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Operating Manual For Bag Destroyer Device: Order No.
Operating Manual For Bag Destroyer Device: Order No.
Annex:
OPERATING MANUAL
SIEMENS MOTOR DOCUMENTATION
TABLE OF CONTENTS
page
1. Fundamental Instructions …………………………………………………………...4
1.1 Address of the Manufacturer ………………………………………………….4
1.2 Machine Designation …………………………………………………………...4
1.3 Customer …………………………………………………………………………4
1.4 Country of Manufacture ………………………………………………………4
1.5 Operating Manual ………………………………………………………………..4
6. Operation …………………………………………………………………………….15
6.1 Foreword ………………………………………………………………………..15
6.2 Safety Regulations During Operation ……………………………………….15
1. Fundamental Instructions
2.1 Foreword
An operating manual can only fulfil its purpose if it is available to the machine operator
at all times. Please ensure, therefore, that the operating manual is handed over to
the operating personnel.
All persons involved in the operation, modification and maintenance of the machine
must therefore read and comply with the whole operating manual. Read the whole
operating manual before installing and operating the machine/plant.
This plant is built to the state of the art and in accordance with the applicable regulations
and rules of engineering. This plant can nevertheless represent a source of
danger for persons and property if:
it is used for other than its intended purpose
it is operated by unqualified personnel
it is modified or altered in a manner detrimental to its intrinsic safety
the safety instructions are not observed
Furthermore,
the relevant accident prevention regulations
the generally recognised rules of engineering
the local and national regulation
must also be observed.
Inspect warning signs and warning paintwork at regular intervals and replace, as
necessary.
Rotating parts are not always covered. They therefore represent a danger of
crushing or of being dragged into the machine.
The operating personnel must wear close-fitting working clothes.
Standing in the immediate vicinity of the machine entails the risk of being struck by
overhanging parts of the material being transported. Keep out of the danger area!
Depending on the type of bulk materials being transported, high dust development
and emissions must be expected. Wear a face mask!
Depending on the overall height, there is a risk of particles of the bulk materials
getting into the eyes of the personnel when walking under the conveyor. Wear
safety goggles!
There is a danger of large lumps of the bulk materials falling onto the operating
personnel. Wear a safety helmet!
The local and national safety regulations must be observed at all times during operation
of the machine/plant.
Danger Points marked with this sign warn of a potential danger for
persons
Caution Points marked with this sign warn of potential damage to the
plant or part of the plant
I Note Points marked with this sign contain value information for the
optimum use of the plant
2.4 Use
For safety reasons, unauthorised modifications to the plant are not permitted.
Modifications to the spatial arrangement, the sequence of operations or functions
and to the individual assemblies must always be agreed upon in advance with the
manufacturer. Failure to observe this restriction will invalidate the warranty and can
lead to unforeseeable dangers for man and machine.
Erection and commissioning are carried out by trained specialist personnel from
the manufacturer.
Modification of the machine for a different method of operation (setting of new parameters)
can be carried out by the owner's specialist personnel. This specialist personnel
must hold qualifications as
power electronics engineer (electrical work)
industrial engineer (mechanical work)
Operation of the plant under normal conditions can be carried out by trainer personnel
from the owner's company. This operation includes:
Switching the plant ON and OFF
Monitoring the operation of the machine
Filling the plant with bulk materials
This personnel must have been instructed in these activities by trained specialist
personnel from the owner's company.
The reactions to malfunctions must be known to the personnel. The operating manual
must have been read and understood. The owner must ensure this in individual
cases.
The service and maintenance of the machine is carried out by the owner's specialist
personnel. This specialist personnel must have completed training as one of the
following:
power electronics engineer (electrical work)
industrial engineer (mechanical work)
Shutting down of the machine is carried out by the owner's specialist personnel.
The manufacturer accepts no liability for damage resulting from improper handling.
Supports and lateral guide elements are, where technically expedient from the point
of view of transport, shipped as separate assemblies and not mounted on the belt
conveyor frame.
During transport, ensure that the components arrive at the erection site without twisting
or dents caused by unsuitable retainers or incorrect attachment of lifting gear.
If, on larger conveyors, lifting eyes are provided on the belt conveyor frame, these
must be used. Particularly in the case of conveyors with a distance between centres
of more than 10,000 mm, ensure that the lifting gear is attached to the belt conveyor
frame in such a way that a distance between hooks of 5.000 mm is not exceeded.
Storage
During storage of the components for conveyor systems designed for use indoors,
ensure that these are not exposed directly to the effects of weathering.
A transport and storage time of six months is generally regarded as a period beyond
which protective and corrosion inhibiting measures are to be taken.
Ambient Conditions
The plant can be stored in closed rooms, protected from the effects of weathering.
BGV A 1
BGV A 3
BGV B 3
Technical Data
Surface
Primer: 1x
Top coat: 1x
RAL: 7035
Coat thickness: 105μm
Drive
Type: 1LG0113-4AA70-Z
kW: 4.0 Number of poles: 4
Voltage: 380V Frequency: 50Hz
IP: 55 ISO: F
Drive shaft: VW 28x60
N2: 1435rpm
Notes
Application:
Exclusively for the conveyance of suitable bulk or piece (pellets) material, corresponding to the order
confirmation or respectively off the material- and mass flow mentioned in the field "material/output"
Attention:
Installation- and repair work on the conveyor and especially on the drive units may only be carried out
at standstill and with the appropriate fuse protection, may only be qualified and pertinent personal.
Spare parts
Spare parts pouches orders should state the order-no., as well as the article-no purchase orders:
from the spare parts list
5.1 Erection
The relevant transport regulations as described under 3. Transport and Storage must
be observed during erection. Particular attention must be given to the parts of the
electrical installation and the drive units.
Erection generally begins at the connecting points where an adjustment is not possible.
Stationary conveyors are fixed at the intended points using anchor bolts, dowels or
hexagon head bolts, depending on the site conditions.
Particular care must be taken that the components are not distorted during assembly
and fitting.
Ensure that chutes, bunkers and other structural elements have an adequate distance
from moving parts such as conveyor belt, drive and return drum, idler rollers
and conveyor and drive chains in order to prevent collisions and damage or premature
wear.
We accept no liability for improper erection by the customer. If these instructions are
not observed, we can accept no warranty obligations, nor in the case of modifications
to the plant having been carried out without our approval.
The wrong direction of rotation of the motor can result in damage to the
drive.
Before commissioning with material, the conveyor should be allowed to run empty for
a few hours in order to allow the parts to run in under minimum load. During this
time, the machine parts should be examined regularly in particular for overheating
and noises. Overheating is a sign of alignment or lubrication faults so that a correction
can be carried out.
When the continuous conveyor has run for a few hours without material, the material
should then be gradually added up to the maximum load. During this period, examine
the machine parts regularly as during commissioning without material for overheating
and noises.
After approx. 20 hours operation at full load, the machine parts and mountings
i
should be checked again and retightened. The shackles and grub screws of
the roller bearings must be tightened again after approx. 120 operating hours.
Even under unfavourable operating, chain drives are relatively tough and operationally
safe. Incorrect installation, inadequate lubrication and maintenance, however,
lead to premature wear of chain and sprockets. For this reason, careful installation of
the chain drives and proper mantenance are also important factors for ensuring a
long service live.
The chain links must be uniformly loaded so that the pin is in contact with the bush
over ist full length.
The initial wear of the cain is determined to a significant extent by the precision of
installation and the smoothing of the surface roughness of the chain parts. For this
reason, chains which have already been run in must be reinstalled so that the running
direction and inner surface corresponds to the original installation condition.
6. Operation
6.1 Foreword
Steps must be taken to ensure that persons involved in the operation of the machine/
plant are instructed in the safety concept and the safety rules for the machine/
plant.
Operation of the belt conveyor is limited to switching on and charging the material to
be conveyed onto the conveyor.
All poles of continuous conveyors must be switched off before cleaning and
repair work!
This requirement is satisfied when the mains plug has been removed or, on
i
permanently installed plants, the master switch has been locked.
As a rule, a correctly aligned and secured continuous conveyor will run for a long
period without problems.
One precondition for this, however, is a preventive maintenance adapted to the operating
conditions.
This also includes the regular removal of soiling and deposits of the conveyed material.
Rotating and linear moving parts must not be hindered in their movement by soiling.
If the chain drive is subject to prolonged seasonal standstills, the chains and
sprockets must be cleaned and coated with corrosion inhibitor.
Also inspect the condition of the chain sprockets. If the tooth flanks exhibit signs of
wear, e.g. hooking, the sprockets must be replaced.
Installation, removal and repair work should be carried out with suitable tools. The
relevant safety regulations must be observed at all times during work.
After the necessary retensioning of chains and/or V-belt drives, ensure that the driving
and driven sprockets/pulleys are correctly aligned and that the shafts are exactly
parallel to one another.
An unnecessarily high tension of the drives can have an unfavourable effect on
i the service life. It must be expected that new chains and V-belts stretch more
during the initial period of operation than during later periods; it is therefore important
to initially pay particular attention to chain and belt drives.
During positioning operations, the chain should be pretensioned so that the part remains
taut under load.
Each belt conveyor will produce drizzling of material in the area of the lower trough.
Even best belt scrapers cannot prevent such drizzling. In particular within the area of
the returning idlers an increased abrasion is usual.
Therefore coverings of the lower trough must be cleaned regularly. Depending of the
specific design a certain volume can be accumulated. However, this may not reach
the level of the returning idlers, since this will cause probably damage of the returning
idlers.
The distance between of drizzled material and the returning idlers has to be at least
50 mm.
The filling level of the coverings must be controlled at least weekly depending upon
the type of materials in order to clean these if necessary, at the latest with reaching
the maximum level quantity.
Gearboxes, General
The casings must be filled with oil before commissioning up to the oil level mark (see
also lubrication instructions). The oil level must not be allowed to drop below the
"low" mark. Check the oil level at regular intervals. Too much oil causes overheating,
too little oil causes wear.
Geared Motors
The casings are filled with lubricant on delivery.
7.4.4 Bearings
Lubricant: universal lubricant at least K2K-20 to DIN 51502
recommendation by manufacturer:
multi purpose grease II Würth Sabesto, KPF 2K-30
Lubrication intervals: under normal operating conditions 1x per week,
at least 1x per month
Quantities for lubrication: approx. 1,5 g/bearing ø 20 mm
approx. 1,7 g/bearing ø 25 mm
approx. 2,9 g/bearing ø 30 mm
approx. 3,4 g/bearing ø 35 mm
approx. 4,4 g/bearing ø 40 mm
approx. 5,6 g/bearing ø 50 mm
approx. 10 g/bearing ø 60 mm
approx. 14 g/bearing ø 70 mm
7.4.5 Chains
Proper lubrication minimises friction and thus also wear, thus significantly prolonging
the service life of chain and sprockets.
The lubricant is applied with on oil can between the straps of the inside and outside
link or with a brush to the inside of the slack chain runs. Chains which are lubricated
periodically should be expediently cleaned with grease and dirt dissolving agents before
greasing or oiling.
Manual lubrication with a spray can is a suitable method for open chain drives. It can
be carried out without removing the chain. An efficient and effective application can
be achieved using an extension tube. The spray jet should be aimed between the
inner and outer straps of the chain. In this way, a lubricant with good penetration
properties can work reliably into the chain link pivots.
If the chain is to be greased, we recommend that the chain be laid in warm liquid
grease. The chain should remain in the grease bath until it has reached the grease
temperature and the air bubbles have ceased to rise. The chain link pivots are then
adequately filled with grease.
Heat the grease in a water bath. Heating over a naked flame will cause the grease to
overheat, thus reducing its lubrication properties.
m
drive motor*
cleaning of the cooling rips and air inlet
from dust and dirt
gear unit* 6m
oil level
noises during operation
temperature, venting screws
w
chain-/ V-belt-drive
tension, wearing, greasind
w
coverings lower trough
cleanness, cleaning from deposits
d
scrapers
function, cleaning from deposits, wear
bearings w
fixing, noises during operation
function, bearing seal, greasing
w
idlers
fixing, noises during operation, function
3m
connecting elements
tight fit of screw- and pin connections
3m
safety coverings / sealings
function, completeness, cleanness
machine surface 6m
corrosion, cracks in welding joints
coating
3m
proximity switch*
fixing, function, working distance
1 E
02 Shaft Asm N1085-3 Steel, ø 50 mm
3 V
03 Blade N1020-3 D=356mm
2 E
04 Sealing oil N3013-3 Felt gasket
1 E
05 Key N3019-3 DIN 6885-A-12X8X50
1 E
06 Coupling N3014-3 XL7-28/40
1 E
07 Motor N1059-3 1LG0113-4AA70-Z
2 E
08 Bearing N1014-3 FY40TF