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DAP

500 LITERS

INSTRUCTION MANUAL
Dear Customer,
We are sure that you will be satisfied with your purchase, considering the technological level achieved by
our products, thanks to our constant commitment which encourages us to grow every day and to cope
professionally with the continuous technological, productive and commercial transformations.
In the certainty that we will be able to fulfil all your future working requirements, we remain at your
disposal for any information you may require and take this opportunity of wishing you every success in
your work.

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


ORDER 2017.0050 R00_02/2018 I
TABLE OF CONTENTS

01 GUARANTEE CONDITIONS 01

02 EC DECLARATION OF CONFORMITY 02

02.1 CE Marking 03

03 IMPORTANCE OF THE MANUAL 04

03.1 Consultation notes 04

03.2 Intended receivers (authorized operators) 05

03.3 Machine off status 06

03.4 Abbreviations 06

03.5 Reserved rights 06

04 DESCRIPTION OF THE DAP SYSTEM 07

05 TECHNICAL DATA 08

05.1 DAP 500 Technical data 08

05.1.1 Dimensions (mm) 09

05.2 SILOS 18000 lt. 10

06 INTENDED USE 11

06.1 Energy supply source 11


06.2 Limits of use 11

06.3 Ambient conditions 11

07 TRANSPORT OF THE MACHINE 12

07.1 Packaging 12

08 UNPACKING AND HANDLING 13

09 GENERAL WARNINGS 14

10 ELECTRICAL CONNECTION 15

11 STORAGE 16

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12 DIRECTIVES AND REFERENCE NORMS 17

13 SAFETY 18

13.1 Safety signals 18

13.2 Residual risks 20

14 CHECKS BEFORE SWITCHING ON 21

15 MAINTENANCE PROGRAMME 22

15.1 Ordinary maintenance 22

15.2 Special maintenance 24

16 PARTS DESCRIPTION 25

16.1 Dissolution tank 25

16.2 Hydraulic system 27

16.2.1 Water inlet unit 27

16.2.2 Recycle system and liquid sending 28

16.2.3 Centrifugal pump 30

16.2.3.1 Instruction to change the mechanical grip of the pump 31

16.2.4 Blowing unit 32

16.3 Pneumatic system 33

16.3.1 Air pressure inlet unit 33

16.3.2 Solenoid valve group 34

16.4 Criss-cross distribution 35

17 CONTROL PANEL 36

17.1 Electric panel warning lights 38

18 DEMOLITION 39

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ORDER 2017.0050 R00_02/2018 III
CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY
IV ORDER 2017.0050 R00_02/2018
01 GUARANTEE CONDITIONS

Guarantee period set at 12 (twelve) months from the date of the approval with signature of both
parties on the “Commissioning report”, but no more than agreed that 18 (eighteen) months from the
date of delivery, with no limitations of tests on all mechanical components which are not casually or, for
improper use, broken.
Guarantee is valid JUST if the maintenance and the use of the manual, supplied by the Seller, will be
completely respected by the Buyer.
Usury materials are out of the guarantee.
Guarantee includes the free substitution or reparation of parts with manufacture flaws.
The delivery of parts which will eventually be substituted, must be done with free return to the client.
If it will be necessary the substitution or reparation of parts during the guarantee period, room and
board together with transport from the hotel/factory and/or car renting costs will be on charge to the
Client.
Guarantee will cover only parts that will be returned to the Seller within 30 days from the receiving of
the replacements.

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


ORDER 2017.0050 R00_02/2018 01
02 EC DECLARATION OF CONFORMITY

COLOR SERVICE S.r.l.


Via Divisione Julia, 15
36031 Dueville (VI) - Italy
Ph.+39 0444 366000 - Fax+39 0444 592469
info@colorservice.net - www.colorservice.net

DECLARES that the newly built machines described below


(how to order n.113 F / 17 (go) Rev.02 of the 11/10/2017):

BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


Model DAP comped by:

N°1 SALT DISSOLVING MODEL DAP 500 LITERS


N°1 SILO 18000 lt.
N°1 LOAD PUMP COMMON FOR SILOS 18000 lt. and 10000 lt. (DAP 360)

Serial number DAP2017161


Year of construction 2017

Complies with the following EU directives:

2006/42/CE “Machinery Directive”


(“Of European Parliament and the Council of 17 May 2006 on machinery and amending Directive 95/16/EC”)

2014/30/EU “Electromagnetic Compatibility Directive”


(“Of the European Parliament and of the Council of 26 February 2014 on the harmonisation of the laws of the Member
States relating to electromagnetic compatibility (recast) Text with EEA relevance”)

and the following harmonized standards:

EN ISO 4414:2012
(Pneumatic – General rules and security requirements for the systems and their components)
EN ISO 13849-1:2016
(Safety of the machinery – Parts of the command system about security – Part 1: General basics for the design)
EN ISO 12100: 2010
(Safety of machinery - General principles for design - Risk assessment and risk reduction)
EN 60204-1: 2006
(Safety of machinery - Electrical equipment of machines - Part 1: General requirements)
EN ISO 13850:2015
(Safety of machinery - Emergency stop - Principles for design)
EN ISO 14120:2015
(Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards)

We declare, as required by Annex V of Directive 2006/42/EC, the marking “CE” symbol is placed on the machine.

The legal representative or his agent:


Name FABRIZIO Signature  
Cognome TOSCHI
Date 20/12/2017

Person authorized to compile the Technical File


Nome Antonello
Surname Turle
e-mail: antonello@colorservice.net

The technical documentation is preserved in:


Color Service S.r.l., via Divisione Julia 15, 36031 Dueville (VI), Italy.

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02.1 CE Marking

The CE marking attests the conformity of the machine with the essential requirements of the health and
safety laid down by the European Directives listed in the EC declaration of conformity.
The CE marking consists of an aluminum metal plate with black printing. It is applied externally and it is
indicated legibly an indelibly (because engraved) with the following data:

• The name and address of the manufacturer


• The CE marking
• The model
• The type
• The serial number
• The year of manufacture

Other data such as:


• The power supply voltage (V)
• The nominal power (kW) and current (A)

is present in an additional white plastic plate with black indelible printing and applied externally on the
front panel of the electrical box.

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03 IMPORTANCE OF THE MANUAL

This technical manual has been drawn up according to the indications given by the European Directives,
in order to ensure easy and correct understanding of the topics dealt with by the operators authorised
to perform the use and maintenance of the machine concerned. If, despite the care taken by the
manufacturer when drawing up the manual, these operators find any problem in understanding it, in
order to avoid incorrect personal interpretations that might endanger safety, they are requested to apply
promptly to the manufacturer for the correct explanations and any further information.
Before using the machine, the authorised operators must read and understand all parts of this technical
manual of and strictly follow all the rules in it, in order to ensure their own safety and that of other
people, obtain the best machine performance, and ensure the maximum efficiency and long life of all
its components. This manual must be at the disposal of the authorised operators at all times and must
always be kept safely, near the machine.

 
THIS MANUAL MUST ALWAYS BE AT THE DISPOSAL OF THE AUTHORISED
OPERATORS AND MUST BE KEPT SAFELY, NEAR THE MACHINE.
 
THE MANUFACTURER DECLINES ALL RESPONSIBILITY FOR ANY DAMAGE TO
PERSONS, ANIMALS AND THINGS RESULTING FROM FAILURE TO OBSERVE THE
RULES AND WARNINGS DESCRIBED IN THIS MANUAL.
THIS MANUAL REFLECTS THE STATE OF THE ART AT THE TIME THE MACHINE WAS
SOLD AND CANNOT BE CONSIDERED INADEQUATE ONLY BECAUSE IT MAY BE
UPDATED LATER IN THE LIGHT OF NEW EXPERIENCE.
IF THE MANUAL IS LOST OR SPOILT, ASK THE MANUFACTURER FOR A NEW COPY,
SPECIFYING THE MACHINE IDENTIFICATION DATA (SEE CE MARKING) AND THE
REVISION.

THIS MANUAL MUST BE HANDED OVER TOGETHER WITH THE MACHINE IF IT IS


TRANSFERRED TO ANOTHER USER.

03.1 Consultation notes

SYMBOL MEANING COMMENT

THE GENERAL DANGER SIGNAL AND THE FRAMED TEXT IN CAPITAL


DANGER LETTERS DRAW THE OPERATOR’S ATTENTION TO THE WARNINGS
GIVEN IN THIS MANUAL.

N.B. (Nota Bene): framed text in capital letters.


Bold print: Highlights some significant sentences in the text.
Italic: Describes the captions of the figures and tables.

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04 ORDER 2017.0050 R00_02/2018
03.2 Intended receivers (authorized operators)

This technical manual is intended exclusively for the operators authorised to carry out use and
maintenance of the machine, according to the specific technical and professional skills required for the
type of activity. The symbols shown below placed at the beginning of a chapter and/or of a paragraph
indicate which operator is involved in the subject dealt with.

THE AUTHORISED OPERATORS MUST PERFORM ON THE MACHINE ONLY THE


ACTIVITIES FOR WHICH THEY ARE SPECIFICALLY COMPETENT.
BEFORE CARRYING OUT ANY ACTIVITY ON THE MACHINE, THE AUTHORISED
OPERATORS MUST ENSURE THAT THEY ARE IN FULL POSSESSION OF THEIR
PHYSICAL AND MENTAL FACULTIES IN ORDER TO ENSURE THAT THE SAFETY
CONDITIONS ARE ALWAYS RESPECTED.
GENERAL OPERATOR
 
This is a professionally trained operator, over 18 years of age, in compliance with the laws
in force in the country of use, authorised only to switch on, use, fine-tune (obligatorily
  with the guards enabled and the machine switched off ) and switch off the machine,
absolutely respecting the instructions given in this manual, provided with the personal
protective equipment (PPE) contemplated.
HANDLING OPERATOR
 
This is a professionally trained operator, over 18 years of age, in compliance with the laws
in force in the country of use, authorised to use fork-lift trucks, bridge cranes or cranes,
  to transport and handle the machine and/or its parts safely, provided with the personal
protective equipment (PPE) contemplated.
MECHANICAL / HYDRAULIC / PNEUMATIC OPERATOR
  This is a qualified technician, approved to perform only operations on the mechanical
/ hydraulic / pneumatic parts to carry out adjustments, maintenance and/or repairs
  even with the guards disabled (with the consent of the safety manager), absolutely
respecting the instructions given in this manual or any other specific document supplied
exclusively by the manufacturer, provided with the personal protective equipment (PPE)
contemplated.
ELECTRICAL OPERATOR
  This is a qualified technician (electrician in possession of the technical and professional
skills required by the regulations in force), approved to perform only operations on
  electric devices to carry out adjustments, maintenance and/or repairs even with the
system live and with the guards disabled (with the consent of the safety manager),
absolutely respecting the instructions given in this manual or any other specific
document supplied exclusively by the manufacturer, provided with the personal
protective equipment (PPE) contemplated.
COMPANY SAFETY MANAGER
  This is a qualified technician designated by the Customer, in possession of the technical
and professional skills required by the regulations in force concerning the safety and
  health of workers in the place of work.
MANUFACTURER’S TECHNICIAN
  This is a qualified technician made available by the Manufacturer and/or by the
authorised Dealer to carry out the requested technical assistance, routine and special
  maintenance jobs and/or operations not listed in this manual which require a specific
knowledge of the machine, provided with the personal protective equipment (PPE)
contemplated.

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ORDER 2017.0050 R00_02/2018 05
03.3 Machine off status

It is obligatory to disconnect the supply of electric power before carrying out any kind of
  maintenance work and/or adjustment on the machine:
1) Main electric switch turned “OFF” and padlocked;
  2) Electric power supply switch (Customer) turned “OFF”;
3) Pressurised air discharged from the machine.

03.4 Abbreviations

TAB. 1 lists some abbreviations used in the text of the “instructions for use and maintenance”.

APPROX. Approximately MIN Minutes


CHAP. Chapter NO. Number
PPE Personal Protective Equipment PAGE Page
RIGHT Right PAR. Paragraph
H Hours POS. Position
EN European Norm REF. Reference
E.G. Example S Seconds
FIG. Figure(s) LEFT Left
MAX. Maximum TAB. Table
MIN. Minimum SEE See
TAB. 01

In the manual you may also find, next to a table, a figure, or a text, a double line “||“; this indicates the
parts of the manual that have been varied with respect to the previous revision.

03.5 Reserved rights

All information (text, drawings, diagrams, etc.) given here is reserved. No part of this manual may be
reproduced and made known (completely or in part) with any means of reproduction (photocopies,
microfilm or other) without the Manufacturer’s authorisation in writing.
All the trade marks mentioned belong to their respective owners.

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04 DESCRIPTION OF THE DAP SYSTEM

The Color Service DAP is a system for stocking, dosing and dissolution of chemical products and
powder’s auxiliars. This model share two silos for stocking with another DAP360. Color Service supplies,
together with the DAP system, a proper software which allows to control the operation of the machines
and allows the creation of new recipes which will be dosed in sequence. The machine is equipped with
a programmable logic controller (PLC) which defines the complete automatic functioning of the system;
the PLC receives signals from the electronic components and from the PC and, depending by the signals
received, guides and controls the movements of the mechanical parts.
The PLC is constantly communicating with the machine’s computer; this allows, at the operator, to
modify the working phases depending by the necessities and to be constantly informed about the
electronic malfunctioning.

Fig. 01 DAP 500

The working cycle is developed as follow:


-- Insertion of the recipe in the computer (by keyboard or by network).
-- The screw motors of the silos, by a special input, allows its rotation for the product’s dosing.
-- The erogation gate of the screw is located on the dissolution tank, so the erogated product goes in
the tank directly.
-- The dissolution tank (Fig. 01) poses on loading cells which allows the check of the product’s weight.
-- Once the weight is obtained, the bath is recycled to dissolve the product in the water.
-- After the recycle, the content of the tank is going to be sent to the distributor through a pump and a
compressed air jet.

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ORDER 2017.0050 R00_02/2018 07
05 TECHNICAL DATA

Silo
10000 lt.

DAP360

Silo
1000 lt.

Fig. 02 DAP 500, Silos and Criss-cross

05.1 DAP 500 Technical data

DAP 500
Total lenght (mm) 2180
Total width (mm) 1220
Total height (mm) 2335
Weight (kg) 1000
Filtered - Pressure 6-8 bar
Compressed air
dehumidified constant
Air consumption 900 l/min
Cold water 120 l/min - Pressure 3 bar - 20/25 °C
Hot Water 120 l/min - Pressure 3 bar - 70 °C
700 l/h max (cold)
Water consumption
1400 l/h max (hot)
Voltage 400 V - 3 Phase + Neutral
Frequency 50 Hz
Power 15 kW
Current max 25 A
TAB. 02

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08 ORDER 2017.0050 R00_02/2018
05.1.1 Dimensions (mm)








Fig. 03 DAP side and top view

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05.2 SILOS 18000 lt.

~8700

204

1650

2780
Ø 2390

Fig. 04 SILO 18000 lt. side and top view

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06 INTENDED USE

The DAP machine has been designed to stocking, dosing and dissolution of chemical products and
powder’s auxiliars.
FIELD OF USE Industrial and handicrafts sector
PLACE OF USE In a closed, covered environment, sufficiently lit, suitable for the legal
requirements in force in the country of use concerning safety and health in
the work place. The machine must stand on a horizontal plane (level) which
ensures its stability in relation to its overall dimensions.
INTENDED USE Dissolution and distribution of products (powder, grains, micropearls) for
productive purpose of mixing.
GENERAL OPERATOR  

 
TAB. 03

06.1 Energy supply source

ENERGY SOURCE SUPPLIES


ELECTRIC Control panel (400 V - 3 Phase + Neutral)
PNEUMATIC Compressed air circuit (6,5 bar)

06.2 Limits of use

The machine has been designed and made exclusively for the intended use described in table 3, so any
other type of use is absolutely forbidden, in order to guarantee, at all times, the safety of the operator
and the efficiency of the machine itself.

LIMITS OF USE: IT IS ABSOLUTELY FORBIDDEN TO USE THE MACHINE


FOR IMPROPER APPLICATIONS, OTHER THAN THE USE INTENDED BY THE
MANUFACTURER (TAB.3).
DURING USE IT IS OBLIGATORY TO BE CONSTANTLY ON GUARD THAT NO
UNAUTHORISED PERSONS GO NEAR THE MACHINE.

IT IS MANDATORY TO ENSURE THE STABILITY OF THE MACHINE ON THE GROUND.

06.3 Ambient conditions

It is necessary to leave a free space around to the machine about 1 meter for easy maintenance.
For a good functioning of the plant, the ambient conditions should be as follows:

Maximum working temperature + 30°C


Minimum working temperature + 10°C
Humidity 10% ; 60%

In the presence of different environmental and operating conditions, the end user shall inform the
Manufacturer in writing about the relevant reference parameters for the necessary measures to be
adopted.

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


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07 TRANSPORT OF THE MACHINE

  The machine is delivered to the buyer by a carrier appointed by the customer, by the
manufacturer or by the authorised dealer, according to the contractual agreements at the
  time of sale.

07.1 Packaging

The system, due to its considerable dimensions, to be packaged, must be disassembled in so that as
to be contained in standard wooden crates and / or special depending by dimension of the machine.
Wooden boxes can have different sizes and then on the outside you have one or more labels with
related information.

ENSURE THAT THE PACKAGING HAS NOT BEEN DAMAGED DURING TRANSPORT.
MAKE A NOTE OF ANY DAMAGE FOUND ON THE DELIVERY NOTE AND SIGN IT
STATING “ACCEPTED WITH RESERVE”.

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08 UNPACKING AND HANDLING

The machine should be lifted only with a pallet truck or a fork lift truck with suitable
  lifting capacity.
• Check the integrity of the packaging.
• Unpack the machine (paying attention to any indications on the packaging).
  • Check the (outer) good condition of the machine.
• Carry out a visual check.
• Dispose of the packing in compliance with the current waste disposal regulations.

IF ANY FAULT IS FOUND, IT IS FORBIDDEN TO USE THE MACHINE. YOU MUST APPLY
TO YOUR DEALER OR TO THE MANUFACTURER FOR TECHNICAL ASSISTANCE.
IT IS RECOMMENDED TO DISPOSE OF THE PACKAGING ACCORDING TO THE
DIFFERENT TYPES OF MATERIAL, ABSOLUTELY RESPECTING THE LAWS IN FORCE IN
THE COUNTRY OF USE.
THE MACHINE PACKAGING MUST BE LIFTED WITH A FORK-LIFT TRUCK (SUITABLE
FOR THE USE), RESPECTING THE INSTRUCTIONS APPLIED ON THE OUTSIDE OF THE
PACKAGING.

Proceed as follows:
1) Using a suitable tool and remove any screws holding the wooden crate;
2) Carefully lift the load and carry it to the place of use;
3) Lower the load very carefully until it is completely resting on the ground.

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09 GENERAL WARNINGS

BEFORE PERFORMING ANY TYPE OF WORK (CLEANING, MAINTENANCE, ETC...)


MAKE SURE YOU HAVE READ AND UNDERSTOOD ALL PARTS OF THIS MANUAL.

Those who use the machine must follow the safety and accident prevention regulations indicated by
Community directives and local laws.
Use suitable protection devices so that each operator can work safely; make sure the PPE used is always
in good condition.
Follow all the safety and danger signs on the machine and do everything possible to ensure they always
remain legible.
Should faults or malfunctions occur in the system or the accident prevention systems, quickly inform the
person in charge and the manufacturer.
It is forbidden to make the machine work in automatic or manual without the shields, or with the shields
installed partially, or with the electronic safety systems bypassed.
Should a situation that endangers the operator arise, immediately press the emergency pushbutton on
the control panel to stop machine operation.
Before starting to work, make sure that all the safety devices are enabled and working correctly.
Keep the floor and the area around the machine clean and free from obstructions.
Maintenance and repairs must only be carried out by suitably trained staff; operators must not act on
their own initiative when faced with interventions that are not part of their job.
Unauthorised people must not be permitted to access the machine when the shields are removed for
maintenance purposes; protect the area involved in the operations with suitable danger signals and
signs.
When maintenance is finished, the shields that were removed must be returned to their position as
quickly as possible.
During maintenance, the electric power supply and the pneumatic supply must be disconnected. To
disconnect the power, rotate the main switch on the control panel to “OFF” and remove the key from the
selector; to disconnect the pneumatic supply, pull down the slide valve near the pressure gauge.
These operations are necessary to stop the machine from starting accidentally.
It is forbidden to clean the electric components with water or a damp cloth.
Do not modify parts of the machine without having received permission from the supplier previously;
the manufacturer is not liable for any malfunctions or the resulting consequences that occur if this
condition is not respected.
Do not modify the system management software.
Requests for permission to modify the software or the machine in general must be made directly to the
manufacturer.
The spare parts used must correspond with the technical performances established by the manufacturer;
this is always guaranteed when original spare parts are used.

THE ORIGINAL SPARE PARTS MUST BE REQUESTED EXCLUSIVELY FROM THE


MANUFACTURER, COMMUNICATING THE SERIAL NUMBER AND THE YEAR OF
MANUFACTURE OF THE MACHINE.

IT IS ABSOLUTELY FORBIDDEN TO REPLACE ANY COMPONENT OF THE MACHINE


WITH NON ORIGINAL SPARE PARTS.

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10 ELECTRICAL CONNECTION

  The electrical connection is performed only when the system is in place, assembled and
wired.
In any case, before starting the connection, it is necessary to make sure that all cables
  intended to be connected to the terminal box are not under tension.
  Check that your mains supply is compatible with the features of the system itself. Power
wires must be firmly and permanently connected to the corresponding terminals of the
  machine.

START UP IS A DELICATE OPERATION AND MUST BE PERFORMED ONLY BY


TECHNICAL QUALIFIED AND EXPRESSLY AUTHORIZED BY MANUFACTURE, WHICH
DECLINES ALL RESPONSIBILITY FOR DAMAGE TO PERSON OR PROPERTY CAUSED
BY NOT CORRECT OPERATION OR PERFORMED BY PERSONNEL NO QUALIFIED OR
UNAUTHORIZED.

IN CASE OF DANGER THE MACHINE MUST BE IMMEDIATELY STOPPED PRESSING


THE APPROPRIATE EMERGENCY PUSHBUTTON.

BEFORE RESTORING THE MACHINE DUE DRIVE OF EMERGENCY PUSHBUTTON,


THE OPERATOR MUST BE SURE THAT THE CONDITIONS THAT HAVE CAUSED THE
ACTIVATION DO NOT HAVE A POTENTIAL HAZARD TO PERSONNEL EXPOSED.

THE MANUFACTURER DECLINES ALL RESPONSIBILITY FOR MACHINE BREAKDOWNS


OR MALFUNCTIONS CAUSED BY SUDDEN CHANGES IN THE ELECTRIC VOLTAGE
BEYOND THE TOLERANCES CONTEMPLATED BY THE POWER DISTRIBUTION
BOARD (VOLTAGE ±10%).

FAILURE TO RESPECT THE ABOVE WARNINGS MAY CAUSE IRREPARABLE DAMAGE


TO THE ELECTRICAL EQUIPMENT OF THE MACHINE AND THE CONSEQUENT
VOIDING OF THE GUARANTEE.

THE MANUFACTURER DECLINES ALL RESPONSIBILITY FOR ANY DAMAGE CAUSED


TO PERSONS, ANIMALS AND/OR THINGS DUE TO THE INCORRECT ELECTRICAL
CONNECTION OF THE MACHINE.

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11 STORAGE

  If for various reasons the machine cannot be installed at the time of delivery and has to
remain some time in storage, it must be placed in a safe environment, with an adequate
  temperature and degree of humidity.

THE CUSTOMER (EMPLOYER) MUST TAKE ALL NECESSARY STEPS TO ENSURE THAT
HIS EMPLOYEES CANNOT ACCESS THE PLACE OF INSTALLATION OF THE MACHINE
FOR ANY REASON UNTIL IT HAS BEEN TESTED.

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12 DIRECTIVES AND REFERENCE NORMS

The machine has been designed and made considering the assessments emerging from an accurate
analysis of risks and aiming to achieve, considering the present state of the art, the objectives
established by the essential safety and health requirements contemplated by the European Directives.
The following table are listed the European Directives and Norms (EN) to which reference has been
made.

REFERENCE DESCRIPTION
2006/42/CE “Of European Parliament and the Council of 17 May 2006 on
machinery and amending Directive 95/16/EC”.
2014/30/EU “Of the European Parliament and of the Council of 26 February
2014 on the harmonisation of the laws of the Member States
relating to electromagnetic compatibility (recast) Text with EEA
relevance”.
EN ISO 4414:2012 “Pneumatic - General rules and safety requirements for systems and
their components”
EN ISO 12100: 2010 “Safety of machiner y - General principles for design - Risk
assessment and risk reduction”.
EN 60204-1: 2006 “Safety of machinery - Electrical equipment of machines - Part 1:
General requirements”.
EN ISO 13849- “Safety of machinery - Command’s system parts about security -
1:2016 Parti 1: General principles for design”.
EN ISO 13850:2015 “Safety of machinery - Emergency stop - Principles for design”.
“Safety of machinery - Guards - General requirements for the
EN 14120:2015
design and construction of fixed and movable guards”.
TAB. 04

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13 SAFETY

WARNING! DO NOT USE WATER TO CLEAN THE MACHINE.

IT IS FORBIDDEN TO TAMPER WITH, EXCLUDE, REMOVE AND/OR REPLACE ANY


SAFETY DEVICE PRESENT IN THE MACHINE.

IT IS OBLIGATORY TO REQUEST THE INTERVENTION OF THE TECHNICAL


ASSISTANCE OF THE MANUFACTURER OR THE AUTHORISED DEALER FOR THE
REPLACEMENT OF ANY SAFETY DEVICE.

13.1 Safety signals

The signals are made up of adhesive labels and / or cartels of yellow color with black pictograms.

WARNING! Electrical danger

WARNING! Moving parts. Entranment danger.

WARNING! Danger

WARNING! Obstacle above

WARNING! Obstacle below

No entry for unauthorized persons

Do not remove protective devices

Do not repair and/or lubricate moving parts

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Do not climb over safety guards

No smoking

Do not use open flames

Obligation to use protective eyewear

Obligation to use gloves

Obligation to use safety footwear

Obligation to use the mask

Obligation to use protective cloths

WARNING! RESPECT THE SIGNALS ON THE MACHINE.

IS COMPULSORY TO KEEP CLEAN THE SAFETY SIGNALS TO ENSURE A GOOD


VISIBILITY.

IT IS OBLIGATORY TO REPLACE ANY DAMAGED SAFETY SIGNALS, ASKING THE


MANUFACTURER TO SUPPLY REPLACEMENTS.

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13.2 Residual risks

For residual risk is defined as a potential danger, impossible to eliminate or partially cleared, it
can cause damage if the operator intervenes using methods and work practices that are incorrect.

We inform the authorised operators that, although the Color Service S.r.l. has taken all the technical and
constructive precautions possible to make the machine safe, there remain some potential residual risks
described in the following table.

Residual risk Frequency Extent of damage Steps taken


Do not put the limbs or
Lesions by contact with any part of the body with
moving mechanical the machine running.
Crushing / shear locks Low parts: amputation (with Comply the safety
loss of one or more signals. Disconnect the
limbs) power supply during all
maintenance operations.
Do not put the limbs or
any part of the body with
the machine running.
Abrasion / drag Low Contusion Comply the safety
signals. Disconnect the
power supply during all
maintenance operations
Danger of contact with
epidermis, ingestion, eye Poisonings by liquid or Comply the safety signals
Low
or mucous membranes of gaseous substances (compulsory use PPE).
liquid and / or fluid
TAB. 05

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


20 ORDER 2017.0050 R00_02/2018
14 CHECKS BEFORE SWITCHING ON

IT IS ABSOLUTELY FORBIDDEN TO SWITCH ON THE MACHINE IF ANY DAMAGE


AND/OR ABNORMAL SITUATION IS FOUND. IF NECESSARY, ASK FOR THE
MANUFACTURER’S INTERVENTION AND NOTIFY THE COMPANY SAFETY MANAGER.

1 ENSURE THE MACHINE IS POSITIONED, INSTALLED AND WIRED.

ENSURE THAT THERE ARE NO UNAUTHORISED PERSONS IN THE VICINITY


2
OF THE MACHINE.

3 ENSURE THAT THE MACHINE IS CORRECTLY INSTALLED.

ENSURE THAT ALL CONNECTIONS (ELECTRIC AND PNEUMATIC) HAS


4
BEEN DONE CORRECTLY.
ENSURE THAT YOU HAVE READ AND UNDERSTOOD ALL PARTS OF THIS
5
MANUAL

TAB. 06

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


ORDER 2017.0050 R00_02/2018 21
15 MAINTENANCE PROGRAMME

Before doing any job inside the machine, unless there are commands that require the machine to be
switched on see chapter 3.3: “Machine off status”.

To guarantee good machine operation and longer component duration, the instructions given below
must be followed scrupulously.
We advise to keep all parts of the machine as clean as is possible.

BEFORE CARRYING OUT ANY MAINTENANCE, MAKE SURE THE MACHINE ELECTRIC
PANEL IS OFF AND THAT THE PNEUMATIC CIRCUIT IS DISCONNECTED.

MAINTENANCE MUST BE CARRIED OUT BY THE MECHANICAL TECHNICIAN WHO


IS IN CHARGE OF REPAIRS, AND BY COLOR SERVICE SPECIALIST STAFF WHEN
INDICATED. SUITABLE PROTECTIVE EQUIPMENT MUST BE WORN WHILE CARRYING
OUT MAINTENANCE (SUIT, GLOVES, OTHER PPE THAT IS NECESSARY ACCORDING
TO WHAT IS TO BE DONE).

ALL THE MAINTENANCE OPERATIONS AND/OR CLEANING MUST BE DONE WITH


THE MACHINE TURNED OFF.

15.1 Ordinary maintenance

Equipment
Operator Operation PPE Note / Description
and/or control

  Verify
machine / Visual check
  status.

Weekly
 
Check the
presence
  of eventual / Visual check
 
product’s
loss.
 

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


22 ORDER 2017.0050 R00_02/2018
Equipment
Operator Operation PPE and/or Note / Description
control

 
Ve r i f y a i r
Set pression between 6 and 7 bar.
pressure
 

In case of missed automatic cleaning:


  Screw or
Verify valves wrench In case of missed cleaning:
status o f p r o p e r • replace gaskets
  dimensions. • replace the valve.

Weekly
Allen key
Verify inlet
o f p r o p e r In case of missed cleaning, remove
water filters
dimensions the material residual parts.
status
 

 
Verify
presence Add one in case of missing of the
/
of antifoam product.
product

Allen key
Verify joint’s
of proper
gasket
dimensions

Verify
solenoid
valves

  Verify
Monthly photocells Contact Color Service
  and sensors
status Visual check
Verify status
of dosing
valves

Ve r i f y t h e
correct
positioning
of sensors
TAB. 07

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


ORDER 2017.0050 R00_02/2018 23
15.2 Special maintenance

  By special maintenance (or extraordinary) we mean all the activities aimed to maintaining
the conditions of use and operation of the equipment with various types of intervention
  performed exclusively by the manufacturer’s technician.

Equipment and/or
Operator Operation PPE Note / Description
control

  Cleaning Contact Color Service


  dosing tank

TAB. 08

For requests and / or information relating to spare parts, please contact


spares@colorservice.net

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


24 ORDER 2017.0050 R00_02/2018
16 PARTS DESCRIPTION

16.1 Dissolution tank

B
C

Fig. 05 Dissolution tank Fig. 06 Dissolution tank interior

The dissolution tank is equipped with a mixer A fixed on the cover; this is composed by a motor build on
a proper cover and by a steel’s shaft, which activates an helix B during the sending phase of the product
(the helix is positioned at the bottom of the tank). On the supporting structure there is the smoke’s
aspirator C connected to the tank’s cover by a flexible pipe.
An endline D mounted on the cover check the position open/close of the lid.

Ref. Code Description


A Mixer PCIMF_7_2_3_3 kW 1,5 4P 50Hz
83011091
B Shaft D.35 L=1300 GIR. D. 160mm
C 55010030 Fan NX202 F6 LF180
D 66000330 Pre-wired plastic endline FF4112-5DN

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ORDER 2017.0050 R00_02/2018 25
The dissolution tank poses over three loading cells E for the product’s weighing; the loading cells are
fixed at the frame of the machine through an apposite steel support and they are connected to the tank
through anti vibration systems E1.

E1

Fig. 07 Loading cell

Ref. Code Description


E 81020654 Loading cell SLB
E1 81020554 Antivibration support for loading cell

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26 ORDER 2017.0050 R00_02/2018
16.2 Hydraulic system

The hydraulic plant of the machine is composed by: a group of hot and cold water inlet, a group of
valves for the recycle and liquid’s sending, a centrifugal pump and a blowing unit on the sending pipe.

16.2.1 Water inlet unit

The water inlet group is composed by: A a manual


A1 sphere valve to open/close the cold water inlet,
A A1 a manual sphere valve to open/close the hot
water inlet, B-B1 two probes for the inlet water
B1 temperature’s control, C-C1 two steel filters to stop
eventual residues which could entry and damage
B the pump or other mechanical parts, D-D1 two
F
pneumatic valves for the automatic control of the
hot and cold water inlet, E a pressure regulator
C1 (the mechanical grip requires 0,3 bar of water
C pressure) complete with gauge, F a pneumatic
valve, connected to the cold water filter, used for
the cooling of the mechanical grip of the pump, G
a flowmeter to check the quantity of dosed water
E D1 inside the tank, H a pneumatic valve used to fill the
tank with water.

The flowmeter G is a flow rate measuring system


composed by a transmitter and a sensor.
If errors happen during the measurement, these are
shown immediately on the display:
D 1) system errors, that include all the device errors as
hardware damages or communication errors;
2) process errors, that include all the application
errors (for example “empty pipe”).
G

Fig. 08 Water inlet

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


ORDER 2017.0050 R00_02/2018 27
Ref. Code Description
A
46010250 Manual sphere valve 1”1/2 F-F A316
A1
B
63011750 Temperature probe PT100
B1
C
05010042 Filter “Y” A316 2” FF
C1
D
42042040 Pneumatic valve PCIPFM_040_2_1_NC - DN40 FF1”1/2 D.70 NC
D1
45040751 Pressure gauge G46-2-02 0-2bar ¼”
E
45040750 Pressure reducer WR110-02-X224
F 42042001 Pneumatic valve PCIPFM_015_0_1_NC - DN15 FF1/2” D.32
G 81030343 Promag 10P40 DN40
H 42042040 Pneumatic valve PCIPFM_040_2_1_NC - DN40 FF1”1/2 D.70 NC

16.2.2 Recycle system and liquid sending

A1

A2

Fig. 09 Recycle valve and centrifugal pump

The recycle and sending system of liquids is composed by a pneumatic 3-ways valve A used to exchange
the recycle phases of liquids (through the A1 pipe) and sending to the distributor or drainage (through
the A2 pipe). The valve is equipped with a component called “vapor barrier” use for the washing of
internal components of the valve.
The centrifugal pump B is used for both the liquid’s recycle, to easily get the complete dissolution of the
used products, and for the sending of the solution got at the end of the recycle phase.

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28 ORDER 2017.0050 R00_02/2018
E
C

D 3

Fig. 10 Sending system / Filling tank valve

The sending product’s unit is composed by: C a three way valve for the liquid sending to the distributor
or in drenage, E a pneumatic valve for the water inlet used to wash the sending line, D a pneumatic valve
for the unloading in drenage of the hot water which do not get requested temperature.
The 3-ways valve C receives the liquids contained in the tank through the pipe 2; the valve could divert
the product to the distributor through the pipe 1 or send the water used for washing in drenage through
the pipe 3.

Ref. Code Description


43053540 3-ways valve DN40 on-off LTSS 316 DE PTFE Vapor Barrier
A
41023250 J-Giotto-top 2 prox PNP PG11
B 80011135 Pump RSA 40-20C 2B75 L180 3 with motor 7.5kW 2P 400V 50 Hz
41023250 J-Giotto-top 2 prox PNP PG11
C
43053531 3-ways valve DN40 on-off LTSS 316 DE PTFE T180 Vapor Barrier
D 42042020 Pneumatic valve PCIPFM_025_1_1_NC - DN25 FF1” D.50 NC
E 42042045 Pneumatic valve PCIPFM_040_2_1_DE - DN25 FF1”1/2 D.70 DE

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ORDER 2017.0050 R00_02/2018 29
16.2.3 Centrifugal pump 230

412.3 506
412.3
The pump has the following features: 7.5kW 2P, 400/50. The cover is in inox steel 316L with joints DIN
11851, mechanical grips, open rotator.

Grandezze - Size: 25-12, 32-12, 32-16, 40-12, 40-16, 50-16, 50-20, 65-16, 65-20

103 161 433.1 344 506 801 183

914

230

412.3
210

Fig. 11 Centrifugal pump RSA

N. DESCRIZIONE DESCRIPTION
103 Corpo Casing
161 Coperchio del corpo Casing cover
210 Albero Shaft
103 Casing
183 Piede di appoggio 412.3 O.ring casingfoot
Support
161 Casing cover 433.1 Mechanical seal
230 Girante Impeller
210 Shaft 801 Electric motor
260 Ogiva girante Impeller Hub
183 Support foot 904 Locking screw
230
344 Lanterna motore
Impeller 914
Lantern bracket
Screw
344 412.3
Lantern O.Ring corpo
bracket O.Ring casing
504.1 Distanziale girante Impeller spacer
506 Paraspruzzi Deflector
433.1 Tenuta meccanica Mechanical seal
801 Motore elettrico Electic motor
904 Grano Locking screw
914 Vite ogivale Screw
940.1 Linguetta girante Impeller key

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


30 ORDER 2017.0050 R00_02/2018
Close coupled sectional view and nomenclature
16.2.3.1 Instruction to change the mechanical Grandezze
grip of the- pump
Size: 32-20, 40-20

103 433.1 161 344 506

504

260

940.1
210

230

412.3
Fig. 12 Mechanical seal RSA

- Size: 25-12, 32-12, 32-16, 40-12, 40-16, 50-16, 50-20, 65-16, 65-20

161 Casing cover 504 Impeller spacer


433.1 344 506 801 183
433.1 Mechanical seal 506 Deflector
260 Impeller hub 940.1 Impeller key

Fixed part assembly: be sure that the round (or the connection) and the placement are perfectly clean
and without any working signs. Wet the spot and the gasket with alchool, glycerol or compatible liquid.
Push the fixed part on the spot using a covered tampon, build it on a sensory drill or handly pressed.
Rotating part assembly: be sure that the shaft is smooth, clean and without cutting angles. Clean the
shaft with abrasive thin sheet (400 grain) even if rectified. After to have wet the shaft with alchool,
glycerol etc. build the rotating part, rotating the grip with slow movements opposite to the spring verse.
Be sure that the two faces are in contact. It is dangerous to have oil, grease or other similar substances
between the gripping faces which must be deeply cleaned.

210 (Exec. C) Double grips counterposed.


The double conterposed assemly is advisable for liquid adhesive, hot, having tendency to make
crystals, gas, etc. With this assembly it is avoided the contact spring-pumped liquid. The cooling
- washing is obtained by the circulation of auxiliary liquid (compatible with the pumped liquid);
that liquid must have a pressure of, at least, 0,5 or major than the existing one in the pump body.

SCRIZIONE DESCRIPTION
po FOR MORE INFORMATION SEE THE PUMP MANUAL
Casing
erchio del corpo Casing cover
ero Shaft
de di appoggio Support foot
nte Impeller
va girante Impeller Hub
terna motore Lantern bracket
ing corpo O.Ring casing
anziale girante Impeller spacer CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY
31
aspruzzi Deflector ORDER 2017.0050 R00_02/2018
16.2.4 Blowing unit

   

Fig. 13 Blowing unit

The pneumatic valve A (complete with position sensor) is connected to the pneumatic system through
the pressure regulator B; it is used to push obtained liquids from the dissolution process to the
distributor through a compressed air jet (blowing phase). It is applied, to this unit, a manual valve C
to close the air line when the machine is turned off; the proximity sensor D check the position of the
manual valve (open, close).
The valve A is controlled by a solenoid valve E located inside the electrical panel, near the solenoid
valves group.

Ref. Code Description


A 42042006 Pneumatic valve PCIPFM_015_2_1_DE - DN15FF1/2” D.70 + Sensor kit
31060020 Filter + pressure regulator 1/4” 0,5-8,5 bar
B
31060105 Pressure gauge 0-4 bar 1/8”
C 45040041 Sphere valve ¼” A316
D 63020520 Sensor IND M8 short
E 31030040 Solenoid valve 5/2 Monost. 24VDC - SY5120-5YO-01F-Q

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32 ORDER 2017.0050 R00_02/2018
16.3 Pneumatic system

16.3.1 Air pressure inlet unit

   

D
 
B

Fig. 14 Compressed air regulation group

The group of compressed air regulation (for the valves activation) is mounted on the machine’s structure,
on the left side of the electrical panel, and is composed by:
A a pressure regulator complete with unloading filter and manometer C;
B a pressure switch to see the presence of compressed air in the line;
D a slide valve to disconnect pneumatic supply when needed.

Ref. Code Description


A 31060020 Filter + pressure regulator 1/4” 0,5-8,5 bar
B 31060125 Pressure switch 0-4 bar 1/8”
C 31060100 Pressure gauge 0-10 bar 1/8”
D 30030105 Slide valve 1/4”

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ORDER 2017.0050 R00_02/2018 33
16.3.2 Solenoid valve group

The solenoid valves group is situated inside the electrical panel.


Solenoid valves activates, through compressed air, all the pneumatic valves of the system.


C A C A C A

Fig. 15 Solenoid valve group

Ref. Code Description


1 31040225 Plug-in base SQ1000 6 pos. multipolar - SS5Q13-06FD0-D-Q
A 31030200 Solenoid valve 5/2 monostable SQ1131N-51-C6-Q
C 31020200 Solenoid valve 3/2 NC D.6 24VDC SQ1A31N-5-C6-Q

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


34 ORDER 2017.0050 R00_02/2018
16.4 Criss-cross distribution

The criss-cross distribution allows to connect every DAP machine to both the destination lines.
1 is the product inlet from the DAP 360, 2 is the product inlet from the DAP 500, E1 is the exit to the first
distribution line, E2 is the exit to the second distribution line.
The system is composed by four 3-ways valve A, each of them controlled by its own solenoid valve.
The position of every valve is checked by an endline mounted on the valve itself.

E2

E1

A
A

Ref. Code Description


43019011 3-way valve A316 DN25 1”
A 31031041 Solenoid valve Namur 5\2 monost. 24 VDC conn.
66000679 Pre-wired plastic endline

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


ORDER 2017.0050 R00_02/2018 35
17 CONTROL PANEL

The DAP electrical panel is composed of a cabinet containing all the electronic components relative
to the machine and a front panel having an indicator light and a button through which you can get
information about system status and reset the machine, and one selector for the automatic/manual
functioning. Below is the list of installed components:

H1
C
Dosing Technologies - Via Divisione Julia, 15 - 36031 Dueville (VI) - ITALY
Tel. +39 0444 366000 - Fax +39 0444 592469 - www.colorservice.net

CUSTOMER BAO MINH


MODEL DAP 500 LITER
ORDER 2017.0050 VOLTAGE 400 V 3PH + N
YEAR 11/2017 kW - A 15 KW - 25 A

1 2 3
SELECTOR RESET LINE POWER
MAN/AUT INSERTION PRESENCE

Fig. 16 Control panel

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


36 ORDER 2017.0050 R00_02/2018
Ref. Code Description
/ 2017.0050.H1 Complete control panel
/ 66000605 Electrical panel 1400x800x400
1 66001275 Orange selector
2 66001266 Blue luminous button
3 66001268 White luminous indicator
66001281+
4 Emergency pushbutton + label
66001301
66002145+
5 Selector ON/OFF
66000965
66002098 Red luminous module
66002099 Green luminous module
6 66002100 Yellow luminous module
66002101 Acoustic module
66002102 Terminal part

1. Orange selector Turning the selector is set to the machine function: automatic or manual.

2. Blue button Pressing the button restart the systems of the machine.

3. White indicator light When it is ON indicates the presence of voltage in the master electrical
panel.

4. Emergency pushbutton Pressing the emergency pushbutton the machine is stopped (mechanical
safety) but the voltage is present in the devices.

5. Switch ON/OFF For electrically isolate the machine (electrical safety) place the switch in
OFF position. In this position (OFF) the power supply to single machine is
discontinued.

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ORDER 2017.0050 R00_02/2018 37
17.1 Electric panel warning lights

A luminous column with siren is installed on the electric panel, whose function is to indicate any system
fault and/or operating status.

Ref. electric panel Signal type Description

Siren Sounds intermittently when an alarm occurs

Red
If on, indicates that the system is in emergency
indicator
H1
Yellow
If on, indicates that at least one alarm is present in the system
indicator
- Machine in automatic mode
Light on fixed
Green - Cycle running
indicator - Machine in automatic mode
Light flashing
- Cycle stationary

SIREN

RED LIGHT

YELLOW LIGHT

GREEN LIGHT

-
Fig. 17 Warning lights on electric panels
 

  THE ASSOCIATION BETWEEN THE DAP STATUS AND THE LUMINOUS MODULE AND
THE RELATIVE CORRESPONDENCE TO THE STEP CARRIED OUT BY THE OPERATOR
  CAN BE CHANGED ACCORDING TO THE CUSTOMER’S REQUIREMENTS.

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


38 ORDER 2017.0050 R00_02/2018
18 DEMOLITION

ALL THE MACHINE COMPONENTS MUST OBLIGATORILY BE IDENTIFIED


ACCORDING TO THE DEFINITIONS OF THE “EWC CODES” (EUROPEAN WASTE
CATALOGUE) AND DISPOSED OF, APPOINTING AUTHORISED AND SPECIALISED
FIRMS, ABSOLUTELY RESPECTING THE REGULATIONS IN FORCE IN THE COUNTRY
OF DEMOLITION.

CORRECT DISPOSAL OF THE PRODUCT: THIS MARK ON THE PRODUCT OR ON


THE DOCUMENTATION INDICATES THAT THE PRODUCT MUST NOT BE DISPOSED
OF WITH OTHER DOMESTIC WASTE AT THE END OF ITS WORKING LIFE. TO AVOID
DAMAGE TO THE ENVIRONMENT OR TO HEALTH CAUSED BY THE INCORRECT
DISPOSAL OF WASTE, THE USER IS INVITED TO SEPARATE THIS PRODUCT FROM
 
OTHER TYPES OF WASTE AND TO RECYCLE IT RESPONSIBLY SO AS TO FAVOUR THE
SUSTAINABLE REUSE OF MATERIAL RESOURCES.
DOMESTIC USERS ARE INVITED TO CONTACT THE DEALER FROM WHICH THEY
BOUGHT THE PRODUCT OR THE LOCAL OFFICE IN CHARGE OF PROVIDING
INFORMATION ON SEPARATE WASTE COLLECTION AND ON RECYCLING FOR THIS
TYPE OF PRODUCT.
COMPANY USERS ARE INVITED TO CONTACT THEIR SUPPLIER AND TO CHECK THE
TERMS AND CONDITIONS OF THEIR PURCHASE CONTRACT. THIS PRODUCT MUST
NOT BE DISPOSED OF WITH OTHER COMMERCIAL WASTE.

CLIENT: BAO MINH TEXTILE AND GARMENT JOINT STOCK COMPANY


ORDER 2017.0050 R00_02/2018 39
COLOR SERVICE S.r.l.
Via Divisione Julia, 15
36031 Dueville (VI) - Italy
Ph.+39 0444 366000 - Fax+39 0444 592469
info@colorservice.net - www.colorservice.net

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