Professional Documents
Culture Documents
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.
01 GUARANTEE CONDITIONS 01
02 EC DECLARATION OF CONFORMITY 02
02.1 CE Marking 03
03.4 Abbreviations 06
05 TECHNICAL DATA 08
06 INTENDED USE 11
07.1 Packaging 12
09 GENERAL WARNINGS 14
10 ELECTRICAL CONNECTION 15
11 STORAGE 16
13 SAFETY 18
15 MAINTENANCE PROGRAMME 22
16 PARTS DESCRIPTION 25
17 CONTROL PANEL 36
18 DEMOLITION 39
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.
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 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:
is present in an additional white plastic plate with black indelible printing and applied externally on the
front panel of the electrical box.
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 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.
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”.
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.
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.
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.
Silo
10000 lt.
DAP360
Silo
1000 lt.
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
~8700
204
1650
2780
Ø 2390
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
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.
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:
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.
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”.
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.
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 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.
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.
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
The signals are made up of adhesive labels and / or cartels of yellow color with black pictograms.
WARNING! Danger
No smoking
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.
TAB. 06
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.
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.
Ve r i f y a i r
Set pression between 6 and 7 bar.
pressure
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
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
TAB. 08
B
C
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.
E1
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.
A1
A2
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.
D 3
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.
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
914
230
412.3
210
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
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
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.
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
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.
D
B
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.
C A C A C A
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
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
1 2 3
SELECTOR RESET LINE POWER
MAN/AUT INSERTION PRESENCE
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.
A luminous column with siren is installed on the electric panel, whose function is to indicate any system
fault and/or operating status.
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.