown below Address For Replacement Parts Rapid International Ltd. Rapid International US A Inc. 96 Mullavilly Road 7081 Brighton Blvd Tandragee Commerce City Craigavon Denver N. Ireland Colorado 80022 BT62 2LX TEL: 028 38840671 TEL: (303) 8530068 FAX: 028 38840880 FAX: (303) 2861416 Rapid International Ltd. are readily available for consultation should any problems arise, and can offer expert advice backed up with many years of experience in the industry.

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SAFETY PRECAUTIONS

• Before commencing any repair or maintenance on any piece of machinery the following

safety precautions should be taken. • Always isolate the power supply at source and lock in the “off” position • Always switch off the air supply, and release air pressure. • Always display a notice ‘DANGER REPAIRS IN PROGESS’ on the main control console. • Always wait for machinery to come to rest before attempting to proceed with any

maintenance. • Always use the correct tools to remove safety guards and retain the bolts etc. to replace

afterwards. • Where there is a risk of parts falling on other personnel the area below must be cordoned

off so that the risk is eliminated. • On completion of work ensure that all safety guards and electric interlocks are replaced and working efficiently. • In addition a ‘Permit to Work’ system should be used to permit competent personnel only

to perform maintenance tasks.

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GENERAL BEARINGS LUBRICATION Bearing Units are all grease lubricated and are basically to be relubricated. The grease injected from the grease fitting by means of the grease gun flows into the bearing chamber passing through the grease groove in the housing and grease hole in the bearing outer ring. For relubrication, it is recommended to supply the grease during operation of Bearing Units so as to avoid excessive greasing and the quantity of the grease to be supplied is about 80% of the standard fill volume at factory lubrication. GREASE 1) Selection of grease As bearings are to be operated for rather long time without supplement of the grease, the grease must be of high quality. When selecting the grease, care must be taken not to use improper grease, as there are various types of grease available by mixing mineral oil and metallic soap base according to the application purpose. The lithium soap base grease is superior to others in waterproof, heat-resistance and mechanical stability and can be used in both high and low temperature operating condition. For relubrication of Bearing Units, it is desirable to use the grease with the same soap base as that originally filled. Suitable Greases Include: Up to 100� C Up to 140� C Shell Alvania R2 or R3 Darina R2 Mobil Mobilplex 47 or 48

Mobilux 2 or 3

Castrol Spheerol AP2 or 3 Mobiltemp 1 BP Energrease LS 2 or 3 Norva 275 Texaco Regal AFB 2 Spheerol BNS Duckhams Admax L2 or L3 HTB 2 Acheson Multi purpose N� 2 Ultra Temp Century Lupus A2 Admix B3 Rocol BRB 1200 BRB 1200

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2) Quantity of grease Quantity of the grease required for relubrication of the self-contained bearing is such that pre-vents metal-to-metal contact between raceways and steel balls and retainer and steel balls, lubricates friction parts of the seal and prevents ingress of dirt’s and moisture from the atmos-phere. 3) Greasing interval Greasing intervals for Bearing Units vary widely according to type and quality of the grease as well as operating condition, but in applications under normal conditions it is recommended to relubricate them at less than half of the value obtained from the following formula. RETENTION Check regularly that the bearing continues to be securely mounted. Loose set screws, bolts, nuts, snap rings, end covers, etc, must be re-tightened. PROBLEMS WITH NEWLY INSTALLED BEARINGS Newly installed bearings may exhibit some of the symptoms indicated in table 6 if wrongly fitted. The most common are: Temperature rises rapidly, grease leakage Probable causes • too much grease • no radial clearance • misalignment • excessive axial loads Bearing emits screaming noise Probable causes: • no radial clearance • covers fouling • skidding under light load/high speed correct operation will only be achieved if the bearings

are properly installed.

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CONVEYOR BELT CARE AND MAINTENANCE Belt life depends primarily upon the following four factors: Correct belt alignment. Good loading conditions. Adequate cleaning. Efficient care and maintenance procedures. CORRECT BELT ALIGNMENT The training of a new belt is most important and a study of the following points is well worthwhile. Unsatisfactory tracking, or running off centre of the belts is due to the following causes: Pulleys may not be mounted level and square at centre line of the conveyor. The belt will run off the slack side. Idlers may not be properly lined up. The belt may not trough sufficiently to give proper contact with the horizontal centre idler of trough idlers. The belt may not be straight. The belt may not be loaded centrally. An off centre load will make the empty side run off. The belt may be exposed to wind. The belt may drag against projecting stationary parts. When fitting a belt, special care should be taken to ensure that the following requirements are met. All pulleys must be set up with shafts parallel and square to the centre line of the conveyor. All idlers must be square to the centre line of the conveyor. Ensure belt is fitted right side up i.e. thickest rubber layer to top. It should be appreciated that a belt cannot usually be trained by hit and miss methods. Methodical procedure and patience are essential and gradual correction will need to be done over a period of several days or possibly a few weeks. Over adjustment is almost certain to occur if hasty corrections are made with the result that trouble free running cannot be obtained. The training or centring of a belt requires that the belt be caused to move towards the centre from the left or right hand side. To cause the belt to do so the tail drum should be adjusted as shown below. To find out where such a correction has to be made, look along the edge of the traveling belt, in the direction of travel, if the belt is travelling off centre, you will observe curving in the belt. If curving occurs at certain positions on the belt the rollers at these positions will need to be slewed out of centre, this method is described as follows: BELT TRAVEL Referring to figure 1, the observer at point A will look along the edge of the belt in the direction of travel, and observe a definite curving out between idlers marked 2 and 11. Such a curve may only extend 3 or 4 idler space or over a much greater length of the conveyor. It is also desirable to mark with chalk, idlers 2 and 11 to fix the extent of the curve. It will also be desirable to mark the position of the belt edge on several idlers between 2 and 11, in order to have a reference mark to judge the effect of the adjustment which will be made.

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To Travel The Belt Towards The Right, Shift Right H and Of Drum Back, And Vice-Versa Now it is important to note that if the belt starts running off at idler 2, correction of idler setting will always be needed one or two idlers ahead of this point. In this case idler 1, or even idler at point B, requires slewing. To bring the belt towards the centre, i.e. from the left to the right side (as shown by the straight arrow), the left end should be moved forward and the right end be brought back. The amount of movement of the idler is small, and must be determined from the effect obtained. To start with, neither end of the idler is moved forward or back more than about 1/16� (2mm). Having adjusted this first idler B, the effect should be noted on idlers 1 and 2. If the effect is insufficient or cannot be noted, idler 1 is adjusted in the same way, followed by idlers 2,3,4, up to 10. If after having done so, the belt has not shifted to the right out of centre at 11, a second adjustment is made starting at idler B. If the second adjustment is insufficient, a third and additional adjustment is made. It should be noted that the adjustment should never be carried so far that the belt is sent to the opposite side at idler 11, where the belt is already centred. Furthermore after each adjustment it is desirable to observe the effect for a sufficiently long period, to permit the belt to travel at least once right around the conveyor before the next adjustment is being made. This is necessary as few belts are perfectly straight. Due to this there is always a certain amount of waving of the belt at each idler, and the position of the belt at any one idler must be judged as the average position of this weaving edge. To train a belt, a start should be made on the return belt, beginning at the head or driving pulley following the direction of the belt travel. Having centred the return belt, the top belt is trained starting at the tail pulley and proceeding in the direction of belt travel towards the head or driving pulley. If it should happen that the top belt should run so much out of centre that it cannot be run for any length of time, it will be necessary to roughly train the top belt before training the return belt. In such a case the top belt should only be trained so far that it can be run without risk of damage to belt edges after which the return belt is centred followed by training of the top belt as previously described. Having trained the empty belt, the belt should also run satisfactorily when it is loaded. If that is not so, it is due to the material not being fed centrally on to the belt. In such a case the correct thing to do is to modify the feed chute so that the feed onto the belt is well centred. A belt may not be straight due to a bad joining. If such a belt is run observation will show that at any given location on the conveyor, the belt will pass centrally for some time and then start to run off centre during the period while the curved portion of the belt passes after which the belt will be located again centrally.

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Looking along the conveyor the curved portion gives the impression that the belt starts running off centre and returns again periodically. Such off centre running, due to the belt not being straight cannot be corrected by slewing the idlers. This is due to bad joining, and the belt joint will have to be re-made. When starting up the conveyors for the first time it is important to note that the conveyor belt direction is correct, as damage to the backstop will occur. BELT TROUGHING New belts of heavy construction i.e. considerable thickness in proportion to width, will not trough so well to start with; when empty such belts may rest almost entirely on the inclined rollers and bear very little on the centre horizontal roller. It is this horizontal roller which does the training or centring. The inclined rollers tend to pull the belt out of centre. For this reason therefore when a new belt is started and some difficulties are experienced in training this new belt when empty, it will be best to train the belt just sufficiently so that running without damage to belt becomes practicable. The belt should then be run under load for several days and gradually be trained until the belt runs true. It will generally be found that after a few days running under load will take out initial stretch and make the belt trough easier. This will cause better contact with the centre roller and help to keep the belt centred. GOOD LOAD CONDITIONS When in service belt wear occurs mainly at loading points. Wear factors include feed direction relative to belt movements, belt speed, material characteristics and impact of lumps on the belt. Loading should be central with material feeding at the same speed and in the same direction as belt travel. • Reduce the free fall of material at the loading point. • Cushion lumps by screening out fines in front of the toe of the chute. • Use impact idlers to absorb the impact energy of the lumps. • If skirting is used keep it just clear of the belt. At loading points the distance between skirt

boards and the belt should increase in the direction of travel to prevent trapping. • Ensure that every delivery chute is not choked. ADEQUATE BELT CLEANING It is important that adequate means are provided for belt cleaning, particularly were materials are damp or sticky and have a tendency to build up on pulleys or return idlers and will cause the belt to run out of line. SCRAPERS These are normally mounted adjacent to the head pulley, care should be taken that the scrapers are held against the belt surface with only sufficient pressure to remove the material, without causing damage to the belt. With sticky materials, it is usually necessary to apply a scraper to the snub pulley.

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SKIRT BOARDS The use of skirt boards is an accepted practice used to centre and settle the material on the belt as it leaves the loading point. The skirt boards should be vertical or inclined slightly outward at the top, and set approximately 1/6 of the belt width in from each edge. Initially the opening is 2/3 of the belt width and then tapers out in the direction of belt travel. The length should be sufficient to properly centre and settle the load and is generally 4-5 times the belt width in length. The skirt board is never brought in tight against the belt surface but is left with a substantial clearance (25mm (1�)) which is then closed with a rubber strip. The clearance between skirt board and belt should increase in the direction of belt travel to permit freeing of any trapped material. To further insure against trapped material here, the strip of rubber should be fitted on the inside of the skirt board. Skirt boards can be termed ‘necessary evils’ and if not properly set can damage the belt cover. BELT CARE The belt itself should be inspected periodically for cover cuts, gouges, abrasion, edge wear, and exposed carcase. Both top and bottom covers of the belt should be inspected. The frequency of inspection will depend on the type and severity of service (typically every month). BELT COVERS MINOR CUTS AND GOUGES Minor cuts and gouges in covers or edges that penetrate to the carcase should be repaired before the effected area spreads. This can readily be done using repair dough's, cold patches or spot vulcanising repairs. MAJOR DAMAGE When the belt cover incurs major damage, the belt should be taken out of service and repairs carried out immediately. Emergency repair may be carried out with repair dough's, but as soon as convenient permanent type repairs should be made. CARCASE Carcase fractures and rips are serious and require immediately repairs. If repair plates are used as an emergency, a permanent vulcanised repair or re-splice should be undertaken as soon as possible, unless the belt has limited service time remaining. CONVEYOR ROLLERS All bearings used on the return rollers are scaled bearings which require no further lubrication during their entire working life. The life of these bearings cannot be predicted therefore it is advised that all rollers are checked every two months to ensure bearings are still functioning and there is no damage to the rollers themselves.

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Loading Conveyor

Outloading Conveyor 10

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Loading Conveyor Component List

ITEM NO. DESCRIPTION AND SPECIFICATION PART No. QTY. 1 Van der Graaf TM400A60 Motorised Drum – 850mm Face c-motdru-08 1

2 Stieber Ø50 Back Stop c-bacsto-15 1

3 TR Type Pillow Block Bearing Ø65 UCPX13 c-bea065-12 2

4 Tail Drum Ø270.180.900.180/65+54/50 Spiral Stepped b-608h1-07 1

5 750mm Wide 20° Inline Trough Set STS/102/750/20 c -troidl-01 1

6 750mm Wide 30° Inline Trough Set STS/102/750/30 c -troidl-02 8

7 Disc Type Return Idler 63.5/107 – 850mm Face c-retidl-45 5

Rope Grip Robur 20 Type f-ropgri-01 10

8 800mm Wide Conveyor Belt EP500/3 5+1.5 – 23 Mtrs d-415h1-01 1

9 Arch Mini Scraper Blade To Suit 750mm Belt c-acrscr-08 1

28” Long Mounting Base To Suit Arch Mini Scraper Blade c-arcbas-08 1

Mini Tensioner assembly To Suit Arch Mini Saber c-arcscr-20 1

Mini Hub Support To Suit Arch Mini Saber c-arcscr-21 1

Tension End Mtg Pipe To Suit Arch Mini Saber c-arcscr-22 1

Free End Mounting Pipe To Suit Arch Mini Saber c-arcscr-23 1

Lever To Tension Arch Mini Saber c-arcscr-24 1

10 M24 Threaded Bar 0.5m Lg f-barm24-01 2

11 Double Acting Hydraulic Ram Ø75 Bore Ø40 Rod 1500 Stroke

b-608h1-08 2

12 PES125-A320 Double Acting Pneumatic Cylinder c-pnecyl-67 2

13 TR Type Ø40 2 Bolt Flange Bearing UCFL208 c-bea040-11 2

14 Gob Hopper 10mm Rubber Lining d-415-k6-ad 1

15 7/8” Rigging Screws b-608-07 4

16 Front Wire Rope Ø10 x 14mLg 6x19(9/9/1) 1WRC Galv.RHOL

b-608-15 2

Middle Wire Rope Ø10 x 15mLg 6x19(9/9/1) 1WRC Galv.RHOL

b-608-18 2

Wire Rope Clips To Suit Ø10 Wire Rope b-608-17 24

Shackles 6.5 S.W.L b-608-03 4

Thimbles to Suit Ø10 Wire Rope b-608-h4 8


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Van der Graaf Motorised Drum

All the components of a conventional conveyor drive assembly i.e electric motor, gearbox, drive pulley, bearing block and bearings are all encompassed within the compact dimensions of the drum motor. The electric supply is direct to the motor winding via a heavy duty terminal box mounted on the shaft end or via an IP67 sealing gland. The complete drum-motor is sealed to a minimum of IP66 suitable for high pressure wash down. The drummotor should be mounted horizontal, square to the conveyor frame and parallel to the tail drum. The indented arrow on the mounting shaft opposite the terminal box must point upwards(See fig 1). This ensures that all the internal rotating parts are adequately submerged in oil.


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Van der Graaf Motorized Drum Maintenance Instructio ns

If repair or maintenance are required the drummotor has to be disconnected from the supply before the terminal box can be opened. The Van der Graaf drums are normally fitted maintenance free and require no specific attention during their operation. All drummotors have been factory pre-filled with the right amount of oil which is recommended to be changed after 50,000 hours of service. It is also advised to inspect the drummotor on a regular basis and to check for excessive noise production. The motorised drum on the out loading conveyor of your Rapidmix 400 is a Van der Graaf TM400 A60 15kW 850mm face. Recommended Lubricants for this Drum are as follows:

MANUFACTURER OIL

ALPHA SP 150

MOBILEGEAR 627

SPARTAN EP 150

GR-XP 150

OMALA 150

MEROPA 150

Oil Capacity is 28 Litres for the specified drum mo tor.


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Changing The Oil

Motor Without Filler Plug

1. Allow the drummotor to cool down to an acceptable and manageable temperature. 2. Loosen the top screw a from the end flange at the connection side slowly to release any

air pressure within the drum, this is normal. 3. Now loosen screw b.. Rotate the drummotor until screw b is at the 6 o’clock position and

drain the oil. 4. Rotate the motor back to its original position. 5. Refill the drummotor with the recommended oil type and quantity. The oil level should be

just below screw b (see fig a). 6. Renew the copper washers and replace the screws.

Motor with filler plug

1. Allow the drummotor to cool down to an acceptable and manageable temperature. 2. Rotate the drummotor until the filler plug (pos.34) is at the 6 o’clock position. 3. Loosen the filler plug slowly to release any air pressure within the drum, this is normal.

Remove the filler plug completely and drain the oil. 4. Rotate the drummotor until the filler plug is at the 12 o’clock position. 5. Refill the drummotor with the recommended oil type and quantity. The radial arrow on the

drum endcap where the filler plug is located must point upwards to check for the correct oil level. With the arrow in the 12 o’clock position oil should just ‘weep'.

6. Replace the filler plug and renew the copper washer.


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Drummotor Wiring


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Drummotor Parts List


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Drummotor Trouble Shooting The drummotor does not run

1. Check all connections. 2. Check the power supply. 3. If it is a three phase drummotor, check the voltage between all three phases, this must

be equal. The drummotor over heats

1. Ensure that the ambient air temperature does not exceed 40°c. 2. Avoid electric overload. 3. Check FLC with a clamp ammeter, the current consumption should not exceed the FLC

value indicated on the data plate. 4. Check the conveyor belt for slip.

The drummotor makes a humming sound, it runs, but e xtremely slow or not at all

1. If it is a three phase drummotor, check the voltage between all three phases, this must be equal. Also check for possible interruptions in the winding.

2. If it is a single phase drummotor, the start capacitor(s) is/are to be checked as well as the start switch. Check for possible interruptions in the winding.

The drummotors overloads have ‘Tripped’

1. Check for a short circuit. 2. If a short circuit is not present, re-activate the power and check the FLC using a clamp

ammeter. The drummotor makes a lot of noise

1. Is the drummotor correctly mounted ? 2. Check whether the indented arrow on the mounting shaft opposite the terminal box end

points upwards. 3. Check if the tension of the conveyor belt is too high.

WARNING: The conveyor belt must never be overtensio ned. Too much tension on the belt could cause internal damage to the drummotor.

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Water Tank

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Water Tank Component List

Water Pump

ITEM NO. DESCRIPTION AND SPECIFICATION PART No. QTY. 1 2.2kw Foot Mounted IE2 Electric Motor 3 Phase 4 Pole c-elemot-41 2 2 2” High Pressure Ball Cock Valve c/w Ball c-balcoc-01 1 3 Jabsco 2” BSP Bronze Pedestal pump 52270-2011 e-watpump-01 2 4 2” Female Equal Galv Union Cone Seat c-fituni-05 3 5 ¾” BSP Female Galv Socket c-fitsoc-02 1 6 2” Equal All Female Galv Tee c-fittee-08 1 7 2” F/F 90° Galv Elbow c-fitelb-10 7 8 2” Forged Brass Gate Valve Full Way Pegler c-fitval-06 2 9 HRC 90 F/F Coupling – 1108 Bush c-cou090-01 2 10 Flexible Insert For Above Coupling HRC190IN c-cou090-02 2 11 Taperlock Bush 1108-25 c-tapbus-63 2 12 Taperlock Bush 1108-28 c-tapbus-42 2 13 2” Galv Male Nipple c-fitnip-03 1 14 2” BSP Female Weld In Socket c-fitsoc-08 1 15 2” Galv Male Blanking Plug c-fitplu-03 1 16 Water Meter 1

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Silo Component List

ITEM NO. DESCRIPTION AND SPECIFICATION PART No. QTY. 1 WAM 25m² Silotop R02 Filter With Plastic Lid c-filter-61

1

Upstand To Suit Silo Filter c-filups-02 1 2 Silo Pressure Relief Valve VCP2731 c-valpre-01 1 3 Aeration Nozzles WAM U025 c/w Steel Socket To Suit c-aerpad-03 24 AKO BV10- Wafer Valve DN100 – Butterfly Valve C/W

Actuator c-butval-54 1

Hydraulic Rams Ø100 Bore x Ø80 Rod x 2540 Stroke Heavy.Duty

b-608d1-01 2 High Level Probe For Silo WAM ILT-CO (110 Volt) c-levpro-01 2 ILC Probe Boss 4538020150 c-levpro-03 2

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Cement Weighing System

Cement Weighing System

ITEM NO. DESCRIPTION AND SPECIFICATION PART No. QTY. 1 Ø219 Screw Conveyor – 960mm Lg d-415f1-01 2 2 Screw Drive SEW KA47TDRE100LC4 3Kw 119RPM c-geamot-473 2 3 TR 2 Bolt Flange Bearing Ø30 UCFL206 c-bea030-02 4 4 300mm Sq Rotolok 26 RPM Left Hand 30RVSCMC8B000E c-rotval-09 1 300mm Sq Rotolok 26 RPM Right Hand 30RVSCMC8B000E c-rotval-09x 1 5 Rubber Socks To Suit Ø219 Outlet 200mm Lg c-linsoc-11 2 6 Clamps To Suit Above f-clamps-10 4 7 Loadcells HLCB/1.76T/ZEL 2

Y

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SILO ROTARY VALVE 300 mm Rotolok Rotary Valve STD square inlet IMPORTANT NOTE Only qualified and/or approved personnel should undertake the installation, start up, putting into service and periodic maintenance of the valve and safety aspects cannot be overemphasised. The attached safety leaflet highlights the major precautionary steps that should be strictly followed. Check List before Running Observe fully all Rotary Valve and geared motor operating instructions provided Ensure that the inlets and outlets are protected by the feed and discharge ducting/trucking or other handling equipment so that it is not possible for operators or maintenance personnel to get hands/fingers or any part of their body close to the point where the rotor is moving. If attention to the rotor for inspection, cleaning or other purpose is necessary. The supply to the geared motor drive must be isolated and “locked out” to prevent accidental motor start up. GENERAL INSTRUCTIONS • The Rotolok Valve is of all metric construction with fasteners of metric threads. • The body is of robust proportions and of cast iron, stainless steel or aluminium material. • The end covers are of similar metals and are spigot located into the valve body to ensure

concentricity. ROTORS Are fully fabricated precision machined with again the choice of material construction and are offered in four main types. A. Closed rotors (shrouded) where material is held within pockets. Fixed bladed open type of 6 or 8 blade construction. Adjustable, replaceable tips open type. Scalloped type normally because of large radius at the base is generally self cleaning and is used in food industry. Other variations include, reduced volume rotors, replaceable tips on closed rotors, Teflon coating etc. BEARINGS Sealed for life ball type rigged outboard in raised boss of end covers and positioned against a shoulder. Shaft Seals Aluminium or cast iron gland follower pressurising PTFE packing.

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Drive The valve is chain driven from a geared motor sidewall mounted to valve body. The chain consisting of taperlock sprockets and roller chain are generally supplied in a completely enclosed guard. Other variations include variable speed drivers (AC Thyristor or mechanical), flameproof motors etc. All units are tested prior to despatch and are ready for installation. It is important that should the valve be held in store, machined shafts and flanges should be given a light coat of mineral oil to prevent the formation of rust and/or preferably kept in a clean dry atmosphere. START UP With guard cover still off and valve inlets and outlets fully protected to ensure safety power should be now supplied to the drive motor and the motor jogged to ensure clockwise rotation when looking at the drive gearmotor output shaft. With chain tension having previously been checked and adjusted the guard cover must now be re-installed. Remember never run the valve with chain cover removed. Tighten gland followers where Rotor Shaft protrudes from the end covers and if air purge facilities are provided to the glands a supply of clean dry air 1-2 PSI above the valve internal pressure should be applied. With the chain cover on, inlets and outlets shielded or unexposed the valve should be run for approximately 15 minutes. Isolate the power then check again the tension of the gland followers to tighten packing. Valve is now ready for production. GENERAL MAINTENANCE

ALWAYS ISOLATE POWER COMMENCING WORK ON THE VALVE. Maintenance apart from planned overhaul should be adequately covered by regular and frequent attention to the rotor shaft glands, reduction gear lubrication, adjustment and lubrication of the motor drive chain and chain sprockets. It is recommended that the complete Rotary Valve is dismantled for cleaning inspection and overhaul as necessary at regular intervals. The interval between such routine overhauls will vary between the product being handled and total operating time. To a large degree the rate of wear for a particular application would be assessed by practical experience. Adjustment to the rotor shaft glands should be made with the unit in a stationary position with the power “off” taking care to ensure that the gland is pulled up evenly and to no greater extent than the amount necessary to prevent leakage.

The importance of gland maintenance cannot be overstressed, since a leakproof gland allows no flow through of dust particles and consequently wear due to erosion is largely eliminated. If normal running adjustment is insufficient to prevent leakage or gives rise to continual overheating, the gland packing should be completely renewed.

Packing Gland Detail

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MOTOR DRIVE SPROCKETS AND CHAIN With the power off remove the chains cover and inspect the rotor and rotor shaft sprockets, examine the sprocket teeth for signs of wear and renew if necessary. When replacing the sprockets and drive chain, ensure that the sprockets are correctly aligned and that the chain tension is correct. With one straight length of chain reasonably taut, it should be possible to manually flex the trailing length a total 12-15mm (11/2”- 5/8”). Adjustment, to vary the distance between sprocket centres and therefore the chain tension is provided for in the motor mounting arrangements where nuts can be adjusted on studs and in effect jacking in/out gear motor. SPECIAL REMARKS On stainless steel valves it is vitally important that rotor/body/end covers do not rub or come into contact as shortly during running pick up will occur causing screeching and eventually lead to valve seizure. On closed (shrouded) rotors this effect is eliminated in machining allowing the rotor to float. However on all other types of rotors, special setting-up procedures must be adopted to ensure that rotor clearances are maintained and held. Details of which follow.

ROTOR CENTRALISATION REMEMBER “POWER OFF” Adjustment on Open Type Rotor (Not Stainless Steel) See Diagram below. On Rotary Valves fitted with open type rotors, a system of rotor centralisation by means of disc springs has been adopted to simplify adjustment. At the drive end of the rotor shaft, disc springs are fitted

between the bearing and a circlip on the rotor shaft. This has the effect of pulling the rotor towards the drive end of the valve. The non-drive end of the rotor shaft is fitted with an adjusting bolt and washer against the bearing. By turning the bolt clockwise the rotor shaft is drawn towards the non drive end against the spring load, hence fine adjustment can be made to centralise the rotor within the body assembly.

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Non-Drive End Endcover I M6 x 12 LG Hex Setscrew Bearing Retainer J M6 Flat Washer Bearing K Drive End Endcover Rotor Shaft L Drive Guard Backplate Flat Washer M Tension Disc Spring Hex Setscrew N Disc spring Washer Locating Disc Spring O Rotor Drive Shaft Locating Washer P Circlip

AIR PURGED GLANDS To prevent dust-laden air from penetrating the packing gland thereby breaking down both packing and rotor shaft, air purging can be a distinct advantage. This is especially true on abrasive products and on pneumatic conveying applications. To satisfy this requirement a phosphor bronze lantern ring is used and replaces one ring of packing. The end cover is drilled and tapped to accommodate a 1/8 BSP connection to which an air supply of 1 - 2 PSI above pneumatic conveying line pressure is applied. This allows air to bleed inwardly into the valve thereby eliminating contamination.

Air Purged Gland By use of lantern ring and applying clean air supply 1-2 PSI above line pressure. Packing Gland Detail with Air Purge Facility Stainless Steel Open Type Rotor and Quick Release Typical

On Stainless Steel Open Rotors the rotors are machined and accurate control is held on the distance between the bearings and the shoulder on the shaft. Inadequate care or attention to this matter will shortly after running, cause “pick-up resulting initially in rubbing, then screeching and will eventually lead to valve seizure. Special “setting-up” procedures must be adopted to

ensure that rotor clearances are maintained and held. This is achieved by shimming the rotor to centralise as per detail on page 7. By inserting a shim at the non-drive of the rotor, between the bearing and the shoulder of the shaft, a gap between the rotor blades and the end plate can be maintained. After placement of the correct shim the rotor should be pulled back by the setscrew and washer against the inner ring bearing. The outer ring is already positioned by means of the retaining plate and the circlip within the raised boss of the end cover. This in effect locks the relative position of the rotor blades in conjunction with the end plate. Any temperature effects due to linear expansion must be compensated for at the drive end.

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Diameter clearances should not need any compensation. The tolerances on the spigot location of the end covers into the body ensure that the rotor is self-centralised. Non Drive Assy Closed Rotors Rotor Removal (other than Quick Release) With Power Off

To remove the rotor from the body the following procedure should be adopted. Remove the chain guard cover by the HEX nut and disconnect the chain drive and remove both sprockets. Remove back plate of guard by unscrewing the 5 M6 set screws holding the plate to the base plate and drive end cover. Working on the non-drive end valve and cover, undo the setscrews holding the cover to the body. With two of these setscrews insert in jacking holes and jack off the end cover. The rotor may come out also. (On open types, rotor will always come out). If action C above does not

remove rotor carry out the same procedure on drive end valve end cover or with “pullers” push rotor through bearing and release.

The rotor can then be checked, repaired or replaced. Quick Release Rotor System To Remove Rotor

Working on the non drive end valve end cover unto the setscrews (S) which hold the cover to the body. With two of these setscrews insert in the threaded jacking holes and jack off the end cover. The rotor will draw out of the body as the end cover is withdrawn. To Refit Rotor Slide the rotor into the valve body with the slot of the rotor shaft inline with the peg of the drive shaft (D) ease the shaft through the drive slid gland and rotate the rotor slightly until you feel the slot engage the peg. Refit the end cover retaining set screws and check the drive end cover gland. Tighten as necessary. Similarly check the non drive end cover gland.

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Sectional View of Quick Release Rotary Valve A. Body B. Rotor C. Quick Release Endcover D. Drive Peg E. Stub Shaft Support F. Drive Guard Backplate G. Stub Shaft H. Stub Shaft Housing Retaining Bolts I. Ball Bearings J. Gland Follower K. Gland Packing L. Standard Endcover M. Jacking Screw N. Bearing Retainer O. Locating Washer P. Locating Bolt Q. Bearing Retainer R. Gland Tensioning Bolt S. Setscrews

Quick Release Rotor Detail

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DISCONNECT ALL POWER BEFORE UNDERTAKING ANY WORK ON THE VALVE OR DRIVE.

DISCONNECT ALL POWER BEFORE UNDERTAKING ANY WORK ON THE VALVE OR DRIVE

SQUARE ROTARY VALVE 1. Body 2. Fixed Open Rotor 3. End Cover 4. Gland Follower 5. Bearing Locating Washer (Cover on Later Models) 6. Ball Bearing 7. Gland Packing 8. End Cover Bolt 9. Gland Tensioner Bolt 10. Mounting Bolt 11. Rotor Locating Washer 12. Disc Spring 13. Disc Spring 14. Motor Plate 15. Gearbox

16 Motor Support 17 Valve Sprocket 18. Motor Taper Lock Bush 19. Valve Taper Lock Bush 20. Chain 21. Key 22. Guard 23. Backplate 24. Motor 25. Washer 26. Circlip 27. Key 28. Washer 29. Washer 30 Washer

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Oil Lubrication The units are, in general, despatched from the factory without lubricant. Before starting up, remove the oil filler plug and fill the box with the recommended grade of oil until it flows from the Oil Level Hole. Allow to settle and then replace oil level and filler plugs. At all times keep the breather holes clear. If these become blocked, pressure will be set up in the box due to the surging of the oil, resulting in leakage through the seals. After the first month in service, drain oil from gearbox, flush and refill with new oil. Tempo units utilize extreme pressure lubricants which protect the teeth in the event of the oil film thinning out due to local temperature rise, of high pressure due to accident overloads. These oils are liable to form sludge after continuous service. The oil should, therefore, be changed after every 1,500 hours of operation, or more often as conditions may dictate. The grades of oil shown in the schedule are for normal conditions of duty and ambient temperature. High ambient temperatures cause the oil to thin out and reduce its protective qualities. In such cases it will be necessary to utilize heavier grades than shown. Conversely, low temperatures will necessitate a thinner grade otherwise trouble may be experienced with burning out of motors at starting. In this connection, the pour point of the oil must be less than the lowest ambient temperature to be encountered. References given are for British Standard mounting positions. Lubrication - quantity (Oil Litres) 4.7L

Alpha SP 220 Spartan EP 220

Macoma Oil R 220 Meropa 220

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Electric Motors Check to ensure that the voltage range specified on the motor corresponds to the supply voltage. Wiring instructions are normally given on the motors, but if in doubt, reference should be made to the particular manufacturer’s handbook.

Straddle Type Plug in Type Solid Type

MOTOR PINIONS - Pinion type is dependent on unit ratio.

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Double and Triple Reduction Left hand Wall Mounting Ref. B6 Tapered roller bearings are fitted in the tempo 20 only

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Item Description 1. Gear case (Foot Mounted) 19. Final Shaft Key 2. Cover 20. Final Wheel Key 3. Motor Pinion 21. First Wheel Key 4. First Wheel or T/R Second Wheel 22. Layshaft Circlip-

(10T Pinion TEMPO 5 only) (11T Pinion TEMPO 10 only)

5. Final Pinion Shaft 23. Motor Pinion Pin 6. Final Wheel 24. Cover screws 7. Final Shaft Metric (Plug-in/Straight-on MTR/P)

25.Filler/Breather Plug

8.First Wheel Spacer 26.Motor Pinion Bearing or Layshaft Bearing T/R 9. Final Wheel Spacer 27.Primary Housing 10. Layshaft bearings 28.Layshaft 11. Final Bearings 29.Motor Pinion Bearing 12. First Wheel Retaining Screw 30.First Wheel Retaining Washer 13. First Wheel Retaining Screw 31.First Wheel Retaining Washer 14. Final Oilseal 32.First Wheel Retaining Screw 15. Final Bearing Circlip or S/R Blanking Plug Circlip

33.Layshaft Ball Bearing

16. Final Bearing Washer 34.Sayshaft Bearing Circlip 17. Layshaft Circlip or S/R Final Bearing Circlip 35.Layshfat Circlip 18. Layshaft Bearing Washer 36Primary Housing Screws

Recommended Spare Parts are shown thus: Motor Pini on NOTE: Please quote until serial number when ordering spares. All goods sold subject to our standard conditions of sale, copy available on request.

FILTER See Appendix A at end of this manual for Wam Silo Filter Manual

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Motor Problems If motor fails to run check to see if the power supply is available and sufficient at the motor against that specified on the nameplate. Check the wiring connectors, fuses, overloads etc. and reset or replace as necessary. Motor fails to run, may be burnt out and will need rewinding or renewing. No oil in gearbox could cause motor failure if so gear/or gearbox may need replacing. Valve rotor may have seized and if so the valve will need stripping and cleaning. Motor may be using greater amperage than nameplate. Disconnect chain drive and run gearmotor to assess whether additional loading is from the gearbox. If from the valve, clearance or product need investigating. If the gearbox is suspect refer to Rotolok. Motor of Drive noise, check oil in gearbox and lubrication on chain. Check chain alignment and chain clearance within guard. If the noise is from gearbox refer to Rotolok. Airlock Problems If noise is from valve check clearances and centralize or clean valve internals. Valve direction must be clockwise. Valve screeching due to type of product being handled which although environmentally troublesome is not detrimental to valve function. Leaking glands due to lack of maintenance causing dust escapement, take out existing packing, thoroughly clean housing and re-pack as per manual. Operational Problems Throughput not being maintained - check valve speed, valve clearances and adjust and renew as required. If problems persists check rotor pockets are being emptied and clean rotor. Inspection Doors At clients specific requests an inspection door can be fitted in the valve body. This inspection door is a facility provided for access and surveying of the valve internals to check for wear etc. It is vitally important that safety regulations are followed and under no circumstances should the inspection door be removed whilst the valve is under power. If the inspection door is frequently removed it is recommended that a limit switch is fitted which will automatically disengage the motor. Rotolok will provide typical details on request.

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Pressure Relief Valve VCP2731

MAINTENANCE Failure to follow the maintenance instructions may cause problems and invalidate the guarantee. It is important to perform the following instructions: Once a week check the area near the valve is free from material. Remove the cover to remove any crusts that have formed. Check the diaphragm moves freely. Once a year the valve needs to be overhauled completely (see disassembly – reassembly), replacing the diaphragm and cleaning all elements. After the overhaul, THE PRESSURE SETTING OF THE VALVE MUST BE CHECKED AND READJUSTED following the procedure described in the paragraph. Every 2 years replace the springs. A1) Replacement of wear parts -Closing Disc -Unscrew eyebolts and remove cover. -Unscrew upper nuts from 3 external screws -Remove (in this order): spacers, bellows and springs. -Slip off the two membranes from the three external screws. -Unscrew the upper nuts from the central screw and remove (in this order): spacer, bellows and central spring (If replacing the central spring and/or membrane). A2) Lubrication No lubrication is required. B) Noise No noise at all C) Dismantling and Disposal Storage of equipment for longer periods. Clean the equipment thoroughly, especially inside. Store the equipment in a container. SCRAPING Recycle plastic materials (e.g. weather protection cover, seals coatings etc.) and dispose according to regulations. Dispose of metal parts at the scrap yard.


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D) Fault Finding Minor problems can be resolved without consulting a specialist. Here are a few examples of possible causes and solutions.

Item Problem Item Possible reason

Item Solution

1 Pressure in silo remains higher than overpressure setting of valve after loading

1 Membrane encrusted

1 Take off cover and remove crust

2 Pressure in silo remains lower than negative pressure setting of valve after emptying

2 Membrane encrusted

2 Take off cover and remove crust

List of Hazards Safety

Measures Norm Reference

Operating Instruction Ref.

Residual Risk

1 Mechanical Hazards 1.1 Crushing User Warning!

Never introduce hands between valve casing and moving parts

EN 292 – 1 EN 294 EN 349

03041 M.03 03041 M.04 0.041 M.05

No 1.3 Shearing 1.3 Cutting 1.4 Entanglement 1.5 Drawing-in Trapping 1.6 Impact 1.7 Stabbing – puncture 1.8 Friction – abrasion 1.9 High pressure fluid

injection

1.10 Ejection of parts 1.11 Loss of stability Not applicable 1.12 Slip Trip and fall Not applicable

List of Hazards Safety

Measures Norm Reference

Operation Instruction Ref.

Residual Risk

2 Electrical Hazard 2.1 Electrical contact Not applicable 2.2 Electrostatic

phenomena Not applicable

2.3 Thermal Radiation 2.4 External influence on

equipment

3 Thermal Hazards 3.1 Burns and scalds.

Health-damaging effects by hot/cold environment

Not applicable 3.2


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List of Hazards Safety measures

Norm Reference

Operating Instruction Ref.

Residual Risk

4 Hazard generated by noise 4.1 Hearing loss Not

applicable

4.2 Interference with speech 5 Hazard generated by vibration Not

applicable

6 Radiation Hazards Not

applicable

7 Hazards generated by materials processed 7.1 Contact of Inhalation 7.2 Fire and explosion 7.3 Biological(Viral/Bacterial) 8 H. generated by neglecting ergonomic principles Not

applicable

9 Hazards combination Not

applicable

10 H. generated by failure of energy supply 10.1 Failure of energy supply Not

applicable

10.2 Unexpected ejection of parts

10.3 Failure of control system 10.4 Errors of fitting 11 H. generated by missing of safety related measures Not

applicable

E) Check list in case of trouble 1) General questions. Fault description

a) Does valve open and close also after long shutdown periods without problems? b) Do weather conditions negatively influence feeder operation?

2) Silo check

a) Is silo pneumatically filled with >1.5 bar? b) With more silos, are all of them equipped with a separate pressure relief valve? c) Are silos connected between each other? d) Does each silo have its own dust filter?


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3) Valve check

a) Is valve installed perfectly vertically? b) Check diaphragm at regular intervals?

4) Material check

a) Material description? b) Bulk density? (Kg/dm³) c) Particle size? (µm/mm) d) Humidity? (%) e) Flowability? (make material slide down a metal plate by varying the angle from low to

steep). f) Compressible material? (can you make a “snowball”?) g) Abrasive material? (does it hurt when rubbing it between fingers?)


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International Ltd


PRESSURE CONTROL SAFETY VALVE – VCP 273.1B

Item Quant. Standards Description Code

1 1 Valve casing 206FW9ULA 2 1 Valve closing plate size 273 206FW9Z1A 3 1 Disc 20.66.151.1/A 4 8 Washer 20.98.477.1/A 5 3 M 10 Threaded stud 206FW9V1A 6 7 M 10 Bevelled washer UNI 6592 29.06.02.0060 7 17 M 10 Nut UNI 5588 29.04.04.0050 8 3 Compression spring type ‘B’ 20.98.313.1/A 8a Compression spring type ‘A’ 20.98.315.1/A 9 3 ∅i12,∅e36,Sp.3 Washer 20.98.454.1/A 10 7 M10 x 65 Hex, head screw 20.68.381.1/A 11 1 Compression spring type ‘C’ 20.98.333.1/A 12 1 Protective bellows 20.99.217.1/A 13 4 M 10,∅e 30 Washer UNI 6593 29.06.12.0090 14 10 Weather protection cover 206FW952A 15 1 M 10 Eyebolt UNI 2948 29.32.02.0510 16 3 Connector sleeve 206FW9Q1A 17 1 ∅ 299 Seal with one sloping side 20.99.219.1/A 18 1 Pair of clamping elements 20.68.908.1/A 19 2 M 10 x 60 Socket screw 8.8 UNI 5931 29.02.08.0790

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Silo Filters FC3J20 with 0.75kW Fan 480V 60Hz This filter uses the compressed air cleaning system. The air is injected in the reverse direction to the flow of the air to be de-dusted. When the dirty air has not the momentum to go through the filtering media it is possible to install a fan on the top side of the filter to create the pressure difference necessary to function. The air, which has to be clean, de-humidified and de-oiled, is blown down each filtering element. The filtering element cleaning is controlled by an electronic board that, depending on the filter size, controls the opening of 1,2 or 4 electro-valves. The opening time of the electrovalves (blow time) and the pause time between the cleaning cycles are adjustable using the dials inside the electronic board. The maintenance of the filtering elements is easy, it is possible to extract the filtering elements individually from the top of the filter with the appropriate tool. Depending on the application it is possible to equip the FJ Filter with elements made from polyester, polypropylene and antistatic materials. Handling of Filters The filters should only be handled and lifted using the handling hooks provided. Use lifting machinery suitable for the weight and dimensions of the filter and for the lifting distances in question. Hook up the filters to the lifting machinery using shackle and safety hooks, do not use clamps, rings, open hooks or any other system that does not guarantee the same degree of safety as shackles and safety hooks. Lifting Machinery

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POSITIONING OF INSERTABLE FILTER

The insertable filter consists of a cleaning unit and cover (or fan). The filter elements are supplied disassembled, as are the venturi tubes (if ordered). The filter should be assembled directly onto the ring (supplied separately by WAM).

Position the filter on two supports which are at least as high as the filter elements to be inserted.

Using a socket spanner (size 10) loosen the safety nuts of the hooks locking the cover.

Pull the hooks sideways to free the upper rim of the filter unit.

Keeping hold of the hooks, lift the front part of the cover and remove it from the body of the filter. The cover is connected to the filter with a safety chain.

The cleaning unit is now accessible. The compressed air supply ducts have to be removed before inserting the filter elements.

Unscrew the ring nuts inside the panel.

Remove the rubber hoses. Grip the distributor as shown in the figure and push downwards carefully.

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Insert the filter elements into the holes provided in the plate.

NEVER HOLD THE DISTRIBUTOR BY THE AIR DUCTS

Keeping the distributor pressed down, rotate anti-clockwise as far as possible, Remove the part.

Greasing the top edge of the filter elements will make it easier to fit them in place. (Use silicon-based grease). Press down on the top of the filter element until it fits in place in the hole in the plate.

Insert the venturi tubes in the elements (if applicable)

Position the distributor on the support column with the air ducts aligned slightly to the left of their respective filter elements. Press down and rotate clockwise. Check that it has locked in position by gently pulling it upwards.

Manually tighten the ring nuts inside the panel.

The distributor is correctly assembled if all the filter elements engage with an air duct.

Lift the cover holding it as its front end.

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Pull the locking hooks inside the cover towards you.

Position the cover on the body of the filter making sure that the rear hooks (inside the cover) engage with the top edge of the body as shown in the diagram.

Lower the cover onto the body of the filter. Check that the circular edge of the body is in contact with the metalwork inside the cover.

Push the hooks inwards under the edge so that they come into contact with the body of the filter.

If necessary use a screwdriver inserted in the holes provided under the cover for extra leverage.

When the hook is properly positioned under the rim of the body of the filter tighten the safety nut with a socket spanner (size 10).

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PNEUMATIC CONNECTION During the assembly of the filter check: 1. Compressed air is: 1.1 clean, ie free of slags which could damage the solenoid valve(s). 1.2 Dehumidified, ie discharge condensed water once a week by opening the tap on the filter. 1.3 deoiled, ie. the presence of oil in the air could irreversibly damage the filter cartridges. 2. Operating Pressure is: 2.1 minimum 5 bar at the inlet of the air reservoir. 2.2 maximum 6 bar at the inlet of the air reservoir. NB. The solenoid valves are suitable to operate with dry air. Compressed air consumption: We recommend a minimum of 5 bar pressure. Here below we specify air consumption for average applications, it must be known that different applications require different intervals which will vary the consumption.

Max Air Pressure

Cleaning Duration

Air Consumption at 25 seconds

cleaning interval

Air supply pipe diameter mm

6 Bar 100 ms 4 N m3/h 10

210 ms For the filter FJ the electronic board is installed in a box and is complete with an electronic board CSA/VDE norms with the electronic component to drive and control the blowing units and the fan. Protection: IP56, CEI norms. The board is delivered with the connections fitted, the solenoid coil connections with the fax are made and tested by WAM. The std equipment is complete with the dial to set the pause times between the cleaning cycle) and with the dial to set the blow time (the adjustable times are shown in the “timing table”)

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ELECTRICAL CONTROLLER - DESCRIPTION The electronic boards of the medium and large size are complete with fixed timer used to clean after the filling cycle. The best cleaning of every de-dusting plant is made without any air entering the filter. In absence of the air flow, the powder comes off from the cartridge with more efficiency, leaving the filtering media cleaner. For a correct use see “electrical connections”.

TIMINGS PAUSE WORK END

CYCLE ∅∅∅∅

MIN MAX SET MIN MAX SET Cartridges Bags, elliptical, pockets.

FIXED TIME

400 600 800 1000

5 5 5 5

90 90 90 90

28 28 28 28

100 100 100 100

300 300 300 300

100

210

10 10 10 10

∗The time of the end cycle is fixed and during this time the cleaning intervals is maintained, controlled by the electronic circuit board.

The length of the feeding wires of the electronic b oard can influence the length of the time, so avoid very long cables. The electronic board is complete with fuse: in case of breakdown, if the fuse has to be replaced pay attention to replace it with one of the same capacity (verify the milliampere printed on the fuse). The maximum working temperature of our elect. board is: MIN. -25°°°°C MAX +70°°°°C

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WIRING DIAGRAM FOR FILTERS WITH FAN ( ≥≥≥≥ 3 kW) CIRCUIT BOARD WITH 1 -2 - 3 - 4 EXITS (EG. 4 EXITS, 230V)

S1. ON/OFF Switch When switched on the cleaning cycle and the fan start. When switched off the fax stops, while the cleaning cycle continues for another 10 minutes max. S2 Emergency Switch Voltage must be always present. NB. S1 and S2 switches not supplied by WAM. Provide for motor protection. Attention: It is absolutely necessary to connect b oth “S1” and “S2” in order to start the cleaning cycle.

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CIRCUIT BOARD WITH 1 - 2 UP TO 12 EXITS (EG. 4 EXITS, 230 V)

S1. ON/OFF Switch When switched on the cleaning cycle and the fan start. When switched off the fax stops, while the cleaning cycle continues for another 10 minutes max. S2 Emergency Switch Voltage must be always present. NB. S1 and S2 switches not supplied by WAM. Provide for motor protection. Attention: It is absolutely necessary to connect b oth “S1” and “S2” in order to start the cleaning cycle.

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TIMER SETTING - WORKING TIME It is possible to alter the preset pause time by operating the micro-switches in the following manner:

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TIMER SETTING - PAUSE TIME It is possible to alter the preset pause time by operating the micro-switches in the following manner:

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COMMISSIONING Preliminary Check After completing electrical and compressed air connections the following check should be made: � Compressed air supply at manifold is 6 bar (90 psi) � Check power supply is live � Check rotation of dust discharge unit (rotary valve, screw conveyor) � With controller switched on open clean air side header door slightly and check that each

electrovalve is allowing compressed air to elements and ensure that interval between pulses is correct.

� Check that after each pulse the compressed air manifold has 6 bar pressure. � Check that all panels are sealed and secured. � Check that all elements are correctly sealed into seal place. � Check that all seals are not damaged and close the header door. � Check rotation of fan impeller � Check that dust collection bin (when fitted) is secure and sealed correctly. Start up procedure Precede as follows (after preliminary check) 1. Start up dust disposal valve or conveyor 2. Start air compressor 3. Start controller and fan. Attention: Ensure that the designed air volume is being exhausted. Excess air volume being drawn through the filter before dust cake is allowed to build up will reduce life of element and impair filtration efficiency. When filter differential pressure reaches 50-150 mm H2Q air volume should be re checked to ensure that designed air volume has been achieved. Pressure differential will vary according to the type of dust and loading of dust to be filtered and this can take up to 100 hours stabilise. Shut down procedure 1. Switch off the fan (when fitted) and the controller will automatically pulse down the filter for

10 minutes if no fan fitted switch off connection “S1” as the shown in wiring diagram. 2. Switch off power controller. 3. Switch off air compressor. 4. Switch off dust discharge valve or screw conveyor.

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MAINTENANCE - PERIODICAL CHECKS Weekly Open compressed air manifold drain tap to remove any moisture collected, measure the pressure differential. Should a higher than normal differential pressure be experienced consult chapter “Fault Findings”. Every 6 months Inspect the clean air section of the filter to see if there is evidence of dust. If there is evidence of dust consult chapter “Fault Findings”. � Check door seals are intact. � Check the reverse pulsing operating. � Check the interval timing on the reverse pulsing. � Check electrovalves and diaphragm valves are operating correctly. � Check motor and fan (if supplied). Frequent checks of the operation of the filter particularly during the first few weeks are essential. Only through these checks one will find out whether the preset pause duration is sufficient in view of a correct cleaning of the filter cartridges. Needless to point out the conditions on different sites, even when dealing with the same problem, are hardly identical. To ensure a problem free operation and non-scheduled stops the following checks should be carried out at least once every six months: 1. Check clean air outlet 2. Check cartridges 3. Check external seals and fastening clamps. 4. Check cleaning cycle works correctly. 5. If possible, measure difference in pressure. 6. Check timing in operation and pause intervals is correct. 7. Check electric motor and fan (fan version only). 8. Check inspection hatch is still tight and top cover is well fastened. 9. Check condensed water release tap.

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PERIODICAL CHECKS

REMOVAL OF FILTER ELEMENTS This process is the opposite of the addition of the filter elements up to this stage then:

1. CHECK FILTERING ELEMENTS ARE CLEAN

2. RELEASE CONDENSED WATER FROM AIR TANK

Remove the tool to extract the filter elements by unscrewing the appropriate nut (size 10).

Holding the tool lock unto the filter element.

Pull up by levering on the plate, repeat the process for all the filter elements that need to be replaced.

Pull out the used filter elements completely and carefully put them to one side making sure that they are not dropped.

RIGHT POSITION OF SEALS

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FAULT FINDING Minor problems can be resolved without consulting a specialist. Fault Action Filter elements 1. Check supply of compressed air are blocked up 2. Check air pressure..

3. Check control card. 4. Check solenoid valve. 5. Check diaphragm of solenoid valve.

Presence of 1. Check if elements are damaged. dust in the 2. Check seals and packings. “clean” area 3. Check elements are correctly mounted. Low Suction 1. Check seals and opening not in use.

2. Check piping system is not blocked up. 3. Check elements replace them, if blocked

up. 4. Check sense of rotation of fan.

Fan Stops 1. Check ammeter data on motor plate.

2. Check ammeter reading 3. If sense of motor rotation is wrong, motor can overheat.

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ELECTRONIC CONTROL CARD Fault Action Faulty A. LED on

1. Check mains supply on terminate 2. Check dust F1 is intact, if fuse must be replaced, use original part with

identical performance data.

B. LED off 1. Check enabling signal by testing with a voltameter the terminals R-S-T

connected between each other (see wiring diagram). 2. The correct operation of the electronic card is given when on each

couple of solenoid terminals named EV in the wiring diagram there is a tension of 24 V (AC).

SAFETY INSTRUCTIONS The connections with the mains supply should be carried out by qualified personnel. Before connections, ensure that plate data and voltage supply match. Carry out a correct grounding of the filter components by connecting the earth wires and ensure that the filter is well mounted onto the supporting structure (hopper, silo etc) which must be equally grounded according to industrial standards. Before carrying out maintenance jobs, ensure that the filter is disconnected from mains and air supply and that the compressed air reservoir is empty.

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AGGREGATE BINS WITH DRAG OUT CONVEYOR

Drag Out Conveyor Shown Above

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Drag Out Conveyor Component List

1200MM Endless Conveyor Belt Length 8900 mm Long Rapid Part No.: d-415h6-02 Quantity: 1

ITEM NO. DESCRIPTION AND SPECIFICATION PART No. QTY. 1 22kw SEW R137DRE180LC4 1480/29 RPM Helical Geared

Motor c-geamot-84 1

2 ASA 1 3/4” Pitch Triplex Chain b-608h6-04 3.2m 3 Head Drum Ø406.140.1300.310.90.Lagged b-608h6-05 1 4 ASA 1 ¾” Pitch 11Tooth Triplex Sprocket C/W 20mm Bearings b-608h6-10g 1 TE8 Self Adjusting Chain Tensioner b-608h6-10 1 5 TR Type Ø90 Pillow Block Bearing UCPX18 c-bea090-05 2 6 ASA 1 ¾” Pitch 25Tooth Triplex Sprocket b-608h6-03 1 7 Snub Drum Ø270.55.1250.55.40.S b-608-h6-07 2 TR Type Ø40 4 Bolt Flange Type Bearings UCFX08 c-bea040-14 2 8 ASA 1 ¾” Pitch 19Tooth Triplex Sprocket – 90mm Bore b-608h6-02a 1 9 Ø102 Return roller x 1300mm Lg C/W Ø20x90 Spindle c-retidl-22 1 M20 Rope Clips Robur-20 Type f-ropgri-01 2

10 1200mm Wide EP630/4 6+2 Conveyor Belt @12m Lg b-608h6-09a 1 11 TR Type Ø60 Pillow Block Bearing UCPX12 c-bea060-09 2 12 Tail Drum Ø323.140.1300.140.60.S b-608h6-06 1 13 Arch Mini Scraper Blade To Suit 1200 Wide Belt c-arcscr-12 1

46” Long Mounting Base to Suit Arch Min Scraper Blade c-arcbas-12 1 Mini Tensioner Assembly To Suit Arch Mini Saber c-arcscr-20 1 Mini Hub Support To Suit Arch Mini Saber c-arcscr-21 1 Tension End Mounting Pipe To Suit Arch Mini Saber c-arcscr-22 1 Free End Mounting Pipe To Suit Arch Mini Saber c-arcscr-23 1 Lever To Tension Arch Mini Saber Scraper c-arcscr-24 1

14 900mm x Ø102mm Impact Rollers Part No. 96302 b-608h6-12 28 15 55mm Standard Duty Impact Bar c-impbar-02 16m 16 T-Bolts To Suit 55mm Impact Bars (M16x40) b-608h6-11 48

M24 Threaded Bars 0.5m Lg f-barm24-01 2

Aggregate Bins 57

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GEARBOX SEW R137DRE180LC4 Face Mounted 22Kw Motor Rapid Part No.: c-geamot-84 Quantity: 1 GENERAL INSTRUCTIONS FOR MOUNTING Ensure that the gear reducer are installed in such a way that they are mounted on a clean and flat surfaces, which will not cause stress or tension in the gear reducer.. The pulleys and pinions should not be forced into the shafts by a hammer or mallet but should enter smoothly by the pressure exerted by a bolt screwed into the threaded hole at the end of the shaft. LUBRICATION The Gearbox SEW R137DRE180LC4 holds 10 Litres of oil from empty in its current mounting position.

Aggregate Bins 58

International Ltd


Recommended Types of Oil

Speed N1/ Min

Ambient temperature [C] mineral oil synthetic oil

00:20 10:40 00:40 >1 180 150 220 150 1 180 - 300 220 320 220 < 300 320 460 320

SPROCKETS ASA 1¾” Pitch Triplex 19 tooth Sprocket Rapid Part No.: b-608h6-02 Quantity: 1 ASA 1¾” Pitch Triplex 25 tooth Sprocket Rapid Part No.: b-608h6-03 Quantity: 1 CHAIN ASA 1¾” Pitch Triplex Chain Rapid Part No.: b-608h6-04 Quantity: 10.5M Long Joining link to suit ASA 1¾” Pitch Triplex Chain Rapid Part No.: b-608h6-04(L) Quantity: 2 CHAIN TENSIONER TE8 Self Adjusting Chain Tensioner Rapid Part No.: b-608h6-10 Quantity: 1

Oil temperature

[C]

Oil change interval [h]

mineral oil

synthetic oil

≤65 5600 12500 65 - 80 2800 9000 80 - 95 1400 6300

Weighed Feeder 59

International Ltd


Weighed Feeder

Weighed Feeder ITEM NO. DESCRIPTION AND SPECIFICATION PART No. QTY.

1 Van der graaf motorised drum TM215A40-

440ZV/3Kw/0.65m/s/1420L c-motdru-07 1

2 TR Type 2 Bolt Flange Bearing Ø50mm UCFL210 c-bea050-04 2 3 M20 Threaded Bars 250mm Lg f-barm20-01 2 4 Tail Drum Ø215.55.1440.55.50 d-415h5b-01 1 5 Troughing Sets To Suit 1400mm Belt set @ 40° c-tr oidl-14 2 6 TR Type 2 Bolt Flange Bearing Ø60mm UCFL212 c-bea060-10 2 7 1400mm Belt EP500/3 @ 2450mm Endless d-415h5b-02 1 8 Arch Mini Scraper Mounting Base 54” Long c-arcbas-16 1 Arch Min Saber Scraper Blade To Suit 1500mm Belt c-arcscr-16 1 Arch Mini Tensioner Assembly c-arcscr-20 1 Arch Mini Hub Support c-arcscr-21 1 Arch Tension Bar End Mounting Pipe c-arcscr-22 1 Arch Free End Mounting Pipe c-arcscr-23 1 Arch Lever To Tension Scraper c-arcscr-24 1 9 Ø60mm Bar H5Y 2

10 “S” Beam Loadcell 1

Mixer 60

International Ltd


MIXER Preventative Maintenance Daily Clean Mixer Thoroughly, run cleanout conveyor during cleaning failure to due this will cause excessive wear on your mixer and will cause gearbox failure Grease front and back twin shaft bearings 5gms per day Check seals on mixer back plate and Bull Gear Housing Check coupling rubber inserts for wear and coupling alignment Check Motor for vibration, noise or overheating Every Six Months Renew Mixer Bull Gear oil with VG 220 (mm2/s @ 40oC) Grade oil (max on gauge) Grease front and back bearings on clean out conveyor Every Year Renew Mixer Gearbox oil with VG 220 (mm2/s @ 40oC) Grade oil 40L Capacity Renew Mixer Conveyor Gear Oil with VG 220 (mm2/s @ 40oC) Grade oil 5L Capacity

Mixer 61

International Ltd


Pugmill Mixer Parts

Mixer 62

International Ltd


Pugmill Mixer Component List

ITEM NO. DESCRIPTION AND SPECIFICATION PART No. QTY. 1 130mm Bearing Housing c-beahou-06 2 2 130mm Spherical Roller Bearing SKF 23126 CC/W33 c-bea130-02 2 External Circlip To Suit Ø110mm Shaft f-circli-05 2 3 80mm Bearing Housing c-beahou-07 2 4 80mm Spherical Roller Bearing SKF 22216E c-bea080-06 2 5 Double Acting Hydraulic Ram 63 Bore, 40mm Rod b-608-p5-01 2 6 Bull Gears 5 D.P – 95 Tooth Gear As Per Dwg B-608-

P18 c-geaope-02 2

7 75kw SEW F127/DVE280S4/90 RPM Geared Motor M5 Mtg

c-geamot-57 1 8 Steel Paddles c-mixoad-06 72 9 F220 Tyre To Suit Coupling c-tyrcou-03 1 F220 Tyre Type Coupling – H Flange c-tyrcou-01 1 F220 Tyre Type Coupling – F Flange c-tyrcou-02 1 Taperlock Bush 5040-110 Cast c-tapbus-59c 2

10 Mixer Side Door Rubbers 3580x1200x12mm Belting c-doorub-08 2 Elevator Bucket Fastener 3/8” x 1 ½” BSW FR 5/03/09 c-elebol-03 60 1000mm Lg Grease Nipple Extension 1/8” Male – 1/8”

Female c-geanip-14 1

450mm Lg Grease Nipple Extension 1/8” Male – 1/8” c-grenip-15 1 1200mm Lg Grease Nipple Extension 1/8” Male – 1/8” c-grenip-16 1

Mixer 63

International Ltd


Mixer Oil Bath

Mixer Oil Bath Components

ITEM NO. DESCRIPTION AND SPECIFICATION PART No. QTY. 1 Oil Bath Face Plate Machined Split P12F 1 2 Machined Split Seal R110x150x16 RIAS-21-NBR c-oilsea-06 1 3 3mm Nitrile Gasket 252 o/d x 150 i/d C/W 10 No. Holes c-gasket-19 1 4 3mm Nitrile Gasket 252 o/d x 109 i/d C/W 10 No. Holes c-gasket-20 1 UCC Oil Level Gauge FLT.223 Mfc. FL 69223 c-levgua-01 1 1 ½” Female Cap BSP Galv C/W Breather c-fitcap-11 1

Mixer 64

International Ltd


Conveyor Under Mixer

Conveyor Under Mixer Component List

ITEM NO. DESCRIPTION AND SPECIFICATION PART No. QTY. 1 Tail Drum Ø270.150.1300.150.60.S b-608h4-04 1 2 TR Type Ø60 Pillow Block Bearing UCPX12 c-bea060-09 2 3 Ø102mm Return Idler x 1300mm Lg C/W 20x120

Spindles c-retidl-56 1

4 1200mm Wide Conveyor Belt EP600/4 6+2, Endless @7440Lg

b-608h4-05 1 5 Head Drum Ø270.150/70.1300.211/70+209/60.L b-608h4-03b 1 6 TR Type Ø70 Pillow Block Bearing UCPX14 c-bea070-12 2 7 SEW 0.75kw KA87/TR57DRE80M4 Geared Motor c-geamot-04 1 8 M20 Threaded Bar 0.5m Lg f-barm20-01 2 9 H/Molecular Reconstituted Polyethelene PPa4

2020x1010x12 c-perpla-04 3

Compressor 65

International Ltd


OPERATORS AND MAINTENANCE MANUAL Hydrovane Compressor Type: HV07RM : c-compre-10 Dryer CompAir Dryer F0011C : c-airdry-03

Compressor 66

International Ltd


Pneumatic System

WARNING: Electrical shock risk.

WARING: Hot surface.

WARNING: Pressurised component or system.

WARNING: Consult the operation and maintenance manual before commencing any maintenance.

WARNING: Do not undertake any maintenance on this machine until the electrical supply is disconnected and the air pressure is totally relieved.

Do not breathe the compressed air from this machine.

Do not operate the machine without the guard being fitted.

On (power)

Off (power)

WARNING: Unit is remotely operated and may start without warning.

Compressor 67

International Ltd


WARNING

1. Safety precautions (U.K. Health and Safety at Work Act 1974). Never direct High

Pressure Air, Grease or Oil Delivery Nozzles at any part of the body. 2. DO NOT work on the compressor without isolating electrical power and releasing

air from the receiver. 3. DO NOT re-adjust the pressure switch above the specified operating pressure of

the compressor. 4. DO NOT attempt to adjust the pressure setting of the safety valve. 5. DO NOT use unit outside when raining. 6. DO NOT use petrol or other inflammable fluids to clean compressor parts. 7. Ensure that the electrical outlet point is of the specified voltage and has adequate

fuse protection. 8. Replace all guard and covers after maintenance work. 9. Follow all local safety regulations when installing, operating or doing maintenance

work on the unit. 10. Maximum recommended working pressures:

BK119-270F-7.5 10 bar(g) (145 psig)

11. Do not use in explosive conditions 12. Potential freezing of air from rapid expansion of compressed air 13. The compressor, contains, pressurised air, and moving parts, and remains hot

after switch off. 14. The compressor is not, intended or applicable, as a work station. 15. The lubricant must be handled, contained, and disposed of in a safe and suitable

manner. ELECTRICAL INSTALLATION If the motor overheats, the thermal overload will operate, cutting off the motor supply. The motor can be restarted by disconnecting the power supply, wait a few minutes, then press the motot-protector button. If the motor-protector trips again when the compressor is restarted, call technical assistance.

Compressor 68

International Ltd


The compressor assembly comprises of an air-end (A),

complete with oil cooler (B), driven by an electric motor

(C). This assembly is mounted to either an air receiver

(D) or tri pod (E) together with the pressure switch (F)

and starter box (R). The air enters the compressor

through an air filter (G). The air is compressed with the

air-end pressure displayed by pressure gauge (H). It is

then discharged through the air out let pipe (J) and the

non-return valve (K) into the air receiver (D). Fitted into

the air receiver is a safety valve (L), drain valve (M),

pressure switch (F) starter (R) and pressure gauge (N)

which displays the pressure in the receiver and air

discharge tap (Z). The oil sight glass (J) allows you to check the oil level, when the compressor has stopped. The

oil filler plug (K) incorporates a thermometer pocket which allows you to monitor the oil temperature. When you fill

or top-up the compressor the correct procedure is to fill to over flow. To drain the compressor oil remove drain plug

(L), to drain the receiver release drain valve (M).

7.1.1 - OPERATION Checking Procedure before Starting

1.Check oil level.

2.Check filler and drain plugs are fitted securely.

3.Check for any signs of oil or water leaks.

4.Refit all covers and secure.

5.Check compressor pressure gauge reads zero.

6.Check air-out let valve is open.

7.Turn mains electricity supply on.

Compressor 69

International Ltd


Starting V07 Receiver/PURS

Complete checking procedure.

Push the green start but ton (A).

The compressor will start immediately and will automatically stop and restart according to air demand. On initial

start-up the air-end pressure will immediately rise and the air-end pressure gauge will read 4-6 bar (58-87 psi). The

air-line pressure will rise slowly and fluctuate with air demand. If there is no demand for air the air-line pressure will

rise until the high setting of the pressure switch is activated. The compressor will stop immediately and will remain

stopped until there is an air demand. When the pressure falls to the differential setting of the pressure switch the

compressor will immediately restart.

Stop/Emergency Stop

Close air outlet valve.

Press the stop/emergency stop button (B).

If an emergency occurs, hit the stop/emergency stop button (B). The button will lock in the depressed position and

stop the compressor immediately.

Clear any faults which may have occurred do not re-start until safe to do so.

Reset the stop/emergency stop but ton by twisting it clockwise before restart.

Compressor Vent Down Time

After stopping the air end must be allowed to vent down naturally. Speeding up the depressurisation may cause

separator flooding.

7.1.3 - MAINTENANCE

WARNING!

SERVICING OF THE COMPRESSOR MUST ONLY BE CARRIED-OU T BY AUTHORISED PERSONS FULLY

TRAINED AND COMPETENT IN THE MAINTENANCE, MAINS ELE CTRICAL SUPPLY AND STARTER

CONTROL EQUIPMENT OF HYDROVANE COMPRESSORS. THEY MUST FULLY UNDERSTAND AND ADOPT

CORRECT AND SAFE WORKING PRACTICES.

Compressor 70

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If you are unable to carry-out the work safely in the required manner then your Hydrovane distributor will be

pleased to help. Use genuine parts and FLUID FORCE RED 2000 or an APPROVED OIL during routine servicing,

the following service kits are available.

Routine Service Schedule

The work listed below must be carried-out at the indicated running hours which must be regarded as a maximum.

In dusty, hot or humid conditions more frequent servicing may be necessary. This section shows the minimum

service requirements for your compressor. To ensure that the full compressor maintenance programme is carried

out, Hydrovane recommend that your compressor is regularly serviced by an authorised Hydrovane distributor.

Check Compressor Operation

Wait until air-end vent down cycle is complete.

Check that the air-end pressure gauge reads zero.

Pour a small amount of oil into the thermometer pocket of the oil filler plug. Screw a temperature gauge or

thermometer into the thermometer pocket. Assuming the compressor is serviced correctly the machine is capable

of operating in ambient temperatures up to a maximum of 40°C (104°F). At this ambient the bulk oil tem perature

measured at the filler plug should be 70-90°C (158- 194°F). Check oil temperature. When the compressor is

working the temperature should be:-

Initial start-up and warm-up period. < 70°C (158°F)

Optimum working temperature. 75-85°C (167-185°F)

High temperature. 90-100°C (194-212°F)

Stop ! See fault finding section. >100°C (212°F)

Check Air Line Pressure

Check the air-line system pressure by using the receiver mounted pressure gauge.

Check Air-End Pressure

To check the air-end pressure, use the pressure gauge located in the air-end.

Check Oil Level

Check that the air-end pressure gauge reads zero.

Remove filler plug and check in side oil chamber.

Oil should be filled to over flow if not top up (see oil top-up procedure).

Draining Air Receiver

Wait for air-end vent down cycle to finish.

Position a suitable container beneath the condensate drain valve (B).

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International Ltd


WARNING!

THE AIR RECEIVER IS PRESSURISED, TAKE GREAT CARE WH EN CARRYING OUT THE NEXT

OPERATION.

Carefully open drain valve and allow pressure to fall slowly to zero. Collect all condensate drained from receiver.

Note: Condensate may contain traces of oil and must be disposed of in an approved manner.

Close drain valve (B) and open air out let valve (A).

Basic Service Procedures

WARNING!

STOP THE COMPRESSOR AND ISOLATE FROM MAINS ELECTRIC AL SUPPLY. LOCK THE ISOLATOR IN

THE OFF POSITION. FIT A SAFETY NOTICE TO THE ISOLAT OR ADVISING THAT WORK IS BEING

CARRIED OUT ON THE COMPRESSOR. CLOSE THE AIR OUTLET VALVE TO ISOLATE THE COMPRESSOR

FROM THE AIR-LINE SYSTEM FIT A SAFETY NOTICE TO TH E VALVE ADVISING T HAT IT IS NOT TO BE

OPENED.

DO NOT PROCEED UNTIL GAUGE READS ZERO!

Oil Top -Up Procedure

Wait until the air-end vent down cycle is complete, check that the air-end pressure gauge reads zero.

Note: If pressure gauge does not fall to zero then non-return valve (D) may be faulty.

Drain air receiver following procedure above. Do not re open air-outlet valve (A).

Carefully unscrew oil filler plug (B), remove filler plug (B), and retain bonded seal (C).

Fill compressor to over flow with FLUID FORCE RED 2000 or an APPROVED OIL, do not over fill

Note: Oils must not be mixed

Examine bonded seal, if not damaged refit to filler plug.

Refit seal and filler plug, tighten to 25 Nm.

Compressor 72

International Ltd


OPERATION (Auto Stop and Start machine) the compressor will start and stop automatically, controlled by a pressure switch responding to air receiver pressure. The pressure switch is factory set. This cut-out pressure can be adjusted but must never be increased above the maximum recommended working pressure. PRESSURE SWITCH ADJUSTMENT Turn the range adjuster at the top of the pressure switch clockwise to increase, anti-clockwise to decrease the main pressure setting (P). Turn the range adjuster (plastic nut) clockwise to increase, anti-clockwise to decrease the differential between cut-in and cut-out pressure (>P). After making adjustment, check the cut-in and cut-out pressure by means of air receiver pressure gauge. CAUTION Never exceed maximum specified pressure. START UP Single Phase Units Single phase units are wired for correct rotation at the factory. If the rotation is incorrect, change motor connections in accordance with motor terminal box instructions. Three Phase Units Start the compressor momentarily and check that the direction of rotation is that shown by the arrow on the shroud/flywheel guard. If the rotation is incorrect, interchange two of the power supply leads.

Compressor 73

International Ltd


INSTALLATION The final installation site should be a flat, stable solid surface. The compressor should be moved as close to the final installation position as possible before finally lifting into place from the pallet as shown.

Install the compressor on a level surface in a cool, frost free, well ventilated area, allowing space around the unit for cooling and accessibility for maintenance. WIRING DIAGRAM

Air Dryer 74

International Ltd


AIR DRYER

The air dryer is located beside the air compressor in the

mixer module of the plant

Type Comp AIR F00011C 230V 50Hz

Rapid Part No.: c-airdry-03

Purpose of dryer

This refrigerant compressed air dryer has been designed to

remove water vapours from industrial compressed air that is

free of any aggressive contaminants like ammonia, gaseous

acid, dust, rust or any other chemical or mineral products

capable of clogging the heat exchangers. The dryer has been

designed for indoor operation. The minimum and maximum values stated must be observed as

well as the safety precautions described in this manual

Dryer Label

The following label is affixed on the cabinet of the refrigerant compressed air dryer

Air Dryer 75

International Ltd


Air Dryer 76

International Ltd


Control panel

The control panel of the dryer includes the following elements.

16. Power – on/off switch

17. Start – Stop push button

Operation and adjustment

1. Push on the green button to start the dryer

2. The start light will indicate that the dryer is running

3. IMPORTANT NOTE!

If the ambient temperature is over 35°C, continue p ushing the start button until the

temperature measured by the thermostatic switch at the compressor inlet is below 35°C.

(This may take about 1 minute.)

4. To stop the dryer, first stop the airflow (either shut-down the air compressor or close the

inlet/outlet or by-pass valve).

IMPORTANT NOTE!

Avoid leaving the dryer stopped when compressed air is still flowing through it.

During Operation

Regularly check the position of the dew point indicator. The reference line has to be in the

green zone. If not read the appropriate action in the trouble shooting section

7.2.1 - MAINTENANCE

Maintenance by an Engineer

• Maintenance and repairs should only be performed when the air dryer is shut down and

depressurised and when the main power is switched off

• Use only the appropriate tools for maintenance and repair

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International Ltd


• Before dismantling a part under pressure, disconnect the pressure sources and

depressurise the system

• Proceed carefully during maintenance and repair. Prevent dirt from entering by covering

parts and orifices with a clean cloth, paper or tape. A receiver should never be welded or

modified in any way.

• Optional water-cooled condenser: End caps of water condenser can be disassembled for

cleaning with help of a water jet

• Never leave tools, loose parts or cleaning rags in or on the air dryer

Air Dryer 78

International Ltd


• Before returning the fryer into service, check the setting of the control and safety devices

as well as the pressure and temperature of the compressed air circuit.

Maintenance by user

• Keep the dryer clean

• In case of more than 2.0Kg of refrigerant, the dryer should be regularly checked to be

leak free by a qualified refrigerant engineer. Refer to section ‘Environmental protection’

of this manual

• Every six months check the correct operation of the condenser drain trap. Replace timer

or solenoid valve in case of clogging or malfunctioning

• Every six months check and clean the drain strainer or the electronic sensor by undoing

the access screw and rinsing the filter with tap water to remove trapped dirt from the

inside

• Every six months if a pressure assisted membrane drain valve is used clean or replace if

required

• For air cooled dryers clean the condenser with a brush or compressed air flushed as

soon as it’s dirty or clogged. Take care not to bend the copper fins of the radiator.

• For water cooled condenser use only clean water and use water counter flow to clean the

condenser when required

• Check the trouble shooting list in case of maintenance troubles

• Check operating pressures, temperatures and time settings after maintenance. If

operating and the safety devices function properly, the air dryer may be used.

Environmental Protection

• EU laws protect the environment against refrigerant being released into the atmosphere

• An annual leak control at less than 5.0gr/year should be performed by a qualified

engineer if the refrigerant dryer contains more than 2.0kg of refrigerant. This control has

to be done twice a year if the dryer contains more than 30.0kg

TAKE NOTE: EU local government may place penalties if this requirement is not

respected

• Before dryer disposal, the refrigerant must be properly recovered by a qualified engineer.

Air Dryer 79

International Ltd


Air Dryer 80

International Ltd


Bekomat drain technical features

Maintenance Recommendations

Replace service unit (5) annually

Danger! Compressed Air! Ensure the unit is depressu rised before disassembly

Working Steps

- Removing control unit (1) by pressing latching hook (2)

- Detach Bekomat from outlet (3)

- Remove service unit (4) from pipe at inlet by undoing union nut (5)

- Check if new service unit (4) matches control unit (1)

o Type, designation and colour of latching hook

- Fit new service unit (4) in reverse order.

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Assembly of control unit onto service unit

Check if service unit (3) matches control unit (1)

1. Check if sensor tube plate (5) with contact springs (4) is clean, dry and free from

foreign matter

2. Insert sensor (2) into sensor tube plate (5)

3. Fit latching hook (6) of control unit (1) into sensor tube plate (5)

4. Press control unit (1) against service unit (3) and snap into place.

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International Ltd


Electrical Diagram

Air Dryer 83

International Ltd


Main Settings

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International Ltd


TROUBLESHOOTING

IMPORTANT- Before beginning maintenance or repair on the dryer, the main switches and on/off switch must be

turned off. Also, the compressed air must be vented from the system.

Problem Possible

Cause

Repair Comments

Dryer on

Light is lit

but

refrigerant

compressor

does not run

Refrigerant unit

is not operating

Check refrigerant

compressor

Several factors may cause compressor failure. A qualified

refrigeration contractor should check all electrical and

refrigerant control

The refrigerant

high pressure

protection has

tripped

The refrigerant

high pressure

switch has

tripped.

The dryer is protected against too high refrigerant

pressure. It will trip in case the condenser efficiency is

reduced. Reset the switch manually (green button)

Excessive

ambient

temperature

Be sure that the

dryer is working

lower than the

maximum

conditions

A high ambient temperature may cause the refrigerant

system to operate at higher than normal pressures.

Results will be a higher than normal evaporator

temperature. Important. There should be adequate air

circulation around the dryer.

Excessive

temperature on

crankcase of

compressor

Allow time for

compressor to

cool down.

Reason may be a

possible miss

adjustment or

shortage of

refrigerant

Compressor is protected against too high temperature of

the crankcase by a thermal switch called a ‘klixon’.

Excessive

compressed air

inlet

temperature

Be sure that dryer

is working lower

than maximum

conditions

Should working conditions be exceeded, the dryer will be

overflowed, dew point will go up and protecting device can

switch off

Clogged

condenser fins

or clogged

water

condenser

Clear fins or

water condenser

of all obstructions

The clogged fins in the condenser will restrict the air

passage and reduce the refrigeration capacity, causing

high temperature in the evaporator. Same will occur if

water condenser is clogged with mud or dirt. Air

condenser and water condenser should be periodically

checked and cleaned. Protect water circuit by an adapted

filter

Too much air

flow

Check actual flow

through dryer

This dryer is designed for a maximum airflow. If too much

air is pumped into the dryer, water removal capacity may

Air Dryer 85

International Ltd


not be sufficient, resulting in liquid carryover downstream.

Check the rated output of the air compressor

Faulty

electrical wiring

Inspect the circuit The compressor-on light should be wired into the

refrigerant compressor circuit. See wiring diagram of this

notice

One electrical

protection has

tripped

Reset the

protection or

replace the blown

fuse

The dryer is protected against too high intensity by fuse

and/or overload relay that can trip in case of need. Reset

or replace fuse once, but do not insist if it trip again,

request assistance of qualified refrigerant contractor.

Dryer-on

light is lit but

fan not

running

Fan has to run

if refrigerant

high pressure

is upper set

point

Check that

compressed air

flows through the

dryer. Check that

fan blades are

free to move

Fan is automatically operated in order to keep refrigerant

pressure upper a minimum value, it may be stopped if

pressure is under the setting

When

compressor

starts, it

vibrates a lot

and makes

mechanical

noise.

Compressor is

sucking liquid

refrigerant at

starting

Be sure that pre-

heating period of

minimum 4 hours

is respected for

dryer equipped

with crankcase

heater

Refrigerant may move between receivers when refrigerant

compressor is stopped and not heated, especially if

stopped for a long time. This migration may cause liquid

shock in values especially on big dryers containing more

refrigerant.

Water in

system

Inlet and outlet

connections

are reversed

Check inlet and

outlet connections

This dryer is designed for air flow in one direction only.

Inlet and outlet directions are identified on the dryer

Drain system is

clogged or

inoperative

Restore a free

flow of water

condensate.

Check water

evacuation.

Drain system may be timer + solenoid valve type or

pneumatically assisted or Beko drain has to be adjusted in

accordance with values listed into maintenance book.

Solenoid valve includes a strainer that has to be

periodically checked and cleaned. Membranes of

pneumatically assisted drains have to be checked or

replaced every six months. Beko drain has to be cleaned

with soft water.

Bypass system

is open

Check the valves Important: Bypass piping should be installed around the

dryer so the dryer must be isolated for service without

shutting down the air supply. During dryer operation

valves must be set so all air goes into the system. Check

tightness of the bypass system.

Air Dryer 86

International Ltd


Free moisture

remains in pipe

lines

Blow out the

system

Before the dryer is first started all free moisture should be

blown out of the system

Excessive air

flow

Check actual flow

through the dryer

The dryer is designed for a maximum air flow. If too much




Excessive free

moisture

Check the

separator and

drain system

ahead of the

dryer

In some systems there may be an accumulation of free

moisture in the line ahead of the dryer. If this moisture is

pumped into the dryer intermittently, the water removal

capacity may not be sufficient. A water separator has to

be installed into the line before the dryer

Excessive

compressed air

inlet

temperature

Be sure that the

dryer is working

lower than

working

conditions.

The dryer is designed for working into calculated

maximum conditions. Should the conditions be exceeded,

the dryer will be overflowed, dew point will go up and

protecting devices can switch off

Clogged

condenser fins

Clear fins of all

obstructions

The clogged fins in the condenser will restrict air passage

and reduce refrigerant capacity causing water

downstream. Fins should be periodically checked and

cleaned

Shortage of

refrigerant

Fix the leak and

add a charge of

refrigerant

Loss of refrigerant will cause improper functioning. A

qualified refrigeration specialist should perform the

necessary repairs, or factory should be contacted if unit is

in warranty

Refrigeration

system is not

functioning

Check to be

certain refrigerant

compressor is

running

To check if the compressor is running, check compressor-

on light. It is possible for the fan to be operating but not

the compressor. Compressor not running can be caused

by several factors. A qualified refrigerant contractor

should check all refrigerant and electrical controls.

Excessive

pressure dew

point

Readjust

refrigerant

evaporating

pressure

The refrigerant pressure adjustment valve is identified by

a label. Turning the adjustment screw counter clockwise

will decrease the refrigerant pressure and lower the dew

point. Adjust valves in ¼ turn increments to allow

15minutes for pressure stabilization with air flowing. Be

sure that gauge indicates that pressure stays in green

zone

High Excessive Check actual This dryer is designed for a maximum air flow. If too much

Air Dryer 87

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pressure

drop

compressed air

flow or too low

air inlet

pressure

pressure and flow

through the dryer




Inlet pre-filter

clogged

Replace the

element

Dryer with 2 or more heat exchangers are equipped with a

25 microns protective pre-filter. Check it regularly and

replace when pressure drop is too high. Contact your

dealer for spares

Freeze up Check that

operating room is

higher than 5°C.

Readjust

refrigeration

controls

Frosting of the lines is an indication that controls are set

too low. Controls may be adjusted in the fields by means

of the hot gas bypass valve. Turn screw clockwise to

increase refrigerant pressure setting which will increase

pressure dew point. Adjust screw in ¼ turn increments to

allow 15minutes for pressure stabilization with air flowing

Clogged heat

exchanger

Clean heat

exchanger with a

reverse air flow

Dryers are supposed to be used with compressed air free

of any aggressive contaminants. Some contamination may

require extensive maintenance of the heat exchanger.

Contact your dealer

The unit will

not run or

cycles on

and off

Line

disconnect

switch is open

Close the start or

disconnect switch

If the dryer is not operating check the disconnect switch or

circuit breaker to be certain it is on

Fuse or

breaker is

open

Replace fuse or

reset breaker

The fuse to the power line should be checked and

replaced if required. Never replace burned fuse with an

oversized fuse

Faulty

refrigerant

compressor or

controls

Determine the

cause and make

connection

Failure of compressor to run may be caused by several

factors. A qualified refrigeration specialist should check all

electrical and refrigeration controls, or factory should be

contacted if unit is in warranty

Excessive

compressed air

inlet

temperature

Be sure that dryer

is working lower

than maximum

conditions

The dryer is designed for working into calculated

maximum conditions. Should the conditions be exceeded,

the dryer will be overflowed, dew point will go up and

protecting devices can switch off

Excessive

ambient

temperature

Be sure that the

dryer is working

lower than the

maximum

conditions

A high ambient temperature may cause the refrigerant

system to operate at higher than normal pressures.

Results will be a higher than normal evaporator

temperature. Important. There should be adequate air

circulation around the dryer.

Clogged Clear fins of all The clogged fins in the condenser will restrict air passage

Air Dryer 88

International Ltd


condenser fins obstructions and reduce refrigerant capacity causing water

downstream. Fins should be periodically checked and

cleaned

Shortage of

refrigerant

Fix the leak and

add a charge of

refrigerant

Loss of refrigerant will cause improper functioning. A

qualified refrigeration specialist should perform the

necessary repairs, or factory should be contacted if the

unit is in warranty

Err sign

occurs on

digital

temperature

control

device

The dew point

is too low or

too high

Check refrigerant

gas and make

sure that the

working

conditions are

within the correct

range

If there is not enough refrigerant gas or if the working

temperatures are very high then the dew point will

increase

Air Dryer 89

International Ltd


Possible Causes

• Power supply Faulty

• Power supply board defective

- Check voltage on type plate

- Check connections

- Check printed circuit boards for possible damage

Possible causes

• Feed and/or outlet line shut off or blocked

• Worn parts

• Power supply board defective

• Service unit defective

• Dropping below necessary minimum pressure

- Check feed line and outlet line

- Check if valve opens audibly (press test button several

times)

- Check printed circuit board for possible damage

- Check operating pressure

Possible Causes

• Feed line with insufficient slope; cross section too

small

• Excessive condensate quantities

• Service unit extremely dirty

- Lay feed line with adequate slope

- Replace service unit

Possible Causes

- Service Unit defective or dirty

- Replace service unit

Air Dryer 90

International Ltd


Generator 91

International Ltd


1. Emergency Stop

2. Module Isolator

3. Screen

4. Start Button

1. GENERATOR SET

Starting Procedure

1. Ensure the emergency stop button is released, to release rotate button.

2. Turn the Module isolator to ON

3. Push the Button with the “Hand” symbol to clear

4. Push the Green button to start.

Generator 92

International Ltd


Stop Procedure

1. To initiate the stop sequence push the Red Stop Button on the screen ONCE

2. The system will begin its shut down procedure this will take approximately 60 seconds, this helps prevent wear on the engine.

3. Once the engine has completed its stop sequence turn the Module Isolator switch

to OFF, this will prevent the batteries from discharging while the machine is not running.

To turn the generator off without waiting for the cool down procedure push the Red button once.

For all other information relating to the Rapidmix Generator please see separate Generator Manuals.

Generator 93

International Ltd


Hydraulics System 94

International Ltd


GENERAL INSTALLATION, MAINTENANCE

AND FAULT FINDING GUIDE FOR HYDRAULIC POWERPACKS Hydraulic oil used ISO 32 or equivalent

COMPONENTS PARTS LIST

NO PART NUMBER G. DESCRIPTION QTY 1 RAPIDMIX 400 TANK HYDRAULIC TANK 1 2 ESA32 B12 WMF SUCTION FILTER ELEMENT 1 3 FRA51 B12 BNCD 32P RETURN FILTER 1 4 PLP30-34DO THREADED PORTS HYDRAULIC PUMP 1 5 11KW 4POLE 3 PHASE FOOT / FLANGE ELECTRIC MOTOR 1 6 2103-01-18.00 PRESSURE TEST POINT ADAPTOR 1 7 1CER90 F4W 20 S 4 COUNTERBALANCE VALVE 4 8 UC 2001 FLOW CONTROL VALVE 2 9 SD8/7(KG3)18L-18L-18L-18L-18L-18L-18L-AET LEVER OPERATED CONTROL VALVE 1

RAPIDMIX 400 HYDRAULIC RECOMMENDED SPARES

NO PART NUMBER / DESCRIPTION QTY 1 ESA32 B12 WMF SUCTION FILTER ELEMENT 2 2 FRA51 NFD RETURN FILTER ELEMENT 4 3 SD8 / 7 CONTROL VALVE SEAL KIT 1 4 SDB D/A WORKING SECTION 1 5 SD8 LEVER PIVOT BOX 1 6 PLP30 CASSAPA HYDRAULIC PUMP SEAL KIT 1 7 1CER 90 *** 20 S4 OVERCENTRE VALVE CARTRIDGE 1 8 SET OF SEALS FOR EACH HYDRAULIC RAM 1


International Ltd



International Ltd


FOREWORD THE COMPONENTS INCORPORATED IN THE HYDRAULIC SYSTEM HAVE BEEN CAREFULLY SELCETED TO ENSURE EFFICIENT OPERATION UNDER NORMALLY ACCEPTED ENVIROMENTAL CONDITIONS, OR EXCEPTIONAL CONDITIONS SPECIFIED AT THE TIME OF ORDERING. SHOULD THERE BE ANY CHANGE IN EXTERNAL CONDITIONS, OR A NEED TO MODIFY DUTIES, OPERATIONS, OR THE FLUID TYPE USED WITHIN THE SYSTEM, IT IS ADVISABLE TO CHECK FIRST WITH YOUR SUPPLIER. IT SHOULD BE REMEMBERED, THAT IN ORDER TO OBTAIN AND MAINTAIN GOOD OVERALL EFFICIENCY IN ANY HYDRAULICALLY OPERATED POWER SYSTEM, THE MAIN HYDRAULIC COMPONENTS, PUMPS, MOTORS, CYLINDERS AND CONTROL VALVES ARE MANUFACTURED TO VERY CLOSE TOLERANCES. IT THEREFORE FOLLOWS THAT ABSOLUTE CLEANLINESS MUST BE MAINTAINED WITHIN THE SYSTEM. IF IT IS NECESSARY AT ANY TIME TO OPEN THE SYSTEM OR DISMANTLE ITEMS FOR SERVICE, EVERY PRECAUTION MUST BE TAKEN TO PREVENT ANY FOREIGN PARTICLES ENTERING THE SYSTEM. INSTALLATION AND MAINTENANCE INSTRUCTIONS, IF ADHERED TO, SHOULD RESULT IN EFFICIENT TROUBLE FREE OPERATION. INSTALLING AND STARTING UP

1. ENSURE THAT ALL EXTERNAL PIPEWORK INSTALLED BETWEEN POERPACK AND OTHER EQUIPMENT IE. CYLINDERS. VALVES, OR MOTORS, IS ABSOLUTELY CLEAN AND FREE FROM SCALE OR BURRS WHICH MAY BECOME LOOSE WITH A FLOW OF OIL. REMEMBER, SCORED CYLINDER BARREL OR DAMAGED MOTOR MAY NECESSITATE A VERY EXPENSIVE REPLACEMENT EXERCISE.

2. USE COMPRESSION TYPE FITTINGS AND ENSURE THAT TUBE AND HOSES ARE ADEQUATE FOR THE OIL

FLOW AND SYSTEM PRESSURE SPECIFIED. ENSURE THAT OIL RETURN LINES ARE OF SUFFICENT SIZE TO HANDLE A FLOW RATE WHICH DURING PART OF AN OPERATIONAL CYCLE, MAYBE GREATER THAN THE OUTPUT PUMP. A RESTRICTED RETURN LINE MAY CAUSE SLUGGISH OPERATION, OVERHEATING, DAMAGE TO RETURN LINE FILTERS AND COOLERS, OR MALFUNCTION OF VALVES INCORPORATED IN THE SYSTEM.

3. ENSURE THAT CYLINDER BLEED POINTS IF INCORPORTATED, OR ALTERNATIVELY THE PORT

CONNECTORS ON AND HYDRAULIC MOTOR DRAIN ARE FACING UPWARDS.

4. WHERE A RETURN FILTER AND / OR COOLER IS FITTED TO THE POWERPACK, THESE ARE NORMALLY IN SERIES BETWEEN THE RETURN LINE BULKHEAD AND RESERVOIR. IF FITTED EXTERNALLY, ENSURE THAT ALL MAIN RETURN LINES PASS BACK THROUGH COOLER AND FILTER, BUT IS ADVISABLE FOR HYDRAULIC MOTOR DRAIN LINES AND ANY OTHER EXTERNAL DRAIN LINES TO BE PIPED DIRECT TO THE RESERVOIR VIA THE SEPARATION BULKHEAD PROVIDED ON THE POWERPACK.

5. MAKE ELECTRICAL CONNECTIONS TO THE ELECTRIC MOTOR VIA THE STARTER OR CONTROL BOX IF

SUPPLIED. WHERE THE CUSTOMER IS WIRING TO THE MOTOR, A WIRING DIAGRAM IS NORMALLY LOCATED INSIDE THE MOTOR TERMINAL BOX. ENSURE THAT THE MOTOR IS CONNECTED TO GIVE CORRECT DIRECTION OF ROTATION. ELECTRIC MOTOR MAY BE DUAL VOLTAGE TYPE; ENSURE CONNECTIONS MADE ARE APPROPRIATE TO THE PARTICULAR POWER SUPPLY.

6. MAKE ELECTRICAL CONNECTIONS BETWEEN ELECTRICAL SUPPLY, CONTROL BOXES, RELAYS,

PRESSURE SWITCHES OR CONTACTORS ETC. AND TO ANY ELECTRICALLY OPERATED VALVES IN THE SYSTEM.

7. WHERE AN ACCUMULATOR IS INCORPORATED IN THE SYSTEM, CHECK THAT THIS IS CHARGED WITH

NITROGEN TO THE PRE-CHARGE PRESSURE SPECIFIED ON THE CIRCUIT DIAGRAM. OWING TO REGULATIONS PERTAINING TO CARRAIGE OF CERTAIN TYPES OF PRESSURE VESSELS, AN ACCUMULATOR FITTED TO A SYSTEM HAS NOT NECESSARILY BEEN CHARGED PRIOR TO DESPATCH. IF ALREADY PRESSURISED AN INDICATING LABEL IS ATTACHED.


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8. FILL RESERVOIR WITH RECOMMENDED HYDRAULIC FLUID, ENSURING THAT THE STRAINER GAUZE IS IN

SITU AND UNDAMAGED IN THE FILLER CAP RECESS. IT IS RECOMMENDED THAT THE RESERVOIR IS FILLED USING A PORTABLE FILTRATION SYSTEM THUS ENSURING THAT THE HYDRAULIC IS FILTERED TO REQUIRED CLEANLINESS INTO RESERVOIR. FOR NORMAL APPLICATIONS USE MINERAL OIL TO I.S.O. VISCOSITY GRADE 32. ALTHOUGH PLEASE NOTE SHOULD THE UNIT HAVE BEEN SUPPLIED FOR USE WITH SPECIAL FLUID, ENSURE THAT TOPPING UP IS WITH SIMILAR FLUID AND COMPATIBLE WITH NUMEROUS OIL SEALS IN THE SYSTEM.

9. UNLESS PRESSURE RELIEF VALVES HAVE BEEN SET TO A PRE-DETERMINED PRESSURE AND LOCKED IN

POSITION, ADJUST RELIEF VALVE TO MINIMUM PRESSURE BY ROTATING ADJUSTING SCREW IN AN ANTI-CLOCKWISE DIRECTION.

10. BEFORE STARTING SYSTEM, MAKE A FINAL CHECK THAT ALL EXTERNAL PIPEWORK CONNECTIONS HAVE

BEEN TIGHTENED AND THAT ALL CONTROL VALVES ARE IN NEUTRAL POSITION. WHENEVER POSSIBLE; PARTICULARILY WHERE EXPENSIVE CYLINDERS AND MOTORS HAVE BEEN INSTALLED, IT IS ADVISABLE TO BREAK CONNECTIONS TO THESE ITEMS AND MAKE TEMPORARY CONNECTIONS OF FLOW AND RETURN PIPEWORK UNTIL THE SYSTEM HAS BEEN ADEQUATELY FLUSHED AND ANY FOREIGN PARTICILES IN THE SYSTEM ARE TRAPPED IN FILTERS.

11. ENSURE THAT ANY ISOLATING VALVE BETWEEN THE RESERVOIR AND PUMP INLET HAS BEEN FULLY

OPENED.

12. PUMPS FITTED EXTERNALLY BUT WITH GRAVITY FED, DO NOT REQUIRE PRIMING, BUT IN CASE RADIAL PISTON PUMPS IT IS NECESSARY TO BLEED OFF AIR BY LOOSENING OFF THE CYLINDER CAP SCREWS; TIGHTEN AS SOON AS AIR HAS ESCAPED AND OIL IS RUNNING FREELY, WITH AXIAL PISTON PUMPS WITH DRAIN CONNECTION, IT IS ADVISABLE TO FILL THE PUMP CASE DRAIN WITH OIL AT THE DRAIN CONNECTION.

13. START SYSTEM AND SCREW IN PRESSURE RELIEF VALVE ADJUSTING SCREW ONLY SUFFICIENTLY TO

ENSURE THAT OIL IS CIRCULATING. ALLOW TO RUN FOR A MINIMUM PERIOD OF FIVE MINUTES OFF LOAD AND IF THE CYLINDERS AND HYDRAULIC MOTORS HAVE BEEN REMOVED FROM THE CIRCUIT, OPERATE DIRECTIONAL CONTROL VALVES TO ENSURE THAT THE SYSTEM IS COMPLETELY FLUSHED.

14. CHECK FILTERS AND CLEAN OR REPLACE ELEMENTS IF NECESSARY.

15. RECONNECT CYLINDERS AND MOTORS INTO CIRCUIT AND FURTHER ADJUST PRESSURE RELIEF VALVES

TO OBTAIN AN OPERATING FORCE. BLEED AIR FROM HYDRAULIC CYLINDERS PORTS AND OTHER POINTS WHERE IT IS POSSIBLE THAT AIR MAY BE COME TRAPPED, BY LOOSENING CONNECTORS AND ALLOWING AIR TO BE FORCED OUT. TIGHTEN CONNECTIONS WHEN ALL AIR HAS ESCAPED AND ONLY OIL HAS COMMENCED TO LEAK FROM JOINTS.

16. ADJUST PRESSURE RELIEF VALVES TO AND SET AT THE PRESSURES INDICATED ON CIRCUIT DIAGRAM.

17. CHECK VISUALLY FOR ANY LEAKS AND TIGHTEN CONNECTIONS IF REQUIRED AS NECESSARY.

18. CHECK OIL LEVEL AND TOP UP TO HIGH LEVEL REPLACING OIL WHICH HAS BEEN UTILISED IN FILLING

THE SYSTEM. IF SYSTEM IS OPERATING SINGLE ACTING CYLINDERS OR DOUBLE ACTING CYLINDERS (NORMALLY WITH AN AREA DIFFERENTIAL), ENSURE THAT CYLINDERS ARE IN THE RETRACTED POSITION PRIOR TO TOPPING UP AND CHECK THAT WHEN EXTENDED, THERE IS SUFFICIENT OIL REMAINING TO ADEQUATELY COVER SUCTION STRAINERS OR PUMP INLETS.

19. MAKE FINAL ADJUSTMENTS TO PRESSURE RELIEF VALVES AND SPEED CONTROL VALVES AS NECESSARY TO PERFORM OPERATIONS AND SEQUENCES INTENDED.

20. TIGHTEN LOCK NUTS OF ALL ADJUSTING SCREWS AND PREFERABLY SEAL TO AVOID TAMPERING.


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GENERAL PERIODIC MAINTENANCE OF HYDRAULIC EQUIPMENT

1. ALL FIXING BOLTS COUPLINGS PUMP TO PRIME MOVER AND PRIME MOVER TO BASE OR RESERVOIR, TO

BE CHECKED AND TIGHTENED WHERE NECESSARY.

2. CHECK HOSES FOR EXTERNAL DAMAGE AND POSSIBLE BULGING UNDER PRESSURE. REPLACE WORN HOSES.

3. CHECK FOR OIL LEAKS IN SYSTEM AND TIGHTEN PIPELINE CONNECTORS WHERE NECESSARY.

4. CHECK THAT ANY PRESSURE GUAGES IN THE SYSTEM ARE FUNCTIONING AND ZEROING CORRECTLY AND THAT THE PRESSURE RELIEF VALVES HAVE NOT BEEN RESET ABOVE RECOMMENDED FOR SYSTEM.

5. CHECK RESERVOIR OIL LEVEL AND TOP UP AS NECESSARY ENSURING THAT THE STRAINER GUAZE IN

SITU AND UNDAMAGED IN THE FILLER CAP RECESS. IT IS RECOMMENDED THAT THE RESERVOIR IS TOPPED UP USING A PORTABLE FILTRATION SYSTEM THUS ENSURING THE HYDRAULIC FLUID IS FILTERED TO THE REQUIRED CLEANLINESS INTO THE RESERVOIR. FOR NORMAL APPLICATIONS USE MINERAL OIL TO I.S.O. GRADE 32. ALTHOUGH PLEASE NOT SHOULD THE UNIT HAVE BEEN SUPPLIED FOR USE WITH SPECIAL FLUID, ENSURE THAT TOPPING UP IS WITH SIMILAR FLUID AND COMPATIBLE WITH NUMEROUS OIL SEALS IN THE SYSTEM.

6. CHECK VISUAL INDICATORS ON PRESSURE AND RETURN LINE FILTERS AND REPLACE ELEMENTS IF

INDICATOR IS ON DANGER LEVEL OR LIKELY TO REACH DANGER PRIOR TO NEXT SCHEDULED SERVICE.

7. REMOVE END CAPS FROM MECHANICAL OR MANUAL DIRECTIONAL CONTROL VALVES, AND FILL WITH SUITABLE GREASE AND RE-FIT.

8. WITH POWER SUPPLY DISCONNECTED, REMOVE SOLENOID COILS FROM ELECTRICALLY OPERATED

VALVES, CHECK OR DAMPNESS OR RUSTING, CLEAN AND REPLACE.

9. CHECK OIL LEVEL IN ANY REDUCTION GEARBOXES AND TOP UP WITH SUITABLE OIL.

10. WITH POWER SUPPLY DISCONNECTED, CHECK ELECTRICAL CONNECTIONS AND WIRING FOR ADEQUATE INSULATION. CHECK SWITCHES AND CONTACTORS, RELAY POINTS ETC., CLEAN OR REPLACE COMPONENTS AS NECESSARY.

11. EVERY TWELVE MONTHS OR MORE FREQUENTLY IF OPERATING IN A POOR ENVIROMENT, DRAIN OIL

FROM RESERVOIR, CHECK AND CLEAN SUCTIONS STRAINERS OR REPLACE AND FLUSH OUT RESERVOIR. CHECK QUALITY OF HYDRAULIC OIL BEFORE REFILLING AND REPLACE AS NECESSARY. PLEASE NOT THAT IT IS RECOMMENDED THAT A PORTABLE FILTRATION SYSTEM BE USED FOR REFILL THUS ENSURING THAT THE HYDRAULIC FLUID ID FILTERED TO REQUIRED CLEANLINESS INTO RESERVOIR.

12. BEFORE RESTARTING SYSTEM ENSURE THAT ANY ISOLATING VALVE BETWEEN RESERVOIR AND PUMP

HAS BEEN FULLY OPENED TO ALLOW OIL FLOW TO THE PUMP.

13. SPECIAL ATTENTION SHOULD BE PAID TO THE HOSE OR CONNECTING PIPEWORK BETWEEN RESERVOIR AND PUMP. A FAULT DUE TO A DAMAGED HOSE OR LOOSE CONNECTION WILL ALLOW AIR TO BE DRAWN INTO THE SYSTEM WHEN IT IS OPERATING AND VERY QUICKLY DAMAGES THE PUMP.

14. PLEASE NOTE SHOULD IT BE NECESSARY DURING MAINTENANCE TO DRAIN OIL FROM SYSTEM OR

REMOVE ITEMS OF EQUIPMENT FOR SERVICES, THE RELEVANT SECTIONS OF INSTALLING AND START UP PROCEDURES SHOULD BE REFERED TO.

15. WARNING. IF IT IS NECESSARY TO REMOVE AN ACCUMULATOR FROM THE SYSTEM, ENSURE THAT OIL

IS ALREADY DISCHARGED.


International Ltd


FAULT TRACING AND RECTIFICATION

1. SYSTEM DEVELOPS EXCESSIVE NOISE LOCATED IN THE PUMP AREA. SWITCH OFF SYSTEM IMMEDIATELY. CHECK OIL LEVEL IN THE RESERVOIR. IF IT IS A GRAVITY FED SYSTEM, CLOSE THE ISOLATING VALVE FROM THE RESERVOIR. REMOVE PUMP AND PLUG THE OUTGOING PIPEWORK TO AVOID EXCESSIVE OIL LOSS FROM THE SYSTEM. CHECK THE PUMP / MOTOR DRIVE COUPLING IS CORRECTLY FITTED AND IS NOT DAMAGED. IF SATISFACTORY, RUN ELECTRIC MOTOR WITHOUT THE PUMP TO CHECK IF NOISE IS COMING FROM THE MOTOR. IF SATISFACTORY, PUMP IS FAULTY AND MUST BE STRIPPED AND INSPECTED. IF ON STRIPPING THE PUMP THERE ARE SIGNS OF CAVITATION, THE MOST LIKELY CAUSES ARE OIL STARVATION, AIR ENTERING THE PUMP INLET OR AIR ENTERING THROUGH PUMP SHAFT SEAL. CHECK SUCTION STRAINERS, PUMP INLET PIPEWORK, PUMP INLET CONNECTIONS AND PUMP SHAFT SEAL. SHOULD A REPLACEMENT PUMP BE FITTED, IT IS ADVISABLE TO OBTAIN AN EXPERT OPINION AS TO THE CAUSE OF THE ORIGINAL FAILURE BEFORE RESTARTING SYSTEM. ENSURE THAT RESERVOIR ISOLATING VALVE IS OPENED FULLY AND ALL CONNECTIONS REMADE BEFORE RESTARTING SYSTEM. IMPORTANT IF ON CHECKING THE FAULTY PUMP THERE IS EVIDENCE THAT PARTICLES OF METAL FROM THE PUMP MAY BE IN THE SYSTEM, CHECK AT THE PRESSURE LINE FILTER AND CLEAN OR REPLACE FILTER ELEMENT. SHOULD THERE BE NO PRESSURE LINE FILTER IT WILL BE ADVISABLE TO FLUSH THE SYSTEM THROUGH WITH THE CYLINDERS, MOTORS ETC, LIKELY TO SUSTAIN DAMAGE DISCONNECTED FROM THE CIRCUIT.


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2. COMPLETE FAILURE. SYSTEM FAILS TO DEVELOP PRESSURE .

SWITCH OFF THE SYSTEM. CAUSE IS MOST LIKELY PUMP FAILURE OR MAIN SYSTEM PRESSURE RELIEF VALVE JAMMED IN THE OPEN POSITION. DISCONNECT THE RELIEF VALVE FROM THE SYSTEM AND DISMANTLE; CHECK THAT THE MAIN SPOOL AND PILOT SPOOL WHERE APPLICABLE ARE FREE MOVING. CHECK THAT NO DAMAGE HAS OCCURRED, RE-FIT TO SYSTEM. RESTART SYSTEM AND CHECK FOR PRESSURE. IF STILL NO PRESSURE, WITH THE PUMP RUNNING, DISCONNECT THE RETURN LINE CONNECTOR NEAR TO THE RESERVOIR AND CHECK FOR OIL FLOW. IF THERE IS NO OIL FLOW, CARRY OUT CHECK AND RECTIFICATION AS DETAILED IN FAULT TRACING AND RECTIFICATION NUMBER ONE. IF THERE IS SATISFACTORY OIL FLOW, IT IS PROBABLE THAT A VALVE IN THE CIRCUIT, DIRECTIONAL CONTROL, SEQUENCE OR UNLOADER HAS JAMMED IN A POSITION TO GIVE OIL FLOW TO RESERVOIR. SWITCH OFF SYSTEM. DISMANTLE VALVES, CHECK AND RECTIFY AS NECESSARY AND RE-FIT. RE-MAKE ALL CONNECTIONS AND RESTART. IMPORTANT WHEN IT IS NECESSARY TO REMOVE ITEMS FROM THE SYSTEM, PARTICULARILY IF THERE IS PART OF THE SYSTEM ABOVE THE LEVEL OF THE ITEM TO BE REMOVED, IT IS ADVISABLE TO HAVE READY SUITABLE PLUGS AND BLANKING PLATES TO TEMPORARILY BLOCK OFF CONNECTING PIPEWORK. THIS WILL PREVENT EXCESSIVE LOSS OF OIL AND INGRESS OF DIRT AND AIR. IT MAY STILL BE NECESSARY ON RESTARTING TO BLEED AIR FROM THE SYSTEM. ENSURE THAT ANY PLUGS USED ARE PERFECTLY CLEAN AND THAT SUBPLATE OR MANIFOLD SURFACES ARE SUITABLY COVERED ON REMOVAL OF VALVES. ENSURE THAT ALL O-RING SEALS ARE CORRECTLY IN PLACE WHEN REFITTING VALVES. IF VARIABLE SWASHPLATE PUMP IS INCORPORATED IN SYSTEM, CHECK THAT THE SWASHPLATE IS NOT LOCKED AT A NO FLOW ANGLE.


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3. PARTIAL FAILURE. INSUFFICIENT PRESSURE DEVELOPE D.

SWITCH OFF THE SYSTEM. BREAK CONNECTION ON OUTGOING SYSTEM SIDE OF PRESSURE RELIEF VALVE AND PLUG OFF AT RELIEF, EFFECTIVELY LEAVING ONLY THE HYDRAULIC PUMP AND PRESSURE RELIEF VALVE IN THE CIRCUIT. ON NO ACCOUNT SHOULD THE CIRCUIT BE BLOCKED OFF AT THE OUTLET OF THE PUMP. ENSURE THAT A PRESSURE GUAGE IS CONNECTED TO THE PUMP / PRESSURE RELIEF VALVE CIRCUIT. START SYSTEM AND CHECK IF REQUIRED PRESSURE IS REGISTERED. IF INSUFFICIENT PRESSURE IS OBTAINABLE BY ADJUSTMENT OF THE RELIEF VALVE ADJUSTING SCREW, SHUT OFF SYSTEM. CARRY OUT CHECK AND NECESSARY REDTIFICATION TO PRESSURE RELIEF VALVE AS DETAILED IN FAULT TRACING AND RECTIFICATION NUMBER TWO. IF THERE WAS NO APPARENT FAULT AND STILL INSUFFIEIENT, CARRY OUT CHECK AND ANY NECESSARY RECTIFICATION TO THE PUMP AS DETAILED IN FAULT TRACING AND RECTIFICATION NUMBER ONE. IF SUFFICIENT PRESSURE IS OBTAINABLE AT THIS POINT, THE FAULT IS ELSEWHERE. SWITCH OFF THE SYSTEM, REMAKE CONNECTIONS AT PRESSURE RELIEF VALVE AND DISCONNECT CYLINDERS AND / OR HYDRAULIC MOTORS FROM SYSTEM. PLUG THE SYSTEM. PLUG THE SYSTEM PIPEWORK AT THIS POINT AND RESTART SYSTEM. SELECT ANY DIRECTIONAL CONTROLS AS IF TO OPERATE CYLINDERS OR MOTORS AND CHECK PRESSURE OBTAINABLE ON GUAGE. IF INSUFFICIENT PRESSURE IS OBTAINABLE GO TO FIRST PARAGRAPH SHOWN ON PAGE NINE. IF SUFFICIENT PRESSURE IS REGISTERED THE FAULT IS IN THE CYLINDER OR MOTOR. A LEAKY CYLINDER PISTON CAN EASILY BE DETECTED BY PRESSURISING TO FULL STROKE AND CHECKING LEAKAGE AT THE OPPOSITE PORT. REPLACE CYLINDER SEALS OR RETURN TO SUPPLIER FOR RECTIFICATION. AN INEFFICIENT MOTOR IS LESS EASY TO DIAGNOSE; ON NO ACCOUNT SHOULD THE MOTOR OUTLET BE BLOCKED. RETURN MOTOR TO SUPPLIER FOR RECTIFICATION.


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4. PARTICAL FAILURE. INSUFFICIENT PRESSURE DEVELOP ED. (CONTINUED)

IF REQUIRED PRESSURE CANNOT BE OBTAINED, IT WEILL BE NECESSARY TO CHECK OTHER VALVES IN THE SYSTEM FOR DAMAGE OR WEAR RESULTING IN AN EXCESSIVE LEAKAGE TO THE LOW PRESSURE RETURN SIDE OF THE SYSTEM. EITHER DISMANTLE AND CHECK EACH VALVE, OR BY A PROCESS OF ELIMINATION, BLOCK OFF PARTS OF THE SYSTEM WORKING OUTWARDS FROM THE RELIEF VALVE UNTIL THE FAULT IS LOCATED. WHEN FAULTY VALVE IS LOCATED RETURN TO SUPPLIER FOR RECTIFICATION OR REPLACE WITH NEW ITEM. IMPORTANT WHEN BLOCKING LINES TO TRACE A FAULT, IT IS ESSENTAIL THAT RETURN LINES REMAIN CONNECTED. FAILURE TO DO THIS MAY RESULT IN DAMAGE TO VALVES, MOTORS OR CYLINDERS AND POSSIBLE BURST LINES OR EQUIPMENT DUE TO PRESSURE. INTENSIFICATION FROM CYLINDER. SPECIAL POINTS TO BE NOTED.

1. A BURST SYSTEM CAN MAIM OR KILL. IF IN DOUBT PLEASE CONTACT A HYDRAULICS SPECIALIST.

2. ELECTRICAL FAULTS SHOULD BE DIAGNOSED AND CORRECTED BY A FULLY QUALIFIED

PERSON.

3. SHOULD THERE BE A LONG DEALY IN INSTALLING THE SYSTEM AND COMMENCING OPERATION, OR SHOULD THE SYSTEM BE TAKEN OUT OF SERVICE FOR A LONG PERIOD OF TIME, STORE IN A DRY EVEN TEMPERATURE, OR ENSURE THAT THE SYSTEM INCLUDING PIPEWORK AND ALL VALVES IS FULL OF OIL, OR THE SYSTEMS IS PERIODICALLY OPERATED IN ORDER TO FLUSH WITH OIL.

4. THIS GUIDE TO INSTALLATION, MAINTENANCE AND FAULT TRACING IS GENERAL. PLEASE

REFER TO ACCOMPANYING DOCUMENTS FOR ADDITIONAL INFORMATION, CIRCUIT DIAGRAMS ETC. RELATING TO THE SUPPLIED SYSTEM.

THE INFORMATION CONTAINED IN THIS BOOKLET IS INTENDED TO BE HELPFUL. HYDRODYNAMICS POWER ENGINEERING LTD WILL NOT ACCEPT RESPONSIBILITY FOR DAMAGE OR INJURY RESULTING FROM FOLLOWING SUGGESTED PROCEDURES.

Components Lists 103

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Genset & Compressor Part Number Genset

COMPONENT DESCRIPTION AND SPECIFICATION PART No. QTY. GENSET Iveco 196 KVA N67TE2X Tier 3 c-genset-03 1

Compressor

COMPONENT DESCRIPTION AND SPECIFICATION PART No. QTY. COMPRESSOR Hydrovane HV07RM Compressor c-compre-10 1 DRYER CompAir F0011C Dryer To Suit

HV07RM c-airdry-03 1

Maintenance Schedule 104

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Schedules The schedules which follow must be applied at the interval (hours or months) which occur first. A. Every day or every 8 hours. B. Every 450 hours or 6 months C. Every 900 hours or 12 months D. Every 3600 hours or 24 months E. Every 5000 hours F. Every 6700 to 7500 hours H. Annually I. First at 500 hours then every 2500 or 6 months J. Monthly or every 160 hours

A B C D E F G H I J Operation

• Clean Mixer Thoroughly

• Grease front and back twin shaft bearings

• Check seals on mixer back plate and Bull Gear Housing

• Check coupling rubber inserts for wear and coupling alignment

• Renew Mixer Bull Gear oil with VG 220 (mm2/s @ 40oC) Grade oil (max on gauge)

• Renew Mixer Gearbox oil with VG 220 (mm2/s @ 40oC) Grade oil 14L

• Renew Mixer Conveyor Gear Oil with VG 220 (mm2/s @ 40oC) Grade oil 5L

• Grease front and back bearings on clean out conveyor

• Check Motor for vibration, noise or overheating

• On PRV Check the area near the valve is free from material.

• Remove the cover to remove any crusts that have formed on PRV

• Check the diaphragm on Pressure Relief Valve moves freely.

• Replace Springs on Pressure Relief Valve

• Replace Rotary Valve oil with VG 220 (mm2/s @ 40oC) Grade oil 4.7L

• Replace oil in Bin Drag out Conveyor with VG 220 (mm2/s @ 40oC) Grade oil 5.1L

• Open air manifold tap to remove any moisture collected, measure pressure differential on silo filter

• Check clean air outlet on silo filter

• Check cartridges on silo filter

• Check external seals and fastening clamps on silo filter

• Check cleaning cycle works correctly on silo filter

• Check timing in operation and pause intervals is correct on silo filter

• Check electric motor and fan on silo filter

• Check inspection hatch is still tight and top cover is well fastened on silo filter

• Check electrovalves and diaphragm valves are operating correctly on silo filter

• Clean Bins Thoroughly

• Oil Chain Drive On Drag Out Conveyor


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A B C D E F G H I J Operation • Replace oil in Van der Graaf drum gearbox on outloading conveyor see table page

12 for details / grade. • Grease front and back bearings on out loading conveyor

• Check Hydraulic system for leaks and hoses for bulging or external damage

• Replace Hydraulic Oil with ISO 32 Grade approx 400L for full system

• Check Oil Level in Compressor

• Drain Compressor Air Receiver

• Remove Compressor Air Intake Element and Replace if Dirty

• Check Compressor Belt Tension and Adjust if Necessary

• Check Compressor Cylinder Head Bolts and Adjust if Required See P90

• Clean Outer Surfaces of Compressor to maintain cooling

• Clean and Check Inlet and Discharge Valves and Replace if Worn or Damaged

• Replace Oil In Compressor With Type 30 Select Synthetic Lubricant

• Check Belt Tracking and Skirt Rubbers

• Ensure that the Genset coolant is at the correct level

• Check the Genset intercooler and the coolant radiator for debris

• Check, and adjust if necessary, the antifreeze mixture (2)

• Test the level of coolant conditioner, and adjust if necessary (2)

• Check the condition of the drive belt on the Genset

• Renew the Genset coolant (4)

• Renew the canister of the coolant filter on Genset (3)

• Inspect the thermostat on Genset (2)

• Drain water from the fuel pre-filter on Genset (1)

• Renew the canister of the fuel filter and renew the fuel strainer on Genset

• Check the amount of lubricating oil in the stump of the Genset

• Check the lubricating oil pressure at the gauge of Genset (1)

• Renew the engine lubricating oil on Genset (5)

• Renew the canister of the lubricating oil filter on Genset

• Clean or renew the Genset air filter element (or earlier if in extremely dusty conditions)

• Ensure that the valve tip clearances of the engine on the Genset are checked and, if necessary, adjusted (2)

• Ensure that the Genset turbocharger impeller and the turbocharger compressor casing are cleaned (2)

• Ensure that the Genset alternator, the starter motor, and the turbo charger are checked

• Inspect the electrical system (2)


International Ltd


1. If one is fitted. 2. By a person who has had the correct training. 3. Also if the coolant system has been drained. 4. The system should be flushed and a new canister fitted. 5. The oil change interval will change with the sulphur content of the fuel (see the table below

and the Fuel Specification in section 5). The interval to change the canister of the lubricating oil filter is not affected.

Use the POWERPART test-kit , part number 26550004

Fuel sulphur content (%)

Oil change interval

<0.5 Normal 0.5 to 1.0 75% of normal

>1.0 50% of normal

Rapid International USA Inc. 7081 Brighton Blvd Commerce City Denver Colorado 80022 Tel (303) 853 0068 Fax (303) 286 1416

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