RKES CONTROL SIFTER MANUAL

MACHINE INDUSTRY AND TRADE INC.
FLOOR AND FEED TECHNOLOGY
INSTRUCTION MANUAL
CONTROL SIFTER Type: RKES
RKES-M.2011.0
ALAPALA Mak. Gıda San. ve Tic. A.Ş.
Established In: 1954
SCOPE OF WORK:
The design, manufacturing and turn-key supply of wheat flour, semolina mills,
maize semolina mills and animal feed mill, and after-sale services.
Steel construction building design, manufacturing, erection, sales and after-sale

services.
ADDRESS:
Factory : Organize Sanayi Bölgesi 12. Cad. 19040 - ÇORUM/TÜRKİYE
Marketing&Sales : Dünya Tic. Merkezi A2 Blok Nr:159 Yeşilköy/İSTANBUL/TÜRKİYE
CONTACT DETAILS:
Factory : Tel: +90 364 254 95 60 (Pbx-5)

Fax: +90 364 254 92 90
Marketing&Sales : Tel: +90 212 465 60 40-41

Fax: +90 212 465 60 42
Web: www.alapala.com ; e-mail: info@alapala.com,
RKES SERIES CONTROL SIFTER MANUAL Page - 1

SUMMARY
1
REGULATIONS AND GENERAL WARNINGS 5
REGULATIONS AND GENERAL WARNINGS 5
SYMBOLS DESCRIPTION 6
LIMITATIONS 9
RESPONSIBILITY 9
CONDITIONS OF WARRANTY 9
LIMITS OF USE 10
ENVIRONMENT CONDITIONS FOR INSTALLATION 10
ARRANGEMENTS TO BE ORGANISED BY THE CUSTOMER 12
SAFETY DEVICES ABOARD THE MACHINE 13
SAFETY RULES (RESIDUAL RISKS) 13
2
IDENTIFICATION AND TRANSPORT 15
MACHINE IDENTIFICATION 15
TRANSPORT 16
UNLOADING - STORAGE OF THE PARTS 17
CHECKING DELIVERY 18
3
DESCRIPTION AND MANUFACTURING CHARACTERISTICS 19
GENERAL DESCRIPTION 19
RANGE OF MODELS AND TONNAGE 19
STRUCTURAL FEATURES 20
PRODUCT INLET UNIT 21
CHASSIS 21
SIEVES 22
BODY 22
SIFTER TENSION SYSTEM 22
VIBRATION HANDLES 24
BEARING HOUSING AND MOTOR GROUP 24
PRODUCT OUTLET 25
SUSTAIN AND GRADE STANDS 25
4
TECHNICAL DATA AND WEIGHTS FOR HANDLING 27
RANGE OF MODELS AND TONNAGE 27
CONTROL SIFTER PROCESS 28
CAPACITY AND DIMENSIONS 30
CHARACTERISTICS CONSTRUCTION 31
SOME EXAMPLE 32

5
ASSEMBLING AND SET AT WORK 33
PROCEDURE IN SAFETY DURING THE ASSEMBLING 33
ASSEMBLING THE MACHINE 34
ELECTRICAL CONNECTION 34
STARTING AND TESTING 35
MOTION CONVEYOR SYSTEM 36
POSITION OF THE MACHINE 36
6
USE AND MAINTENANCE 37
USE 37
MAINTENANCE 38
LUBRICATION 41
SPARE PARTS 45
EQUIPMENT FOR THE MAINTENANCE 47
7
DISMANTLING AND DISPOSAL 49
DISMANTLING 49
ELIMINATION 50
8
Information sheet for the ATEX DIRECTIVE 51
NEWS FOR THE SAFETY AT WORKING PLACES 51
NEWS CE MARKING 56
ASSOCIATION FOR DANGEROUS ZONES-ATEX CATEGORY FOR INSTRUMENTS OF GROUP II 57
SUPPLEMENTARY MARKS FORESEEN BY THE TECHNICAL NORMS OF CONSTRUCTION 57
MARKS IN SENSE OF THE CERTIFICATION 58

1
RKES SERIES CONTROL SIFTER

ASSEMBLY, MAINTENANCE AND USER MANUAL
REGULATIONS AND GENERAL WARNINGS

REGULATIONS AND GENERAL WARNINGS
We thank you for having chosen an RKES Series Control Sifter. As you can see, it is an especially robust
machine which is easy toassemble and simple to maintain. In the course of time, you will discover all the
advantages to be gained from your choice interms of performance, consumption and maintenance costs.
This manual is principally addressed to:

-the machine’s final owner
-the plant’s technical manager
-the plant’s safety manager
-the personnel delegated to the handling of the parts, assembly and start up of the Machine
-the personnel designated to use the Machine
-the personnel delegated to the machine’s maintenance
-the personnel delegated to the machine’s dismantling
All the information contained in this manual pertains principally to:
-the machine’s technical characteristics
-the instructions necessary for the machine’s handling, assembly and use
-the instructions for the machine’s correct maintenance
-the instructions for operation of the machine under conditions of safety

SYMBOLS DESCRIPTION
IMPORTANT!
For their safety, it is strongly recommended to the people operating or adjusting the
machinery or dealing with the machinery for any other purposes, to read the warning instructions in
this document and to behave accordingly.
The well understanding of the warnings is important. If they are not understandable, because
of the inadequate explanation or other reason, ‘ALAPALA MAK. GIDA SAN. VE TİC. A.Ş.’
should be noticed immediately.
In addition, during the operation, adjustment and maintenance of the machinery, attention
must be paid to the warning labels and notes on the machinery. The warn out labels and notes are to
be renewed by the operator.
It should not be forgotten that; the problems caused by operator mistakes, inadequate and
incomplete maintanance, wrong fuel and oil usage are of warranty.
THIS DOCUMENT MUST BE KEPT AT A PLACE THAT THE OPERATOR CAN EASILY
REACH AND IF POSSIBLE TO BE KEPT ON THE MACHINE.
The meanings of the symbols and signals used in this manual
Watch Your Hands Don’t Operate Without Guard
Read the Written Instructions Lifting Point
Use Appropriate Equipment Do Not Insert Your Hands
Danger Smoking and Open Flame Forbidden
Don’t Touch Attention! Moving Components
Periodical Checks Case of Panic
Maintenance and Repairement Ask In Case of Doubt
Use personal protective Cleaning Regularly
Electrical Hazard Do Not Approach
Pest Status Use Protective Clothes

3.1. General Warnings
Warning
This machine is designed and manufactured for only sorting and sifting out the
grain flour. DO NOT use for any other purpose.
The workplace MUST be properly illuminated for seeing the operation clearly by
the staff.
Please DO NOT make any changes on the Machine without a written permission
from the Original Equipment Manufaturer.
This Machine can ONLY be operated by an operator that is over 18 years of age,
with no addiction to Alcohol, and similar substances, and capable of operating
Flour Mill Machines.
The tools and apparatus provided by the Manufacturer should be used for
Maintenance and Repair. If appropriate, the substitutes or similar tools can also be
used.
Please do not forget that hazardous lubricants, hydraulic, and other mineral oils are
being used in the machine. These hazardous liquids are detrimental to Human
Health and Safety in case of leakage, regular changes, and discharge for
maintenance purposes. NEVER approach the machine with fire, flammables, and
cigarettes during discharge or changeover.
Please DO NOT hold and lift the machine by bare hands while carrying. Use
appropriate lifting equipment. Please follow the instructions in ‘Instructional
regulations for lifting and carrying by hands, # R.G. 11.02.2004-25370’.
3.2. Warnings Related to Machine Controls

Warning
Some of the Machine Controls may be multifunctional (forward-backward shift,

movement etc). Therefore, please pay attention to the signs, and instructions on
the decals/labels on the machine for proper use.
Please make sure that there is no one nearby before start up. Keep Children and
Pets away from the Machine.
3.3. Warnings Related to Mechanical Accidents

Warning
Some mechanical parts have limited operational life. These parts MUST be replaced
by spares according to the list and instructions in Maintenance Manual. The
wornout metal parts may cause accidents if they break up during operation.
Please follow all Maintenance instructions strictly to avoid incidents and accidents.
3.4. Warnings For Covers, Guards and Protective Parts

Warning
The covers and guards on the machine protects operators against accidents. Please
make sure that the covers and guards are in proper position while running the
machine to avoid accident risk.

3.5. Warnings For Maintenance and Repair Activities
Warning
All set up, repair, maintenance, cleaning and service activities should be carried out
by trained, qualified personnel.
Please make sure the machine is turned off, and all turning, reciprocating, and
vibrating elements stalled, and also the machine is safe guarded before performing
set up, maintenance, repair, cleaning and servicing. The turn key should be
displaced from the machine and kept by the operator during these activities.
Do not clean up the machine in operation. NEVER use flammable material for
cleaning purposes.
Please turn down the system pressure before working with pneumatic equipment
on the machine.
Please make sure that tools and material used for Maintenance, cleaning, servicing
are not left on the machine before start up.
The warnings, cautions, instructions and signals should NOT be removed from the
machine. Please renew all instructional, and warning labels immidiately as they
wear out.
Mineral oils, Grease, Lubricant and other liquids in the machine may be hazardous.
These material iritate eyes. Use proper lubricator cans, grease cans and similar
tools, and wear your safety glasses to avoid any splash, split that may cause eye
iritation. Make sure that proper neoprene or nytril gloves is worn while working
with these materials.
3.6. Warnings For The Risks Imposed By Moving Parts Of The Machine
Warning
The operator must check out all guards and covers are in place, and functional
before staring up the machine.
DO NOT put or insert your hands through into the vibrating and moving sections.
DO NOT enter the vibrating or moving machines.
3.7. Warnings For Personal Protection

Warning
Please use protective safety shoes, glasses, gloves and other necessary stuff during
maintenance, cleaning, and lubricating.
Please properly dressed up to avoid any jam or squeeze in moving parts of the
machine. Please wear your safety shoes during installation, maintenance or
dismantling of the machine.
Please use ear protection to avoid hearing losses.
Please use protective mask to avoid breathing dust.
Please use protective gloves during adjustments, maintenance and repair activities.

LIMITATIONS
This manual:
-can never completely substitute for the direct experience of the user
-can never include all the case studies relative to the machine’s installation and working conditions
(these being tied to the plant in which the machine is to be installed)
-for the more complex operations, it cannot represent anything more than a memorandum, such
operations being bound to the context of the plant in which the machine is to be installed.
This manual must be considered as being an integral part of the machine and must be correctly
preserved for any reference and/or consultation up to the disassembly of the machine itself.
Furthermore, it must be preserved in a place adjacent to the machine so that it can be consulted easily.
This manual represents the state of the art at the time of sale of the CONTROL SIFTER to you,
however, we reserve ourselves the right to produce, without any obligation of notice and communication,
all the updates arising from constructional modifications and/or new experiences with regards to the
handling, assembly, start up and use of our RKES Series CONTROL SIFTERs.
RESPONSIBILITY
Our company considers itself to be above any responsibility in the case of:
-an improper use of the Machine
-a use contrary to the current regulations in matters of safety and accident prevention
-an incorrect assembly and installation
-a defective electrical supply
-serious insufficiency of maintenance provided for the Machine
-any modifications and interventions on the machine that are not expressly authorised
-use of unspecific spare parts or materials not expressly authorised
-non-observance (even partially) of the instructions furnished with this manual
-exceptional events.
CONDITIONS OF WARRANTY
The warranty on the CONTROL SIFTER purchased by you, with the exception of different written
agreement, is 12 months from the date of delivery. Such warranty regards all the faulty parts
manufactured by us, which will be replaced by our factory at ÇORUM.
The respective manufacturers’ conditions apply to all the accessory materials (such as the vibroting
motor, hoppers, sıfter etc.).

LIMITS OF USE
The RKES Series CONTROL SIFTER; It is used in cereal processing plants especially where wheat
semolina is produced and in common flour mills in case of requirement.
The machine’s conditions of use and the performance were specified when it was sold.
Any use of the machine over and above what was specifically expected at the moment of purchase,
without our preventive authorization, involves the release of all responsibility for possible damages to
people or objects and the decline of the normal conditions of warranty.
It is used to separate the stones effectivly from the raw material in cereal processing plants.
The separation application is carried out by considering spesific weight, the heavy materials are separated
from light materials.
-the regulations contained in this manual
-the legal regulations in matters of safety and accident prevention
-the sector’s operating procedures if they are not in contrast with the previous points.
We remind you that these machines present a high risk with regards to possible explosion of the dusts
which are suspended inside the machines when they are running. Such dusts cannot be removed and
thus it is necessary to perform all the checks suggested in this manual, so as to drastically reduce the
risk of an explosion. Furthermore, it is advisable to provide an aspiration system for the dusts in the
CONTROL SIFTER’s plant of destination so that the machine works under slightly lowered pressure, and
a system to remove all the foreign metal parts from the product, which could cause internal sparks. It is
further advised to install all the safety systems provided in the options for the machine,
These accessories are extremely important in the prevention of explosions.
Should you require any further information or clarification with regard to what is contained in this manual,
kindly do not hesitate to contact our Technical Service.
We remind you that only a firm respect of what is reported in this technical handbook about assembling,
starting, use and maintenance of the RKES Series CONTROL SIFTER, will grant you the best utilisation
of the machine in the long run.
ENVIRONMENT CONDITIONS FOR INSTALLATION
The staff involved in the assembling, installation and maintenance of the RKES Series CONTROL
SIFTER has to operate in:
-general safety conditions of the working environment in accordance with what is provided by the
existing regulations
-specific safety conditions for the machine’s assembly in accordance with what is provided by the
existing regulations
-suitable working area conditions with regards to the lighting, ventilation and cleanliness of the machine’s
installation room

-suitable conditions of accessibility to the machine (with ladders, gangways, galleries, etc. suitable for
working under safe conditions in accordance with the regulations in force)
In the absence of adequate conditions of safety and accident prevention for operators, then any
assembly, start up, maintenance or disassembly operations must be forbidden.
Particular attention must be given to the ventilation and cleanliness of the installation premises
(especially if the CONTROL SIFTER is used for easilyperishable or particularly powdery products), and
to their possible rat disinfestation.
The emission of harmful gases deriving from the fermentation processes of the transported product, the
presence of highly flammable dusts, the presence of rat excrement and urine, all represent specific risks
for the operators and therefore all the actions necessary for the cleanliness and ventilation of the
premises must be taken prior to any intervention.
AIRING
The CONTROL SIFTER has to be installed in properly aired places according to the current legislation.
As previously said, the fermentation process due to the deterioration of the product conveyed, may
produce carbon dioxide, therefore, especially for maintenance it is necessary to verify if the place has
been properly aerated to avoid the presence of this lethal gas. Even the concentration of dust can be
dangerous since the dust of cereals are inflammable. It is therefore necessary to clean and air the place
to avoid the uncontrolled flames.
TEMPERATURE
The CONTROL SIFTER are manufactured in steel, therefore they have a high conductivity. Their use in
particular climatic conditions or with products having high temperatures may produce an overheating of
the machine with risk for the staff.
In these cases, all the safety measures have to respect to the laws of the country where the CONTROL
SIFTER is installed.
LIGHTING
The supply does not provide for any lighting system for the machine, as it is not necessary for its
operation. The Purchaser must in any case prepare a lighting system in the installation premises, in
accordance with the existing regulations. In the event that the lighting is insufficient, naked flames must
not be used in order to avoid the risk of an explosion in the presence of dusts.
ELECTROCUTION HAZARD
The machine’s connection must be carried out with the strictest respect for the regulations in force. It is
forbidden to use the machine if the electrical system has not been provided with a “Declaration of
Electrical Conformity”.

FIRE HAZARD
It is forbidden to store inflammable substances such as pallets and wood in general, solvents, lubricants,
fuels and any other flammable goods near the elevator, so as to avoid - in the event of a fire - the flames
from spreading to the machine’s proximity.
EXPLOSION HAZARD
As has already been pointed out, cereal dusts are highly explosive. Therefore, it is necessary to keep
the installation premise sclean and ventilated and to carefully avoid the use of naked flames - especially
in the presence of suspended dusts.
VIBRATIONS
The vibrations induced by the working of the CONTROL SIFTER (with a correct assembly) are
absolutely marginal, therefore they do not prejudice the operators’ safety in any way.
POLLUTING SUBSTANCES
The CONTROL SIFTERs of the RKES Series do not produce pollutant substances. The problems of
pollution can only come from the type of conveyed product. The cereal, especially when they are humid,
are perishable and their stagnation inside the machine causes fermentation and presence of carbon
dioxide. At the same time, cereals are very attractive for insects and rats that can defile the environment
with their excrements and urine representing a serious risk for the staff. It is therefore fundamental to
keep in clean conditions the machines and the places of installation.
ARRANGEMENTS TO BE ORGANISED BY THE CUSTOMER
The CONTROL SIFTERs of the RKES Series are installed inside a plant. The Customer, except different
agreement at the moment of purchase, will be in charge of preparing the following things:
-suitable means of transport which will be specified before delivery of the materials
-adequate means of lifting and handling for the unloading of the boxes with relative operators
-an adequate place for the storage of the components prior to their assembly
-the organisation of possible civil engineering works to be carried out according to the manufacturer’s
instructions
-the preparation of possible carpentry structures for the machine’s support and inspection
-the preparation of the electrical system
-the skilled personnel and casual workers required for the assembly
-adequate means of lifting and handling for the assembly, as well as possible scaffolding, ladders and
aerial platforms
-the assistance during the possible testing of skilled personnel for the electrical and pneumatic systems.

SAFETY DEVICES ABOARD THE MACHINE
The CONTROL SIFTERs of the RKES Series have been designed and produced with a particular
attention to safety measures and prevention of accidents for the staff. The machines are provided of the
following safety measures:
-Blunting of all the sharp edges in the steel structure of the machine.
-Protection of all the parts in motion with covers or timing case, secured with bolts.
-Installation on the head station of a pair of big inspection holes to check the level of the product in the
final exit (with exclusionof the RKES Series)
-Predisposition of accident prevention signals on the machine.
SAFETY RULES (RESIDUAL RISKS)
-The CONTROL SIFTERs of the RKES Series have been studied and realised to operate in a safe and
reliable way when all the rule scontained in this Technical Handbook are respected. Therefore, it is
necessary to read carefully all parts of the present Technical Handbook.
-We decline all responsibility for damages or injuries due to the non-observance of the rules and
instructions contained in this Technical Handbook.
-The assembling, starting and maintaining of the machine have to made by skilled staff who knows
perfectly the features and employ of a CONTROL SIFTER, the risks in its use and the rules contained in
this Technical Handbook.
-The uagee of the CONTROL SIFTER must respect the rules contained in this Technical Handbook.
-The machine is not provided with electrical control board. The user is therefore responsible for the
connection to the general control board. This connection must respect the current legislation of the
country where the machine is installed. It will be provided of a sectioning system before the machine. In
particular the electrical plant has to be provided of an automatic release system before the general
control board and of a specific earthing plant in conformity with the recent laws.
-Do not use the machine if not provided of a “Declaration of Electrical Conformity”.
-In order to avoid risks of injury, use only electrical tools correctly connected to the earthing plant and in
conformity with the recent laws.
-Before every intervention on the CONTROL SIFTER, verify if the power has been switched off (F/F
position) so as to take off the input during the intervention.
- Before stopping the machine, make sure that all the moving parts are stopped. If necessary wait some
time for a complete unloading and use the switch to stop the machine.
- Before the starting of the machine, check the presence of warning light on the control board. It is
necessary that all the parts of the machine are in function. To start the machine, use the switch.
-For a prevention of all risks, it is necessary to point out with proper signs any intervention of maintaining
on the machine.

- In case of lack of an adequate illumination, the operator has to use a flashlight at least of 100 Lux for
maintenance.
-Every intervention inside or outside the machine has to be executed with protection equipments (gloves,
dust masks, safety shoes, safety glasses, ear-protections, helmets etc.). Do not stand beside the
machine with ragged or dangling clothes, scarfs, unbuttoned jackets or any other dress that may get
entangled in the moving parts of the CONTROL SIFTER.
-Before every intervention make sure to operate in safe conditions and that access and passage ways
are clear and without obstacles.
-Do not tamper with the fastening systems of the machine or with the earthing circuit.
-Do not take away, remove or cover (even partially) the sign-boards, the labels or other devices
containing informations about the CONTROL SIFTER.
-Do not use the machine as a support since stands and supports have been designed and dimensioned
to be loaded ulterior. Do not walk on the machine’s covers, they haven’t been designed for this use and
are unprovided of safety measures.
-Do not use hands or other not suitable means to locate leaks of air or liquid or to catch parts in motion.
-Before every intervention of maintenance check if the superficial temperature of the mechanical and
structural part is on normal values. In case of conveyance of hot materials, before opening the machine,
wait the fall of temperature to a value close to the room temperature.
-Verify if the place of installation of the CONTROL SIFTER is well aired and if there are the hygienic
conditions to operate in safety. Even in case of urgency do not operate any intervention on the machine
in closed or dusty or not suitable places.
-Do not tamper with the protections and with the safety devices of the machine. In case of opening of the
CONTROL SIFTER, check if all the bolts have been properly fastened before setting the CONTROL
SIFTER in motion.
-Do not make any adjustment, lubrication or cleaning while the machine is in function.
-All the operations of maintenance that require the removal of the protection devices are under the
responsibility of the purchaser. For these operations in particular, we suggest to employ only technical
skilled and authorised staff.
-To lift, move, or install the parts of the CONTROL SIFTER use only means that are suitable to the
weight and to the geometrical features of the piece to be moved. The access to the area where the
machine is operating has to be controlled.
-In case of operations in banked CONTROL SIFTERs use only ladders, movable platforms, scaffolds or
others means of lifting in agreement with the current laws.
-Avoid hasty or provisional fixings that may represent a risk for the staff and compromise the correct
functioning of the CONTROL SIFTER.
All these rules don’t substitute the rules about safety and prevention of accidents of the country where
the CONTROL SIFTER is installed, they only integrate them.

2

MANUAL OF ASSEMBLING, USE AND MAINTENANCE
IDENTIFICATION AND TRANSPORT

MACHINE IDENTIFICATION
RKES 85/8
Control Sifter The number of sieve The dimension of sieve
Every CONTROL SIFTER of the RKES Series is provided with an identification plate set on the
body. It includes the following identification data:
-Model
-Serial Number
-Year of Construction

Other data regarding the electric motor unit and the electric current specifications (voltage
and frequency) are reported on the label put on the electric motor by the firm that produce it.
CONTROL SIFTER
Type RKES
Year
Serial
Number
ALAPALA MACHINE INDUSTRY AND TRADE INC.P.O. BOX 54

. 19001 ÇORUM/TÜRKİYE
Tel: +90. 364. 254 95 60 (5 Lines)
Fax: +90. 364. 254 92 90-213 17 42
TRANSPORT
The dimensions and the structure of the CONTROL SIFTER Series do allow the transporting of
the machine assembled.
The accessories delivered with the Machine;
1. hanging chassis,
2. product outlet fork pipes,
3. clamps,
4. product flow bags,
5. various accessories.
The packing and the transporting of the machine are provided according to the Customer
requests, to the means of transport used, to the place of destination, and to the type and quantity of
material to be transported.
The transport of the machine is generally at the Customer expenses. In case of different
conditions of sale, the producer collaborates with specialized transport companies.

Fig.:01
UNLOADING - STORAGE OF THE PARTS

Unload the materials at their arrival giving a particular attention to the machine (normally
including a electric motor unit pre-assembled in workshop).
During the unloading check carefully:
-The tonnage of the lifting apparatus that has to be proportionate to the weight of
the packages.
-The slings of the packages

The operations of unloading have to be made by skilled staff with authorisation for
the use of lifting means. During the unloading stage it is necessary to follow all the safety
rules.
Protect with the proper materials all parts that may be damaged by rubbing. Give a
particular attention to the balancing of the package before lifting.
All materials have to be stored correctly in order to prevent damages in the period between their
arrival and assembling. More precisely it is necessary to respect the following rules:
-Store in a sheltered place the package and eventually the outlet slides.
-Lay the various packages standing outside on supports in order to avoid their direct contact with the
ground.
-In case of materials painted for a location of the machine inside, check if all the packages have been
stored in a closed place, on the contrary the painting may be damaged irreversibly.
CHECKING DELIVERY
Continue with the check of quantity and quality according to the documents and eventual
instructions of assembling. If all is integral take off the packing and check if all the parts are free from
damages due to the transport. Check the presence of damage due to the squeezing or breaking.
In the case of lack or damaging of packages and single pieces, please contact our Technical
Service and specify the type of problem.

3

ASSEMBLY, MAINTENANCE AND USER MANUAL
DESCRIPTION AND MANUFACTURING CHARACTERISTICS

GENERAL DESCRIPTION
The CONTROL SIFTERs of the RKES Series; It is used in the flour mills to separate any foreign
material may be mixed into final product during milling process or in silo . It is also used to caliber
and clean the cereal.
Every aspect of the project has been carefully considered in order to obtain high standard quality
machines.
The machine can be provided both in the galvanised and in the painted version.
A particular attention has been dedicated to safety measures, to the prevention of accidents and to the
environmental protection laws.
RANGE OF MODELS AND TONNAGE
The CONTROL SIFTERs are provided in various series and models to offer a wide range of solutions
and satisfy the various needs of the industry with feed rates from 30 to 40 TON/h (with floor).
All the machines can be provided both in the the painted version.

STRUCTURAL FEATURES
Each machine includes the following parts:

-product inlet unit
-chassis
-sieves
-body
-sifter tension system
-vibration handles
-product outlet
-various accessories for the regulation of feeding an unloading.
The various parts are assembled directly in the place where the machine is installed through bolts.
The total length of the CONTROL SIFTER is reached through a series of casings connected to a head
and to a terminal station.
The CONTROL SIFTERs of the RKES Series are generally placed horizontally.
Product inlet
Sifter tension system
Sieves
Body
Vibration
handles
Chassis
Bearing and
motor group
Product
outlet
Fig.:02

PRODUCT INLET UNIT
Granulated flour run into Control Sifter via loading

pipe on the top of the machine. There is a single
inlet on each machine. Loading pipe is located in
the mid of the sfter. Transmission line and sifter’s
inlet are combined with cotton bags to absorb the
vibration of the machine. Inlet pipe is separately
located to the floor with a steel profile.
The inlet diameters of sifter are 120 and
150 mm.
Fig.:03
CHASSIS
It has been designed and produced in steel iron sheet. Control sifter is connected to the canals on the
shasses through screws. The tray part of the shasses is produced in iron profile and located on the
surface or the space opened on the floor. 6 different products and drainage passing hole are exist on
the tray.Flanges are closed if the holes are not used. Product and drainage pipes are connected to
open-holes.
Fig.:04

SIEVES
Sieves are the parts having basic functions of Control Sifter. They are produced in different
dimensions, sections and bore diameters. The main stage is laminated wooden. The material of the
sieves are in stainless steel wire and artificial wire. Linen fiber is stuck on the bottom surface of the
sifter’s case for leak tightness.
The number of sieves’ case is six or eight. The dimension of sieves’ case is 85 cm or 120 cm.
Fig.:05
BODY
The main structure of Control Sifter is designed and produced in durable iron sheet to have high
swinging movement. There are facing twist and welded surfaces to increase durability.
There are holes for the outlet of the product on the floor of the sieves.
The canals wearing vibration handles and the bearings wearing tension mechnasim are welded to the
body.
Fig.:06
SIFTER TENSION SYSTEM

The case of sifter needs to have swinging movement in an harmony with the main structre to perform sieving. In
here, both service intervene (mount and demount) and rigidity are important for leantightness. Therefore, the
thrust cover is encased after the case of sifter is placed on the canal of the main structure successive. The

screws are screwed from 4 edges in equal pressure by mounting vertical tension mechanism on the bearing
between thrust cover and the main structure. Horizantal tension mechanism is screwed and located to the
bearings surrounding edges of the cases.
Right and left screwed thrust are combined with an specific nut on the horizantal tension mechanism. Thus, one
side of the nut provides screwing movement and the other one provides loosing movement.
Fig.:07

VIBRATION HANDLES
The iron canals welded to edge of profile coloumn are crank connection centers. There are four handles
on each edge of the machine. One point of the handle is connected to the body of the machine and the other one
is connected to the cranks whose priority structure is rubber. The cranks are located inside of steel casting body
via hole and healthy rubber. The structure of crank meets the reaction of swinging movement of every direction.
The crank is connected to the location each edge through two across bolt.
There are immobilization parts to prevent shaking of the machine in shipping period and assembly.
These parts are need to be taken off before the machine is switched on.
Fig.:08
BEARING HOUSING AND MOTOR GROUP

It is the weight that has been located in the shaft providing swinging motion of the control sifter. The weight has
been designed and produced in appropriate value and location to ensure suitable sieving. Rotation number of
electric engine is transmitted through the pulley which has been beared on the shaft.. Centrifugal movement
which is caused by the weights on the machine causes swinging of the machine. This swinging movement
ensures required sieving.
Fig.:09

PRODUCT OUTLET
Product outlet holes on the bottom of the machine opens in accordance with product process. The facing on the
shasses are also kept open. Product inlet pipe screwed on the shasses on side opened branch pipe. The flow of
the product can be observed from the branch part. This part is normally closed with a rubber cover. Transmission
of product through product outlet to the pipe on the shasses is ensured with cotton bags. Reflection of swinging
effect to the shasses must be prevented.
Fig.:10
SUSTAIN AND GRADE STANDS
Grade Stand Sustain Stand
Fig.:11

Fig.:12

4

TECHNICAL DATA AND WEIGHTS FOR HANDLING

RANGE OF MODELS AND TONNAGE
TECHNICAL FEATURES
MODEL
Weights
Motor Eccentr. Surface Opening of mesh Kg Gross volume
Kw (mm) (m²) (micron) m³
Net Gross
RKES 85/6 1.92 700 882 3.8
1.1
RKES 85/8 2.56 720 913 4.2
55 300
RKES 120/6 5.7 950 1223 6.6
1.5
RKES 120/8 7.6 1000 1287 7.3
Table:01

CONTROL SIFTER PROCESS
Fig.:13

Fig.:14

CAPACITY AND DIMENSIONS
TECHNICAL FEATURES
DIMENSIONS mm
MODEL
Capacity
A B C D E F G ØH ØJ
t/h
RKES 85/6 1380 1645 3

1271 1271 942 942 268 120
RKES 85/8 1560 1825 4
150
RKES 120/6 1459 1724 8
1713 1713 1320 1320 266 150
RKES 120/8 1639 1904 12
Table:02

CHARACTERISTICS CONSTRUCTION
Product inlet space
vertical clamping
print table horizontal clamping
print brackets
vertical clamping
screw mechanism
horizontal clamping
Product inlet pipe
screw mechanism
and stand
The machine; bearing

group, weight and Sieve wooden crates
pulley
the motor pulley and

the housing plate The machine
Electic motor
Vibration handles
Chassis and product

outlets Motor
connection kit
Fig.:15

SOME EXAMPLE
Fig.:16
Fig.:17

5

ASSEMBLING AND SET AT WORK

PROCEDURE IN SAFETY DURING THE ASSEMBLING
The CONTROL SİFTER can normally be installed on the floor.
If the CONTROL SIFTER is going to be mounted on a tunnel, before the assembling, verify if this is
opportunely ventilated (better if artificially).
Anyhow assembling involves a series of operations that need attention and a constant respect of the
recent laws regarding prevention of accidents.
Generally, for a correct assembling of the machine reducing risks to the minimum, it is necessary:
-to commit all the complex operations to skilled staff, trying to limit the employ of unskilled workers.
-to require a constant respect of the laws regarding safety and prevention of accidents.
-to demand from the Supervision of Construction to check the application of the laws mentioned by all
the staff employed in the plant.
-to enclose the area of assembling in order to prevent the access to non-authorised people.
-to use scaffolds manufactured according to the laws or movable platforms for assembling in elevation.
-to use power lifts with tonnage proportionate to the weight of the various parts.
-to check carefully the slings and the balancing of the weight.

We decline all responsibility for damages or injuries during the assembling if this operation haven’t been
entrusted to us and specified in the contract with the Customer.
We specify that what is reported in this technical handbook and what will follow is not
exhaustive for all the events that may happen in the assembling, installation and starting of a CONTROL
SİFTER. In a plant, the particular needs of installation and the accessories that the machine may include
do not allow us to consider all the cases. It is therefore necessary to respect the laws regarding
prevention of accidents and to entrust the assembling only to skilled staff so as to limit the risks
connected with these operations.
ASSEMBLING THE MACHINE

The bodies, chassis, shaft, and housing group, pressure system, electric motor and sieves are delivered
assembled as per the diagram in the contract.
The preliminary setup of the Machine consists of all assembled main parts connected to each other by bolts and
nuts.
Please make sure all bolts are tight enough to avoid leakage through the sections.
The Placement of the Machine
Settle the machine to its last location. Ensure the tough and supported connection of the chassis.
Place the temporary chocks under the machine while alligning the machine. Smooth the level differences caused
by the displacement of the floor by lifting with crane or jacks.
Control Swinging
Safe chocks need to be take off after control of the shasses connection. The machine is switched on without
product in order to control swinging. Review the connection errors.
Installation of Product Inlet-Outlet Pipes and Sacks
The product inlet-outlet pipes are delivered assembled as per the diagram. There are belts on the pipe heads.
After the setup of the machine the sifter bags are tied to the heads with the belts. There are rubber belts to hold
the bags.
ELECTRICAL CONNECTION
The machine is provided without electrical control panel and connections.
The electrical connection to a general control panel must be provided directly by the Customer, where
there are not agreements for particular supplies.
All the electrical connections must be arranged by skilled staff in the respect of the laws of the country
where the machine is installed.
The machine can be tested only after having received a copy of the complete documentation in
conformity with the current laws regarding electrical connection and safety.
We decline all responsibility for damages or injuries due to mistakes or omissions in the execution of the
electrical plant.

STARTING AND TESTING
Before the starting of the machine without load, it is necessary:
1.Check the oil level of the bearing housing and fill it if necessary ( follow the instructions of the
constructor)
2.Make an ulterior inspection of the CONTROL SIFTER and make sure that all the covers and the
protection cases are closed with bolts correctly fastened
3.Verify if the CONTROL SIFTER is properly secured to the electric motor or to the shaft and check the
connections for the feeding and for the unloading
4. Attached during transport, temporary security disconnect
Start the machine verifying the direction of the shaft and of the electric motor.
Set the machine in function with no load for about two hours to allow the adjustement of the mechanical
parts in motion. In this stage it is necessary to check the electrical input that should have minimum values.
In case of particular noise or anomalous electrical input it is necessary to verify these things:
-alignment of the machine
-alignment of the shaft in the middle frame
-presence of eventual foreign bodies inside the machine
-hanging rods tension
-alignment of handing rods parts
After this period of adjustement and testing without load, start the CONTROL SIFTER with the product,
operating gradually and checking the electrical absorption. During this phase verify if the unloading of
the machine is regular. Increase the feeding of the CONTROL SIFTER only after few hours of
functioning.
Once you have reached the 75% of the tonnage leave the machine in function for at least 50 hours
before testing with full load.
During the stage of final testing, check the level of the casings (when possible through the inspection
holes in the machine) and verify if the unloading is regular.
Transportation Safety Signs
Fig.:18

MOTION CONVEYOR SYSTEM
Fig.:19
POSITION OF THE MACHINE
Fig.:20

6

USE AND MAINTENANCE

USE
For a correct use of the CONTROL SİFTER verify if all the circuits after the machine are in function or, in
case of unloading in a silo or in a warehouse, verify if at least one of the unloading exits is open.
In case of stop of the machine caused by:

-intervention on the magnetometric switch installed on the general control panel
-intervention of the micro-switch of the overflow control system of the Machine
Follow these instructions:

-Close the inlet circuits of the CONTROL SİFTER
-In case of installation of the CONTROL SİFTER inside a building or in a gallery, before every
intervention, ventilate the place with the forced air and verify if there are toxic gas
-Locate the problem that has stopped the CONTROL SİFTER (generally caused by occlusions in the
outlet circuits or by the presence of foreign bodies in the machine)
-Start again the CONTROL SIFTER and leave it in function until the complete unloading
-Put the machine in function until the complete unloading

-Leave the machine in function without load for few minutes controlling the electrical absorption to the
restoration of the regular tonnage.
During the operations above mentioned we recommend the respect of the safety rules described on
“General rules” in the present Manual.
Before opening the covers of the CONTROL SIFTER or the covers of the inlet hoppers verify if
the machine is stopped and that no one set it in operation.
Avoid the stagnation of the product inside the machine for long periods especially if the product
is perishable.
We suggest to set the electrical plant so as to ensure the complete unloading of the CONTROL SİFTER
before its stop.
The stagnation of moist cereals inside the CONTROL SIFTER or in its proximity causes in
many cases the fermentation and the exit of toxic gas.
In these cases before every intervention, ventilate the place and make sure if there is carbon dioxide
with the proper instruments.
DO NOT ALLOW TO ANYONE TO APPROACH THE MACHINE IN PRESENCE OF CARBON DIOXIDE!
MAINTENANCE
SERVICING
The servicing program includes not only ordinary maintenance, i.e. inspections, checks and tests carried
out by the operator and/or by the company’s specialist staff responsible for routine maintenance, but
also scheduled measures that include replacements, adjustments and lubrication performed by suitably-
trained staff.
It is very important to perform maintenance at the specified times, both to reduce the risk of malfunctions
and to avoid premature wear on the machine’s components. “ALAPALA” will accept no claims under
guarantee for faulty components if, at their own discretion, they judge these defects to be directly or
indirectly due to lack ofmaintenance, or erroneously-performed maintenance.
This servicing manual deals in particular with the action to take for maintenance purposes, so you are
Ordinary servicing
This includes servicing operations that can be done by the operator, or by specialist staff, according to
the specifications of the present documentation and that does not involve the use of any particular tools
and equipment.
Every day:
- clean the machine
- check the sleeves and their clamps
Scheduled servicing

This includes servicing measures performed by staff instructed for said purpose and includes
replacements, adjustments and lubrication (for this last operation, refer to the LUBRICATION section),
as specified in the table.
During servicing operations on mechanical parts and/or electrical components, it is essential to

disconnect the machine at the main circuit breaker.
After the first 200 hours
- Separately dismantle all the frames from the machine, making sure that there are no signs of damage
or abnormal wear; check the state of the bolting cloth. Then re-assemble the nest, paying attention to the
position of the numbered nameplates: these must be on the side opposite the motor and on the right-
hand side of each frame in ascending numerical order from the top downwards.
- Check the tightness of the nest of frames: to do so, use a torque wrench to ensure that the four nuts at
the top of the fixing tie rods (detail No. 1 in figure 2) are tightened to 6 kgm
- Check the tension on the belts: to do so, remove the guard on the bottom of the machine and make
sure that exerting a pressure of approximately 3 daN at the centerline of the free stretch of each belt
makes the belt sag by no more than 15 mm; if this is not the case, take action on the four tie rods that
support the motor baseplate. After completing this operation, check the tightness of the nuts that fix the
motor baseplate and then carefully close the guard once again.
After the first 1000 hours
- Check the tightness of the nest of frames: to do so, use the torque wrench to makesure that the four
nuts on the top of the fixing tie rods (detail No. 1 figure 2) are tightened to 6 kgm.
Every 2000 hours
- Grease the bearings: with the aid of the grease nipples provided (details Nos. 2 and 3 fig. 3), insert
approximately 25 gr of LGEP 2 grease (see machine greasing § 07.04)
- Separately dismantle all the frames from the machine, making sure that there are no signs of damage
or abnormal wear; check the state of the bolting cloth. Then re-assemble the nest, paying attention to the
position of the numbered nameplates: these must be on the side opposite the motor and on the right-
hand side of each frame in ascending numerical order from the top downwards.
- Check the tightness of the nest of frames: to do so, use a torque wrench to ensure that the four nuts at
the top of the fixing tie rods (detail No. 1 in figure 2) are tightened to 6 kgm.
Every 4000 hours
- Check the condition of the bearings: to do so, remove the guard from the bottom of the machine and,
after removing the belts, loosen the four nuts attaching the motor baseplate; while turning the pulley by
hand (the one for the motor and the one for the machine), check for any unusual noises and any
resistance to the rotation: in the event of such problems being detected, proceed with the dismantling of
the bearings (see § 8.5).
- Check the state and tension of the belts: if the belts show signs of wear or small cracks, they should
both be replaced. As for tensioning the belts, make sure that exerting a pressure of approximately 3
daN at the centerline of the free stretch of each belt makes the belt sag by no more than 15 mm; if this is

not the case, take action on the four tie rods that support the motor baseplate. After completing this
operation, check the tightness of the nuts that fix the motor baseplate and then carefully close the guard
once again.
- Visual inspection of the state of the "ROSTA" elastic motorbases: if there are any signs of the rubber
collapsing, the motorbase must be replaced immediately.
Extraordinary servicing
This includes all servicing measures performed by staff instructed specifically for the purpose and
relating to changing parts of the machine no longer capable of performing adequately due to wear and
tear.
Important: during servicing operations on mechanical parts and/or electrical components, it is essential
to disconnect the machine at the main circuit breaker.
Changing the “ROSTA” elastic motorbases
Place a suitable spacer in line with the motorbase that you intend to replace, so that the machine
remains supported at all four corners. Then remove the screws that fix the “ROSTA", detail No. 5 and
No. 7 - fig. 2, respectively to the brackets No. 4 and No. 8; then you can remove the whole leg, detail No.
6 - fig. 2 with the two "ROSTA" attached, which can be changed at the workbench.
When you reinstall the leg, fix the screws only after fitting the leg to the machine so that it is
perpendicular to the supporting surface.
All the screws that fix the "ROSTA" in place must be tightened with the torque wrench to 8 kgm.
Changing the bearings and sealing rings
- Dismantle the nest of frames until you arrive at the bottom table, which can be left in place.
- Dismantle the guard and the belts as explained above.
- Remove the screws that fix the four "ROSTA" to the upper bracket, detail 5 fig. 2
- Now, using suitable equipment, you can turn the machine upside down (it weighs approximately 300
kilos), paying attention to the fact that the counterweight, being free, will turn in the direction in which the
machine is tilted and will consequently also make the pulley turn. The machine can then be placed
either on the floor or on a workbench.
- Remove the pulley, detail No. 12 fig. 3, unscrewing the two dowels that hold the bushing, then screw
one back into the hole opposite the cut in the bushing.
- Remove the grease nipple pipe. - Remove the delivery outlets and all the screws that fix the cover to
the box and to the housing, detail No. 13 fig. 3.
- Now remove the cover, paying attention to the elastic reference studs.
- Unscrew the ring nut, detail No. 14, and slide out the housing, detail No. 13
- Slide out the counterweight assembly, detail No. 15 fig. 3.

- Remove the cover, detail No. 16 on the upper journal box and slide out the shaft. To facilitate this
operation, you can push the shaft through the M10 threaded hole, detail No. 17, situated at the top.
- Then change both of the bearings and the sealing rings (see list of recommended spare parts) and
reinstall all the parts, paying attention to ensure that the seats of the bearings are clean and adding
approximately 150 g of grease to the seat of each bearing.
- Check the tightness of all the screws (including the ones that have not beendismantled).
- Proceed with the reassembly, performing all the above actions in reverse order.
- Seal the delivery outlets with non-toxic sealant.
IMPORTANT:
Once these servicing operations have been completed, make sure that all the safety devices on the machine
have been restored and that no tools have been left inside the machine, especially in the moving parts.
LUBRICATION
Pos. DETAIL TYPE OF Q.TY RESETTING EVERY OPERATING
LUBRICATION (g.) HOURS
A Support Grease XM2 or EP2 50 4000
Table 03
Use lubricators reported in table 03 only, in case you wish to use a different product make sure it complies with
those included in the table.
The possible addition of grease has to be performed as the machine stands through the suitable grease
points.
Grease must not be injected too fast to prevent damage of the seals.

Fig.:21

TABLE L-101
CHARACTERISTICS OF LUBRICANTS
Part to be lubricated Lubricant Grade °E Clas. SAE
50°C
- Hydraulic system Oil VG 10 1,7 Gearmotor
- Air lubricators VG 32 3 5 W 70W
- Pneumatic control and oil dynamic VG 68 6 10W 70W
circuits. 15 W 70W
- Mandos y circuitos oleodinamicos. 20W 70W
25W 80W
- Specifications: High quality mineral oil with wear- and oxidation-resistant properties.
Part to be lubricated Lubricant Grade °E Clas. SAE

50°C
- Gears Reducers - Blowers – Compressors Oil VG 100 8 30 85W
VG 150 12 40 90W
VG 220 16 50 90W
VG 320 24 90
VG 460 33 140
VG 680 47 140
- Specifications: Top-quality refined mineral oil with special anti-wear and anti-oxidation additive.
High load-bearing capacity.
Part to be lubricated Lub. Type Clas. Note/Notes/Nota

Grease XM 2 NLGI 2 *
- Grease lubricated parts Long Life XP **
- * Specif. Multi-purpose lithium grease with a high mechanical stability and high drop point. ASTM
dmm. 265-295.
- ** Specif. High-quality special grease for high-speed (rpm) roller bearings with heavy load and
temperatures.
ISO 3448 VG…= Mean value of kinematic viscosity mm2/s (cSt) a 40°C.

COMPARISON CHART
TO TAL TEXACO SHELL MOBIL KLUBER FINA ESSO CHEVRON BP AGIP
Gradazione
Lubrificante
Grade
Lubricant
Degre
Lubrifiant
Gradacion
Lubrificante
ISO 3448
EP Hydraulic OIL 10 Energol HP 10

VG 10 Azolla ZS15 Rando OIL HD 10 Tellsu OIL C10 Mobil DTE 21 Crucolan 10 Compound 100 NL Energol GR XP OSO10
Hydran 10 Spinesso 10
VG 32 Azolla ZS32 Rando OIL HD 32 Tellsu OIL32 Mobil DTE24 Airpress 32 Gear 100 OSO32
Hydran 32 Nuto H 32
RKES SERIES CONTROL SIFTER MANUAL

Olio VG 68 Azolla ZS68 Rando OIL HD 68 Tellsu OIL68 Mobil DTE26 Lamora 68 Compound 150 NL Energol GR XP OSO68
Hydran 68 Nuto H 68
VG 100 Carter EP 100 Meropa 100 Omala OIL 100 Mobil DTE27 Lamora 100 Gear 150 Blasia 100
Oil Giran 100 Spartan EP 100
VG 150 Carter EP 150 Meropa150 Omala OIL 150 Mobilgear 629 Lamora 150 Compound 220 NL Energol GR XP Blasia 150
Huile Giran 150 Spartan EP 150
VG 220 Carter EP 220 Meropa220 Omala OIL 220 Mobilgear 630 Lamora 220 Gear 220 Blasia220
Aceite Giran 220 Spartan EP 220
Giran320 Spartan EP 320
VG 460 Carter EP 460 Meropa460 Omala OIL 460 Mobilgear 634 Lamora 460 Gear 320 Blasia 460
Giran460 Spartan EP 460
Gear 460
Table 04
Compound 680 NL Energol GR XP
Gear 680
(Standard)
Tipo XM2 GRMU EP2
Alvania Grease R Marson Duralith Energrese LS2
Type XM2 Multis EP2 Multıfak EP2 Mobilux 2 Centoplex EP2 Beacon EP2
2 EPL2 Grease EP2 Greaseltx 2
Tipo XM2 GRLP 2
Type XM2
Grasso
Grease
Graisse
Grasa
(Long life)
Energrese LS2
Tipo XP Staburags NBU4
Glygoyle Grease EP Rocol HT
Type XP Carter SY 00 Tivela compund A MF Staburags
00 Greaseltx LTX 2 BRB 1200
Tipo XP NBU 12/300 kp
EP
Type XP
Page - 44
SPARE PARTS
Table 05

MACHINE AND MODELS
CONTROL SIFTER Min.
SPARE PART LIST RKES-85-R RKES-120-R Figure Stock
SPARE
PART No
150YDYI350215
PRODUCT INLET
1
SACK
QUANTITY 1or 2
SPARE
PART No
YPRKES0001-003 YPRKES0004-003
VERTICAL TENSION
2
MECHANISM
QUANTITY 4
SPARE
HORIZANTALTENSION PART No
3
MECHANISM
QUANTITY 4
SPARE
PART No
CASE 4
QUANTITY BY DIAGRAM
SPARE
PART No
RKES0T0100
TAPOTEN 5
QUANTITY BY DIAGRAM
SPARE
MOTOR PULLEY
PART No
150YDYI150101
50 Hz.
QUANTITY 1
6
SPARE
PART No
150YDYI150102
60 Hz.
QUANTITY 1
SPARE
PART No
150FSYI010802
MACHINE PULLEY 7
QUANTITY 1
SPARE
PART No
150YDYI170106
50 Hz.
QUANTITY 3
BELT
8 SPARE
PART No
150YDYI170111
60 Hz.
QUANTITY 3
SPARE
PART No
150YDYI430101 150YDYI430102
JOINT 9
QUANTITY 8
SPARE
PART No
150YDYI350208 or 150YDYI350203
PRODUCT OUTLET
10
SACK
QUANTITY 1 or 2
SPARE
PART No
150YDYI251311
ROLLER 11
QUANTITY 2
SPARE
PART No
150YDYI060115
OIL SEAL 12
QUANTITY 3
SPARE
PART No
150MTYI020711 150MTYI020712
ELECTRIC MOTOR 13
QUANTITY 1
Table 06

To use the eventual spare parts it is therefore necessary to keep this Machine Technical Card included
in the present manual to specify the parts of Your CONTROL SIFTER. Our Technical Service is at your disposal
for every request. We ask you to specify the following data, for the identification of the machine (these data are
reported on the plate that is on the body):
-model
-matriculation number
-year of production
The use of eventual unoriginal spare parts may compromise the correct functioning of the CONTROL
SIFTER and in all the cases cancel every responsibility of the constructor in what is specified in the
Machines Directive 94/9 and the following revisions.
EQUIPMENT FOR THE MAINTENANCE

The equipment of the workers employed in the maintenance includes:
-a flashlight of 100 Lux
-spanners and mechanical tools
-gloves
-dust mask
-helmet
-safety shoes
-safety belt for banked conveyors
-trowel for the cleaning of the casings
-a container for the material drawn in the casings.

7

DISMANTLING AND DISPOSAL

DISMANTLING
To dismantle correctly the CONTROL SIFTER of the RKES Series it is necessary to observe
the following advices:
-Entrust any intervention of dismantling of the machine to skilled staff, provided with proper instruments.
-Before every intervention on the CONTROL SIFTER, verify if the electrical connections have been
removed. This operation must be done by skilled staff.
-Delimitate the place of intervention using proper warning notices and specify the type of intervention.
-Clean the machine carefully inside and outside, verify the wear conditions of the various elements that,
during the dismantling may bring particular risks.
-RKES assemble the various elements of the CONTROL SİFTER doing what is described in the chapter
5 of the present manual in the opposite order.

-It is forbidden to cut parts of the CONTROL SİFTER using disk grinding wheels or similar tools,
especially with banked CONTROL SIFTERs
-It is forbidden to use the disk grinding wheel to remove rusty bolts
-Before the dismantling of parts or elements verify if these are subject to tension and if their removal
damages machines or structures connected to them.
-Before every intervention of dismantling or removal verify if the part is sustained by stands or by slings.
-For the CONTROL SİFTERs installed on a gallery or inside a building, before every intervention it is
necessary to aerate and to clean the place to avoid the risk of explosion, the dangers caused by the
presence of toxic gas and/or possible infections.
ELIMINATION
The CONTROL SIFTERs of the RKES Series are made with:
-steel for the structural and mechanical parts
-polizene for the sliding blocks of the chain ( this product can be considered plastic)
-oil and/or grease contained in the geared motor units
Each product has to be eliminated in the respect of the laws of the country where the machine is
installed.

8
CONTROL SIFTERS
Information sheet for the ATEX DIRECTIVE
Explosion risks: two important news for the safety inside working places
NEWS FOR THE SAFETY AT WORKING PLACES

The European Community introduced two new Directives, the IEC 60079-10-2:2009 (ATEX
100a) and the 99/92/CE (ATEX 137), which have modified radically the approach with the safety
inside the working environment, where gas, liquids or inflammable dusts are used.
All the employers are obliged by the directive 99/92/CE (introduced in Turkey 26 th of December
2003, with the application of the new title 25328), to evaluate explosion risks, on which their own
employees are submitted.
The directive 1999/92/CE fixes the minimum standards for the improvement of the safety and
the health of the workers, whom could be exposed to the risk of explosive atmospheres.

The risk of explosions could verify in each ambient where inflammable substances are
handled. These substances are many different materials, intermediate products, finished products and
waste substances produced by the process of daily work, as shown in: figure 22.
Figure 22: Example of how an explosive atmosphere could be created.
Most of industrial activities are covered from the moment that the procedures and the processes
of different workers can generate the danger of an explosive atmosphere. Examples are mentioned in
the table 07.
It is possible to have an explosion when fuel is mixed with air (which means with a sufficient
quantity of oxygen) between the ignition limits and in presence of an ignition source (figure 42).
It has to be mentioned, that the special definition of "explosions" contained in the directive, is
also applied to an ignition in which the combustion is reproduced to all the unburnt mix.
Figure 23: The explosions triangle
In case of an explosion, the employees are in danger for the uncontrollable effects of the flames
and the pressure, under the form of heat irradiation, flames, pressure waves and flying fragments, as
for the harmful reaction products and for the oxygen of the surrounding air burning, that is needed for
worker's respiration. The obligations scheduled by the Title VIII-bis could be executed in two phases:
- PHASE 1: Classification of the zones with explosion risk present at working places, or the
zones in which a dangerous concentration of gas, fumes and inflammable dusts can be present.
- PHASE 2: Predisposition of the document for the valuation of explosion risks.

Table 07: Examples of explosion risks in different sectors
The classification or distribution of dangerous areas at working places, it is a duty of the
employer, who must give this classification to the electrical and mechanical designer, and in some
cases, also to the maker of machines/plants, in order that suitable equipments corresponding to IEC
60079-10-2:2009 could be installed.

The classification of dangerous zones has preferably to be made according to the norms as follow:
GAS, FUMES AND INFLAMMABLE DUSTS CEI EN 60079-10 (CEI 31-30)

INFLAMMABLE DUSTS CEI EN 50281-3 (CEI 31-52)
An area (or zone) under risk of explosion, is an area in which a dangerous explosive
atmosphere could be created in such a quantity, that it is necessary to have norms for the protection of
the workers concerning the risks of explosion. A similar quantity is declared explosive dangerous
atmosphere. As basics for the valuation of the types of measures for the protection, the areas with
explosion risks must be divided in zones, concerning the possibilities to create dangerous explosive
atmospheres.
Zone 0: Area in which an explosive atmosphere is present all the time, for long periods
or often. An explosive atmosphere is a mixture of air and of inflammable
substances in form of gasses, vapours or mists.
Example: Normally the conditions of zone 0 are present only inside of vessels or
equipments (evaporators, vessels for reactions, etc.), but could also be verified
close to ventilations and other openings.
Zone 1: Area in which during normal operation, the formation of an explosive

atmosphere occurs occasionally, in a mixture of airand inflammable
substances in form of gasses, vapours or mists.
Example: They could belong to:
• places with an immediate closeness to the zone 0;
• places with an immediate closeness to feeding openings;
• places with an immediate closeness to instruments, protection systems and

components of fragile glass, ceramics and similar materials, excluding the
cases in which the substance itself is not able to create a dangerous, explosive
atmosphere;
• places with an immediate closeness to stuffing nuts not well tightened, for
example on pumps and valves with stuffingn
• the inside of installations as evaporators and reaction vessels. uts;
Zone 2: Area in which during a normal function, the formation of an explosive

atmosphere, consistent in a mixture of air and inflammable substances in form
of gasses, vapours or mists, is not likely to occur; if it happens, it is just for a
short period.
Example: To the zone 2 also belong:
• the areas which surround the zone 0 or the zone 1.
Zone 20: Area in which an explosive atmosphere is present all the time, for long
periods, or often in form of clouds of dust in the air.
Example: Those conditions are present, generally just inside of vessels, tubes,
instruments, etc. Normally it belongs only to the inside of the plants (mills,
dryers, mixers, wires for the transport, silos, etc.), in the cases explosive
mixtures of dust in a menacing quantity could be formed permanent, for long
periods or often.

Zone 21: Area in which during a normal operation, the formation of an explosive
atmosphere in form of clouds of dust in the air, is possible just occasionally.
Example: To this could belong areas with an immediate closeness to out take or
collection points, areas where are stored dusts and where occasionally in the
course of a normal operation in a mixture of air, a concentration of
inflammable dusts is formed.
Zone 22: Area in which during a normal operation, the formation of an explosive
atmosphere in form of clouds of dust in the air, is not likely to occur and if it
happens, it takes place just for a short period.
Example: It could belong to:
• those areas, in which the dust inside the plants is able to go out from
openings and so forms dust deposits in a dangerous quantity.
The employer has to create and to keep updated a "document for the protection against
explosions", in which is indicated:
- to have individuated the dangerous zones present at working places (zone 0, 1, 2 for gas
and inflammable liquids; zone 20, 21, 22 for inflammable dust);
- to use CE marked equipment as for the directive ATEX IEC 60079-10-2:2009, of the
group and category suitable to the classified zones;
- to have valuated all the possible ignitions, also coming from working activities as welding,
sanding, etc.;
- to have managed the coordination between different builders to reach the safety for
explosive risks;
- to have informed and trained workers;
- to have marked with special signs, the beginning of dangerous zones;
- to have declared the electrical installations located in the zones 0, 1, 20, 21 to the
authorities and to have made, each two years, the periodical verification by the authorities, or
by institutions in possession of a special qualification from the Minister for productive
activities.
Figure 24: Example for a sign, which has to be used to mark the beginning of a
dangerous zone

NEWS CE MARKING
The directive IEC 60079-10-2:2009, fixes the minimum safety rules for the following types of
products:
- Instruments;
- protection systems;
- safety control and regulation devices;
- components
destinated to be used in potential explosive atmospheres.
As instruments are intended the machines, the material, fixed or moveable devices, the
control systems, the instrumentation and the systems for bearing and prevention, which
themselves or combined, are destined to the production, to the transport, to the deposit, to the
measurement, to the regulation and conversion of energy, to the transformation of materials,
and that, due to their own potential sources of ignition make the risk to cause an ignition.
Synthetically all the instruments (electrical or non-electrical) which can be found to

work in potential explosive atmospheres, in ordinary and anomalous operations, could create
sources of ignitions (potential or effective), those sparks, warm surfaces, arcs, flames, warm
gas, etc.; fall into the range of the application to the directive IEC 60079-10-2:2009.
Since 2009, only instruments, machines and protection systems CE marked and
corresponding to the ATEX norm (falls into the range of applications to the directive), can be
introduced into the market and be installed; the producer (or his mandatory) has to effect the
CE mark in order to write the following information:
-1st row: mark foreseen by the directive IEC 60079-10-2:2009
-2nd row: supplementary mark foreseen the technical norms of construction (EN50014
for electrical instruments and EN13463-1 for non-electrical instruments)
-3rd row: mark as for the certification
Mark foreseen by the directive IEC 60079-10-2:2009- CE symbol on the instrument

indicating the conformity to the directive IEC 60079-10-2:2009;
-identification number of the notified organism, if present in the process for the
valuation of the conformity;
-hexagonal symbol indicating the specific mark against explosion;
-the group (the products for mines or the products for the surface industry;
-the category (1,2,3) and the nature of danger G = gas, D = dust, G/D = gas and dust
-the class of temperature or the maximum surface temperature reached (T1,T2, T3, T4,
T5, T6).

Table 08: Class of the maximum surface temperature reached
ASSOCIATION FOR DANGEROUS ZONES-ATEX CATEGORY FOR

INSTRUMENTS OF GROUP II
IEC 60079-10-2:2009
Figure 25: association for dangerous zones - Atex category for instruments of Group II
SUPPLEMENTARY MARKS FORESEEN BY THE TECHNICAL NORMS OF

CONSTRUCTION
Further to the information above indicated and foreseen specially by the directive IEC 60079-
10-2:2009, on the data plate the information foreseen to the technical norms of the product, or rather
the method, or the protection methods used for the construction of the instruments; are inserted.
For the electrical instruments in dangerous zones derived from gas, the norm EN50014 fixes
the modalities, how the protection method or the used protection methods have to be inserted.
The protection methods foreseen by the EN50014 for the electrical instruments in relation to
the type of dangerous zones for the presence of GAS, are indicated.
In the case in which the electrical instruments are destined to dangerous zones for the presence
of dusts, the norms of the series EN50281 have to be followed.
On the contrary, the protection methods foreseen by the EN13463-1 for NON-ELECTRICAL
instruments in relation to the type of dangerous zones due to the presence of GAS and DUSTS, are
indicated.

MARKS IN SENSE OF THE CERTIFICATION
In some cases it is foreseen that for the valuation of the conformity, intervenes a notified body
which releases a certificate of CE examination of the type confirming the respect of the essential
requirements of safety to the directive IEC 60079-10-2:2009 and the notification of guarantee for the
quality of production. The information regarding the notified body and the certificate are inserted in
the data plate as indicated in figure 26.
Specific mark of protection for explosions
Belonging group (II)
Category (3)
Relating letter to explosive atmospheres due

to gas, vapour, fog (D)
II 3 D MAIN MARK
EEx d IIB T1 SUPLEMENTARY MARK
Class of temperature
Gas group
Method of protection (against explosions)
Conformity to European norms relating to

Ex-products
Figure 26: Example for the CE mark which has to appear on the plate of an instrument

DECLARATION OF CONFORMITY
with the Directives of the European Union
The undersigned company ALAPALA MAK. Organize Sanayi Bölgesi 12. cad. 19040- ÇORUM -
TURKEY
Declares under its own responsibility that the machinery:

THE MACHINE TYPE SERIAL NUMBER MANUFACTURE YEAR
CONTROL SIFTER RKES
The conformity has been verified according to the conditions included in the following
standard documents: Marquage
EN 1127-1 EN 13463-1 EN ISO 12100-1

EN ISO 12100-2 EN 294 EN 50081-1
EN 50081-2
-Directive “ATEX IEC 60079-10-2:2009”

-Directive “Machines” 2004/42/EC and integrations
-Directive “Electromagnetic Compatibility” 2004/108/EC
-Directive “Low Voltage” 2006/95/EC
II 3 D (1350) T4
Environmental temperature - 20°C / + 40°C
This equipment must never be put into operation before the machine or plant into which it
has been integrated has been declared in conformity with the pro-visions of Directive
98/37/CE, and provisions for national implementation standards.
Signature of the Manager:

Nurettin ALAPALA

RKES CONTROL SIFTER MANUAL

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MACHINE INDUSTRY AND TRADE INC.

FLOOR AND FEED TECHNOLOGY

Steel construction building design, manufacturing, erection, sales and after-sale

Factory : Organize Sanayi Bölgesi 12. Cad. 19040 - ÇORUM/TÜRKİYE

Marketing&Sales : Dünya Tic. Merkezi A2 Blok Nr:159 Yeşilköy/İSTANBUL/TÜRKİYE

Factory : Tel: +90 364 254 95 60 (Pbx-5)

Marketing&Sales : Tel: +90 212 465 60 40-41

Web: www.alapala.com ; e-mail: info@alapala.com,

RKES SERIES CONTROL SIFTER MANUAL Page - 1

RKES SERIES CONTROL SIFTER MANUAL Page - 3

RKES SERIES CONTROL SIFTER MANUAL Page - 4

RKES SERIES CONTROL SIFTER

REGULATIONS AND GENERAL WARNINGS

This manual is principally addressed to:

RKES SERIES CONTROL SIFTER MANUAL Page - 5

The meanings of the symbols and signals used in this manual

Watch Your Hands Don’t Operate Without Guard

Read the Written Instructions Lifting Point

Use Appropriate Equipment Do Not Insert Your Hands

Danger Smoking and Open Flame Forbidden

Don’t Touch Attention! Moving Components

Periodical Checks Case of Panic

Maintenance and Repairement Ask In Case of Doubt

Use personal protective Cleaning Regularly

Electrical Hazard Do Not Approach

Pest Status Use Protective Clothes

RKES SERIES CONTROL SIFTER MANUAL Page - 6

3.2. Warnings Related to Machine Controls

Some of the Machine Controls may be multifunctional (forward-backward shift,

3.3. Warnings Related to Mechanical Accidents

3.4. Warnings For Covers, Guards and Protective Parts

RKES SERIES CONTROL SIFTER MANUAL Page - 7

3.7. Warnings For Personal Protection

RKES SERIES CONTROL SIFTER MANUAL Page - 8

-an improper use of the Machine

-an incorrect assembly and installation

-a defective electrical supply

-serious insufficiency of maintenance provided for the Machine

-use of unspecific spare parts or materials not expressly authorised

-non-observance (even partially) of the instructions furnished with this manual

RKES SERIES CONTROL SIFTER MANUAL Page - 9

-the regulations contained in this manual

-the legal regulations in matters of safety and accident prevention

These accessories are extremely important in the prevention of explosions.

ENVIRONMENT CONDITIONS FOR INSTALLATION

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ARRANGEMENTS TO BE ORGANISED BY THE CUSTOMER

-the preparation of the electrical system

RKES SERIES CONTROL SIFTER MANUAL Page - 12

SAFETY RULES (RESIDUAL RISKS)

RKES SERIES CONTROL SIFTER MANUAL Page - 13

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RKES SERIES CONTROL SIFTER

IDENTIFICATION AND TRANSPORT

Control Sifter The number of sieve The dimension of sieve

RKES SERIES CONTROL SIFTER MANUAL Page - 15

ALAPALA MACHINE INDUSTRY AND TRADE INC.P.O. BOX 54

The accessories delivered with the Machine;

2. product outlet fork pipes,

4. product flow bags,

RKES SERIES CONTROL SIFTER MANUAL Page - 16

UNLOADING - STORAGE OF THE PARTS