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    19 views28 pages

    MH 03

    Uploaded by

    Wanderson Alcantara
    as

    Copyright:

    © All Rights Reserved
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    507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 6 Operation 6.1. Preparatory procedures Prerequisites for optimum operation are the correct set-up of the machine in ac- cordance with the design drawing and the professional and correct assembly and connection of the components, the ductings, the control and measuring in- ‘strumentation and the filter hoses/cartridges. Before operating the machine, check the following: — Check all bolted connections and all clamping ring closures. Check for leaks. — Check the electric and pneumatic connections. ~ Check the safety equipment. = Turn the classifying wheel over by hand and check for freedom of move~ ment. — Check the classifier in idling mode. ~ Check for any vibrations or scraping noises. Tum the ZPS beater unit over by hand and check for freedom of movement. — Check the ZPS drive in idling mode. ~ Pay attention to any directives issued by the user with respect to grinding operations! 6.2 Opening and closing the classifier cover The rotating machine parts constitute a safety hazard When reaching into a running machine, parts of the body can get caught up in the rotating parts which can ultimately result in serious injuries. Physical contact with the product in the machine can lead to serious injuries (e.g. caused by inhalation or contact with the eyes). + Switch off the machine and system, disconnect from mains power and se- cure against unauthorised and unintentional restarting (e.g. lock it). + Depressurise the compressed air lines. + Wait until the drives come to a standstill + Wait until the dust settles in the machine, + Allow any hot components to cool down before touching them or wear sult- able protective gloves. + Always make use of personal safety equipment (industrial breathing set, face mask or goggles, etc.) a ~&}- wosoKawa avpina 38/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 3 © ‘ illustration 14: Classifier top section with dosing unit 1 Plate 2 Classifier cover 3 Clamping ring 4 Pressure measurement 5 Clamping ring 6 Dosing unit 7 Product feed bin 8 Cover Opening the classifier cover + Remove the pressure measurement line. + Remove the clamping ring (5). * Lift the metering device with the plate slightly at the front and move off to the side. + Remove the clamping ring (3) and remove the classifier cover. Closing the classifier cover * Clean the flange surfaces and seals carefully. * Locate the classifier cover and secure with the clamping ring (3). * Lit the metering device with the plate slightly at the front and move it back to its original position + Replace the clamping ring (5). + Connect up the pressure measurement line. a ~GB- Hosokawa ALPINE 39/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 6.3 Classifying operations ‘The classifer top section with dive, clessitying wheel and spiral discharge is common tothe fllowing system variants ~ Classifier ATP — Jet mill AFG = Classifier mil 2PS Cut point of classifier For every particle size, the Tromp curve indicates the probability with which the particle will move into the coarse fraction. This Tromp curve is used to determ- ine the cut point. The cut point d, (d,.) according to Tromp is defined as the particle size where the probability of the particle moving into the fine or coarse fraction is equally as great. The precision of cut = d../d,, can also be derived from the Tromp curve. The fineness of the end product depends on the cut point set at the classifier. This in turn is a function of the peripheral speed or the speed of the classifying wheel and the radial speed of the air flowing through the classifying wheel, i. the volume of classifying air that is drawn through the machine by the fan. Setting the cut polnt as a functlon of the speed and the alr flow rate Operating mode Parameters Result At variable speed high speed fine classifying result low speed coarse classifying result ‘At constant speed high air flow rate coarse classifying result low air flow rate fine classifying result Table 1: Cut point, speed and air flow rate Calculation formula The relationship of the cut point to the airflow rate and speed is approximately reflected in the following equation: Cut point volume flow rate of working air ‘Speed © constant - dependent on product and system of units, can be determined by tests ‘The system is normally operated with the nominal air volume (50-75 m’/h clas- sifying air + approx. 23 m’th rinsing air) and the speed is set to correspond to the desired cut point, a ~GB- Hosokawa ALPINE 40/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation Cut point and speed ‘The calibration curve shows the relationship between the cut point d,, and the speed. da, is the particle size of the fines at which 97% pass through This calibration curve applies only to limestone and to materials of the same density and a similar particle shape — and at maximum air low rate. For materials of different densities p,, the cut point can be roughly calculated using the following formula: [Po ho, = tor, Ver For materials of different densities and different particle shapes, itis advisable to plot a separate calibration curve in each case. Calibration _forlimestone _p = 2.65 kg/dm® curve Airflow rate 65 m'/h Loading <0.1 kgim’ Classifying wheel (monobloc) 36 vanes E 8 a 6 Classifying wheel speed n [min-1] Setting the speed ‘The speed which needs to be set for the desired cut point d,,, can be read off the calibration curve. Example: A cut point of 6 um will be achieved with a classifier speed of 10,000 min Set the respective speed at the operating panel or by means of the hand wheel, of the variable-speed gearing. ‘The speed measured at the classifier is indicated on the operating panel. ‘Setting the nominal alr flow rate The nominal air flow rate is set, adjusted and indicated at the control panel. a ~&}- wosoKawa avpina 41198 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation Evaluating the classification After a test, weigh the fines and the coarse material ‘Take representative samples and evaluate the classifying result (e.g. determine the cut point dor d, as per Tromp, and prepare a Tromp curve). Plotting the calibration curve The calibration curve for any particular material is relatively easy to plot, provided that the exact particle composition of a powder (of which a sufficient ‘quantity is available) is known from, for example, a sedimentation analysis or sieving analysis (e.g. with the Alpine air jet siove €200 LS). First of all, the coarse product yield (in percent) should be determined for iffer- cent classifier settings (speed, max. air flow rate) ‘The analytical cut point is the particle size of feed material at which the residue percentage is equal to the coarse product yield percentage obtained during the classification, Although the analytical cut point corresponds sufficiently with the cut point d_ determined as per Tromp's definition, it deviates from the cut point d,. The val- ues obtained are plotted on a graph and are then joined up to form a curve by drawing a continuous line through them. When drawing up the calibration curve, we recommend keeping within the fob lowing capacity ranges for limestone: Cut point Fines yield 34m approx. 1.5 -4 kg/h 104m approx. 6-12 kg/h 60 um approx. 30-50 kg/h Feed metering unit ‘Test the feed metering unit for function, Itis good policy to prepare a calibration curve for the feed metering unit with re- ‘spect to each product to be ground or classified with this system, Pay attention to the instructions issued by the respective manufacturer. Fiter Check the filter elements for correct installation. The filter elements should touch neither one another nor the filter housing at any point. ‘The opening time (pulses) of the solenoid valves and the intervals between the cleaning blasts can be set at the operating panel, Remove any valves which are constantly open and clean them; it may be ne- cessary to exchange parts if damaged. a ~GB- Hosokawa ALPINE 42198 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 6.4 Grinding operations 6.4.1 Jet mill AFG Alr flow rate of AFG Jet mill Approximately in accordance with the following formula: V=9.5xD? xp, x fExn VT The formula applies only to the supercritical range p, > 1 bar g V m'my Volume flow rate of working air D [mm] diameter P, [bar] absolute pressure in front of grinding nozzles T,[*kelvin] Temperature of working air n number of nozzles Maximum air flow rate of working air = approx. 75 m'/h Maximum total alr flow rate (working alr + rinsing alr + filter cleaning alr) = 100 m'vh Product level control The product level control of the mill is regulated as a function of the classifier's ‘current loading, The current loading of the classifier is dependent on the product level inside the mil, the produc itself, the speed and the airflow rate, Because the speed, air flow rate, and product are not altered during the grinding process, the current loading is really only a function of the material throughput rate. In its tur, the material throughput rate can only achieve its maximum value if the product level is optimal Ifthe product level is too low, this results in an incomplete utilisation of the jet ‘energy, meaning that the throughput rates wil be lower, Ifthe product level Is too high, this will obstruct the return of the coarse material to the material bed, The resultant classifier overload situation leads to a sudden increase of the classifier current loading, which then causes the speed to drop. The consequence is that product will be discharged whose par above that of the set cut point. To prevent the product level in the grinding chamber exceeding a maximum level during operation, the feed metering unit shuts off automatically as soon as the classifier current loading has reached a certain level. The maximum filling volume is 0.8 litre Determining the current loading or shut-off polnt for the feed metering system at a given speed and a predefined grinding air pressure: ‘tthe operating panel, set the contact ammeter intially to between 0.2 and 0.3 A above the idling mode current loading value, so thatif the current loading exceeds this idling mode value, the feed metering unit and thus the product a ~GB- Hosokawa ALPINE 43198 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 6.4.1.1 feed will shut down, By switching the system off during the test, i.e. with the mill in “filled” instead of “empty” condition, the product level can be checked, Open the mil ‘A product level where the product just covers the nozzles is totally acceptable. If this is not the case, run further tests, altering the switch point of the contact am- meter upwards or downwards until the aforementioned product level situation is attained Now set the ammeter contact to a value which lies more or less in the middle between the upper value just determined and a lower limit value, This lower limit value should always be above the idling current loading value of the classifier 0 that the mill does not run empty. ‘The set limit value is now the switch point for the feed metering unit. If the set limit value is reached, a delayed relay turns the feed metering unit on or off, as the case may be, The time delay can be set at the operating panel, Because, as already mentioned, the “fine-tuning” of the system is dependent to ‘a great extent on the product being processed, the foregoing is perforce a gen- eralised description of the adjustment procedure, In the case of difficult products, experience with the product may be necessary before optimum operation is possible. Pressure monitoring The mill may only be operated up to a certain design-dictated maximum operat ing pressure. A pressure sensor with pressure transducer Is used for monitoring the pressure which automatically shuts down the system if the set maximum pressure is reached. In this case, an overpressure error message appears on the display of the operating panel Set value (can be adjusted after suffi. 60-70 mbar cient practical experience) Maximum value 90 mbar a ~GB- Hosokawa ALPINE 44198 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 6.4.2 Pressure test connection 5 4 8 24 Be é @giohe js Ilustration 15: Pressure test connection 1 Filter disc 2 Round seal 3 Cover 4 Clamping ring 5 Tube to pressure gauge 6 Pressure test connection 7 Tube to dosing unit ‘The pressure sensor is connected to the pressure test point on the head of the classifier top section by a tube. The pressure test point must always be equipped with a fier disc. A round seal- ing ring serves to press the fiter disc against the head of the classifier top sec- tion, Check the pressure test point regularly for dirt and leaks (section Cleaning the pressure test point). Classifier mill ZPS ‘Changing the end-product fineness ‘The end-product fineness can be influenced by altering the impact angle. Dependent on the properties of the product to be ground and the problem spe- ification, the rotational direction can be towards either the "short" or the "long" ‘edge of the grinding track. ‘The rotational direction towards the short edge is preferred for hard and brittle products. It results in a slightly finer end product than the rotational direction to- wards the long edge. The rotational direction towards the long edge is preferred for softer, more com> pressible products that tend to form deposits. The decision on which way the grinding track or grinding track segment should be fitted must be based on corresponding tests or experience with the respect- ive product. The rotational direction towards the short edge is the preferred dir. ection ‘The impact angle can be altered by turning the grin« ‘segment through 180°, 1g track or grinding track a ~GB- Hosokawa ALPINE 45/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation short edge long edge ia Hlustration 16: Changing the end-product fineness 1 Grinding track 2 Beater unit X Grinding gap ‘Comminutlon effect With decreasing particle size, the strength of the individual product particles in- creases, and in the case of agglomerates containing single primary particles which have bound together, the strength increases even more. The product to be classified must therefore always be deglomerated in the classifier before a fine classification is at all possible. In the case of extremely fine feed products, the stress necessary for deglomera- tion is so great that any larger primary particles in the feed product can be com= mminuted ‘The comminution effect can be measured by passing the same coarse material through the classifier several times, paying close attention above all to the de- cline in coarser particles of the coarse material fraction Mill speed With classifier mills, selection of the right impact velocity (dictated by the beater unit speed or peripheral speed) has a major influence on the fineness and on the throughput. Generally speaking, a lower peripheral speed results in higher throughputs and a coarse end fineness in the case of easily grindable (brittle) products. How- ‘ever, it is wrong to select a speed that is too low, otherwise the product circula- tion rate in the mill will increase sharply as a result of too litle finished product being generated per pass. Besides this, too much product circulating In the mill increases the energy consumption, overloads the classifier and the beater unit, and ultimately leads to standstill of the beater unit andlor classifier. This increase in the product circulation rate is not always immediately notice- able because the build-up of poorly grindable material is only gradual. A throughput measurement is not appropriate until exactly the same amount of product (of all degrees of grindabilty) is comminuted as is fed into the machine. In practice, a lower limit for the peripheral speed of approx. 60 misec has estab- lished itself (corresponds to a beater unit speed of 12 000 min"), ‘A turther reduction of the speed does not bring any advantages. The upper limit for the peripheral speed is approx. 110 m/sec, which corresponds to a beater a ~GB- Hosokawa ALPINE 46/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 6.5 6.5.1 6.5.2 Unit speed of 22 000 min’. The most common peripheral speeds range between 100 and 110 misec (correspond to beater unit speeds of between 21 000 - 22.000 min”, respectively. If the mill Is overloaded: — Check the current loading value. = Switch off the metering unit and wait until “normal” conditions are restored, then start up again with altered parameters (e.g. reduced feed rate), System operation PLC control unit ‘The machine is controlled by means of a PLC program. ‘A description of the PLC program is delivered if ordered, Al process variables as well as the screen settings can be selected either by means of a parameter bar or direct on a touch screen. A graphical representa- tion of the selected operating mode is displayed on the screen. Allthe physical parameters required for smooth operation are indicated on the screen. The control program is menu-guided. ‘The machine can be operated manually or automatically via the operating panel, Operation with product TNs Risk of explosion when processing potentially explosive and/or flam= mable products Without special safety measures, the machine is not suitable for processing po- tentially explosive andlor flammable products. Serious or even fatal injuries are possible. + Without special safety measures, do not operate the machine with poten- tially explosive and/or flammable products. + Among others, special safety measures can be: © Machine installation in an enclosed and separate room that is capable of withstanding a possible explosion. It is not permitted to enter or to be in this room during machine operation. + When in doubt, contact HOSOKAWA ALPINE. a ~GB- Hosokawa ALPINE 47198 Ld 507760 / Version 1.0 ATP 50/ AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation If processing harmful or toxic substance: Safety hazard: make sure no product is inhaled or gets into the eyes + Take appropriate safety measures to suit the hazard class of the product being processed, e.g. + Pay attention to the safety data sheet of the product being processed. + Always make use of personal safety equipment (industrial breathing set, face mask or goggles, etc.) + Install the machine in an enclosed and separate room that may not be entered unless protective clothing is worn. + Ifin doubt, contact HOSOKAWA ALPINE. ‘The machine is usually operated in batch mode, Por Illustration 17: Operation with product 1 Dosing unit / product feed bin 2 _ Filter container 3 Cyclone container 4 Disc valve 5 Disc valve 6 ATP container Feeding the product ¥ The machine is switched off. + Fill feed material into the supply bin of the dosing unit, * Close the cover on the supply bin of the dosing unit so that a hermetic seal is created. The cover must not be removed during operation because product can then leak out of the system due to the altered pressure ratios. a ~&}- wosoKawa avpina 48/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 65.3 Removing the product + Before removing the containers (3, 6), close the respective disc valves (4, 6), * Shut the machine down before removing the bin (2). + Wait until the dust has settled in the containers. Generally speaking, the containers undemeath the collection devices should be removed and emptied every time a batch of material has been run through the machine and the system is at a standstil ‘Avoid leaving the disc valves (4, 5) closed for any length of time during opera- tion as this will impair the function of the collection devices. System start-up ‘An Incompletely closed machine Is a serlous safety hazard, When reaching into a running machine, parts of the body can get caught up in the rotating parts which can ultimately result in serious injuries, Physical con- tact with the product in the machine can lead to serious injuries (e.g. caused by inhalation or contact with the eyes) + Never start up the machine unless itis completely closed and fully as- sembled + The classifier or mill module (ATP, AFG, ZPS, etc.) must be installed on the classifier top section. + All connecting ductings must be installed and secure. {see also the separate Instructions for the operating panel) = Fit the required module (ATP, AFG or ZPS) to the classifier top section and effect the connections, — Dependent on the installed module, install the containers under the collec- tion devices and open the disc valves. — Check visually to make sure the system is completely assembled. Press the "ON" push-button for the control voltage located on the operating panel. The system control unit starts up. After a brief delay, the "start menu" is displayed on the screen of the operating panel, ‘Open the manual valve for the compressed air supply located on the side of the installation table. ~ Select "ATP", "AFG" or "ZPS" operating mode at the operating panel. ~ Check the operating parameters at the operating panel and correct if neces- sary. = Select "Automatic" operating mode at the operating panel = Inocessary, carry out a test run without product (select at the operating panel) a ~&}- wosoKawa avpina 49/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 6.5.4 © Start the machine by press © Check the machine for leaks, error messages, and check the target/ac- tual values, etc, 1g “Start” on the operating panel. © Stop the machine by pressing "Stop" on the operating panel. — Start the product feed. If applicable, weigh the product first. ~ Start production operations by pressing "Start” on the operating panel. = Once all the product has passed through the machine, shut the machine down, The test run without product mentioned above should be carried out every time parameters are changed, the system is cleaned and reassembled, and after changing over to a different module, etc. System shut-down ‘The system can be shut down manually at any time (even during production op- erations). System shut-down is usually in reverse sequence to start-up. In an emergency, actuate the EMERGENCY-STOP switch, Normal shut-down — Press “Stop” on the operating panel. — Wait until all machine sections are shut down and at a standstill = Close the manual valve for the compressed air supply located on the side of the installation table. ~ Press the "OFF" push-button for the control voltage located on the operating panel. — Dependent on the installed module, close the disc valves and remove the {ull containers under the collection devices, EMERGENCY STOP ‘The EMERGENCY-STOP actuator is only to be used in emergencies and to test its function, All system components shut down instantly. The product present in the system at this moment is not discharged. Itis possible for unground product still in the system at the moment of switch-off to shift into the end product and contaminate it. Restarting after an EMERGENCY STOP: * Locate and remedy the reason for the EMERGENCY STOP. * It may be necessary to remove product from the machine. + Reset the EMERGENCY-STOP actuator. + Restart the system in the prescribed switch-on sequence, a ~GB- Hosokawa ALPINE 50/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 6 | Operation 6.5.5 6.5.5.1 6.5.5.2 Filter differential pressure ‘The differential pressure between the filter housing (dust side) and the fier head (clean air side) is measured constantly by a pressure transducer. A pres- sure evaluator evaluates the measured data and displays them on the screen of the control panel. I the differential pressure is too high, an error message ap- pears on the screen and the system shuts down. The differential pressure is usually lower than 20 mbar. The cleaning intervals can be altered (usually decreased) at the operating panel. This influences the differential pressure. If the differential pressure rises to above 20, the filter hoses or cartridges will need to be cleaned or renewed. Filter resistance The collection efficiency of the filter reaches optimal values as soon as a layer of filtrate has built up in the pores of the fiter hose fabric. In our experience, this is characterised by a differential pressure of at least 6 mbar. This is why with new or washed filter hoses, the dust content in the clean air is always some- what higher at first and does not return to normal unti this layer of filtrate has formed. By changing (usually decreasing) the intervals of the valve control unit (timer), the filter resistance can be influenced. Should the filter resistance rise to above 15 mbar and all methods of reducing it fall, the fiter hoses must be cleaned or renewed. Dust discharge Ejecting or leaking product. Injuries possible if product is inhaled or gets into the eyes. + Switch off the machine and system, disconnect from mains power and se- cure against unauthorised and unintentional restarting (e.g. lock it). + Wait until the fan air has stopped circulating, + Tum off the compressed air supply. Wait untl the compressed air in the system has expanded to normal values. + Wait until the dust settles in the filter. Empty the product bin regularly, To ensure perfect functioning of the filter, itis not permitted to use the fiter cone for buffer storage of the discharged product. a ~GB- Hosokawa ALPINE 51/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 | Maintenance 7 Maintenance Safety information The rotating machine parts constitute a safety hazard When reaching into a running machine, parts of the body can get caught up in the rotating parts which can ultimately result in serious injuries. Physical contact with the product in the machine can lead to serious injuries (e.g. caused by inhalation or contact with the eyes). + Switch off the machine and system, disconnect from mains power and se- cure against unauthorised and unintentional restarting (e.g. lock it). + Depressurise the compressed air lines. + Wait unti the drives come to a standstill + Wait until the dust settles in the machine. + Allow any hot components to cool down before touching them or wear suit- able protective gloves. + Always make use of personal safety equipment (industrial breathing set, face mask or goggles, etc.) 7.1 Lubrication Dispose of used lubricants properly and in a responsible manner! Drives Because all drives are permanently lubricated, they need no relubrication. Relubrication only during a major overhaul carried out by the manufacturer. Auxiliary units Refer to the manufacturer's instructions for details of lubricating the feed meter- ing unit, the fan and other auxiliary units, 7.2 Dismantling and cleaning the system ANGER Risk of explosion If flammable or potentially explosive detergents are used + Never use flammable or potentially explosive detergents! All cleaning waste (product residues, dirty cloths, etc.) must be disposed of in a responsible and environmentally compatible manner. ‘The method and frequency of cleaning is dependent on the product being pro- cessed, a ~&}- wosoKawa avpina 52/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 | Maintenance 7.2.1. Dismantling the system ‘Thoroughly clean the machine prior to every product change. To this end, dismantle the machine: Remove the dosing unit Ilustration 18: Dosing unit 4 3 5 Clamping ring 2 Dosing unit Container 4 Cover Safety grille 6 Plate Remove the clamping ring Shift the plate with the metering device off to the side. Remove the cover and remove the safety grille. © The feed metering unit is now accessible, If applicable, dismantle the feed metering unit into its component parts in accordance with the manufacturer's instructions. Undo and remove the clamping rings and ductwork fitings. Replace the safety grille after completing the cleaning procedures. Removing the classifier and mill Remove the installed module (ATP, AFG, ZPS) (section System conversion). 53/98 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 | Maintenance 7.22 Removing the cyclone Release the clamping ring closure and remove the cover with outlet bend. Removing the filter Refer to the separate operating instructions issued by the manufacturer for de- tails of removal and dismantling Cleaning the system Dry cleaning Itis usually sufficient if the machine is brushed out with a handbrush or wiped ‘out with a dry cloth and then vacuumed with an industrial vacuum cleaner. Wet cleaning If this dry cleaning method does not prove thorough enough, material residues can be washed off with plain water or a weak washing solution. Check that the detergent solution used for cleaning is compatible with the construction materi- als of the machine! Never use acids or leaching solutions for cleaning! Dry the component parts thoroughly after wet cleaning or run the machine in id~ ling mode after assembly to dry them. Stalniess steel parts Stainless steel parts are suitable for manual cleaning, for cleaning in an indus- trial washing machine, in an autoclave or in an ultrasound bath, Max. permissible temperature: 150°C Seals The seals (silicone, Teflon) are suitable for manual cleaning or for cleaning in an ultrasound bath. Max. permissible temperature: 90°C Cleaning the fiter Check the filter housing and filter head regularly for any caked-on deposits. If any filter hoses or cartridges have become damaged, itis advisable to thor- ‘oughly clean the fier head. Refer to the manufacturer's instructions for details of cleaning. Cleaning the feed metering unit, fan and disc valves Refer to the manufacturer's instructions for details of cleaning. It may be neces- sary to remove the components. a ~GB- Hosokawa ALPINE 54198 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 [Maintenance 7.2.3 Cleaning the pressure test point 7.2.4 — ACAUTION, Injurles possible Ifthe filter ruptures and/or product elects (e.g. Inhala~ tion, eye irritation), Clogged-up or soiled fiter discs can falsify measurement of the pressure inside the filter. + Check the test points regularly. + Clean or exchange the filter insert as necessary. ‘The pressure test point is equipped with a filter disc. + Remove the clamping ring and cover. + Remove the round seal and filter disc from the test point, * Clean, blow out or renew the filer disc. Check the round seal * Blow through the tubes. * Then screw the pressure test point back together again, 6 lustration 19: Pressure test connection 1 Filter disc 2 — Round seal 3 Cover 4 Clamping ring 5 Tube to pressure gauge 6 Pressure test connection 7 Tube to dosing unit Cleaning the filter All cleaning waste (product residues, dirty cloths, etc.) must be disposed of in a responsible and environmentally compatible manner. ‘The method and frequency of cleaning is dependent on the product being pro- cessed. a ~GB- Hosokawa ALPINE 55/98 Ld 507760 / Version 1.0 ATP 50/ AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 | Maintenance 7.2.4.1 Dismantling the filter 1s I 51 52 ° 4 a) % (EE Bd jp 3 = 7 T > a4 14 at . of = aN fa ‘ 82 : cs A 8 oz c lustration 20: Filter conus designs 1 Filter housing 2 Filterhead 3 Filler element Head plate 5 Dedusting unit (diaphragm and 5.1 Diaphragm valve solenoid valve) 5.2. Solenoid valve 6 Installation table 7 Airidust inlet 8 Clean air outlet 9 Retaining pin 10 Blast pipe 11. Clamped connection 12 Angle bracket 13 Clamping ring 14 Clamping ring ‘A Varlant A (order-specific) Al Filter cone ‘A2_ Container (20 dm) B Varlant B (order-specific) B1 Filter cone B2 Container (50 dm’) C Variant C (order-specific) 1 Filter cone C2 Container (20 dm’) C3. Disc valve The filter and system are switched off and secured against restarting. 56 / 98 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 [Maintenance Removing the product bin * Hold the product bin securely + Get a second person to release the clamping ring on the product bin. + Remove the product bin, Removing the fiter cone + Remove the ductings leading to the airldust inlet. * Hold the filter cone securely. + Get a second person to release the clamping ring between filter cone and filter housing + Remove the filter cone. Removing the filter housing * Disconnect and remove the test point for measuring the filter resistance. + Get a second person to release the clamping ring between filter head and filter housing. = The filter housing lowers by a few millimetres, but remains suspended in the angle brackets of the installation table, + Now lift the filter housing including the head plate out of the angle brackets and deposit on a clean surface. Removing the head plate Lift the head plate including the filter elements up and out of the filter hous- ing by the handles and deposit on two assembly stands or a similar sub- structure, Removing the filter elements + Open the hose clip and pull the filter hose together with the wire cage sup- port downwards off the injector. * Strip the filter hose off the wire cage support a ~GB- Hosokawa ALPINE 57/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 | Maintenance 2 3 4 5 i Ilustration 21: Filter hose assembly 1 Head plate 2 Hose clip 3 Filter hose 4 Injector 5 Wire cage support Removing the filter head + Remove the test point, mains power connection and compressed air inlet. A.caution: The compressed air is a safety hazard and can cause injuries when car- rying out any work to the compressed air system. Turn off the com- pressed air supply and wait until the compressed air in the system has expanded to normal values. + Remove the ducting from the clean gas outlet, + Undo the clamp connection on the blast pipes and remove the filter head, * Release the screwed pipe connections and remove the dedusting unit 7.2.4.2 Assembling the filter Make sure the sealing surfaces are clean and that the seals are seated cor- rectly. Check the seals for damage and renew if necessary. Installing the filter head * Fit the dedusting unit to the fiter head. + Lift the filter head onto the installation table and fasten in place with the clamp connections. Installing the head plate + Grip the head plate by the handles and lift into the filter housing. Pay atten- tion to exact positioning! Installing the filter elements * Deposit the head plate with the inserted injectors on an assembly stand or similar, a ~GB- Hosokawa ALPINE 58/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 [Maintenance * Push the wire cage support with its base plate to the fore into the filter hose such that the filter hose envelops the wire cage support without creases. Make sure in doing so that the longitudinal seam of the filter hose engages In the groove of the beaded collar of the wire cage support. * Fold the projecting open end of the filter hose over and into the wire cage support. * Slip a hose alip over the open end of the filter hose and tighten it somewhat close to the bead in the collar of the wire cage support such that the hose clip does not shift but the collar of the wire cage support is not yet drawn to- gether. Slide the filter hose with wire cage support over the injector until the bead in the collar of the wire cage support engages in the groove around the pert- phery of the injector, The fier hose must be perpendicular to the head plate and parallel to the other filter hoses. + Now tighten the hose clip securely. 2 —3 4 H 5 i lustration 22: Filter hose assembly 1 Head plate 2 Hose clip 3 Filter hose 4 Injector 5 Wire cage support Installing the fiter housing * Lif up the filter housing with installed fiter elements and locate in the angle brackets. + Replace the clamping ring on the fiter head, Installing the filter cone + Raise the filer cone. * Get a second person to engage the clamping ring. Installing the product bin * Raise the product bin. + Get a second person to engage the clamping ring on the product bin a ~GB- Hosokawa ALPINE 59/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 | Maintenance 7.2.4.3 7.2.4.4 Preparing the filter for operation + Flange all removed ductings back onto the filter. + Connect up the test points and the compressed air supply. + Restore mains power. Cleaning the filter housing Check the inside of the filter at regular intervals for any product deposits and coating formation. To this end, the filter must be dismantled and thoroughly cleaned, Personal experience with the respective product should be used as a basis for determining the cleaning intervals. If the filter elements are damaged, thoroughly clean the fiter head (clean air zone) Dry cleaning Dry cleaning with a brush, broom or industrial vacuum cleaner is usually suffi- cient, Wet cleaning Only use a wet cloth for wiping out the filter or wash by hand if absolutely ne- cessary. Dry the filter in idling mode after wet cleaning. Cleaning the filter hoses If the fiter resistance rises from intially normal values (approx. 15 mbar) and then sels in at a constant fier resistance of 20 mbar, this usually indicates that the pores ofthe fiter hoses are clogged up. Ifit is possible (e.g. during a system standstil) to run the fiter empty, an attempt can be made with dry cleaning to bring the filter resistance back down to normal values. To this end, operate the filer's compressed air dedusting system over a long period with the fan switched off. If such a measure is not possible or proves unsuccessful, replace the filter hoses with new or washed (cleaned) ones. Pay attention to the following when washing the filter hoses: — the temperature and pH value of the detergent solution, — the intensity of the mechanical stress exercised during washing must be brought into line with the respective filter hose material and type of filter, dust, — because washing will cause wool felt hoses to shrink, always dry-clean them, — pay attention to the washing instructions issued by the filter hose manufac- turer, — Filter hoses that have become damaged as the result of mechanical, chem- ical or thermal stress must always be exchanged for new ones. 7.2.4.5 Cleaning the valves Although the valves are largely maintenance-free, it may become necessary to clean them, a ~GB- Hosokawa ALPINE 60/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 [Maintenance 7.2.4.6 Cleaning the diaphragm valves Dismantle the diaphragm valves, clean them and exchange the diaphragms. Cleaning the solenold valves If applicable, refer to the manufacturer's instructions for details of cleaning the solenoid valve. It may be necessary to exchange a defective solenoid valve for anew one. Cleaning the pressure test connections Injurles possible If the fter ruptures and/or product ejects (e.g, Inhala= tion, eye Irritation). ‘Clogged-up or soiled filter discs can falsify measurement of the pressure inside the filter. + Check the test points regularly. + Clean or exchange the fier insert as necessary. ‘The pressure test connections at the test points on the filter head and filter housing are equipped with a filter disc made of sintered material and/or cotton or glass wool, + Unscrew the pressure test connections, remove the cotton/glass wool (if ap~ plicable) as well as the pressure section and filter disc. + Clean, wash or blast out the filter disc and exchange the cottoniglass wool (if applicable). * Blow through the tubes. + Replace the pressure test connections. 2 3 llustration 23: Pressure test connection 1 Filter dise 2 Pressure section 3 Tube to pressure gauge a ~&}- wosoKawa avpina 61/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 | Maintenance 7.3. Regular inspections - wear control 7.3.1 7.3.2 7.3.3 Maintenance schedule Malntenance Additonal Information cycle Monthly 7.4.1 Check the shaft lip seal in the classifier drive 7.42 Mill drive ZPS Quarterly 7.3.2 Regular inspection procedures Annually 7.3.4 Filter cartridge of ultrafine fitter Asnecessary 7.3.2 Regular inspection procedures See chapter 3.6 Safety equipment 7.1 Lubrication 7.3.3. Wear control Regular inspection procedures The following inspection procedures must be carried out every 3 months — Check all moving machine parts for function. = Check all bolted connections, especially connection of the classifying wheel on the shaff; tighten if necessary. Check all measuring equipment for perfect function. — Check the pressure test connections for soiling and leaks. — Check all visible seals for damage. = Check the inside of the machine for deposits and caking formation, ete. = Check all hose lines for damage, material fatigue and cracks, etc. Exchange damaged ones immediately. Observe the exchange intervals specified by the manufacturer of the hose lines. Inspection procedures and test work of the safety circuits — The accompanying documentation “Safety of machinery — Functional safety” includes a description and test specification for each safety circuit Be sure to read the document carefully and have the test performed accord- ingly by a qualified electrician, Wear control Wear and corroston are safety hazards and can lead to Injurles Machine parts lose their original strength as the result of wear and corrosion, ‘They can subsequently break, damage the machine and be catapulted out of the machine. Serious or even fatal injuries are possible, + Always exchange worn and/or corroded parts promptly and professionally. a ~&}- wosoKawa avpina 62/98 Ld 507760 / Version 1.0 ATP 50 / AFG 100 / ZPS 50 | BA 1288/99 - C1-290385-1000 EN 7 [Maintenance Inspection Intervals The wall thickness of the components that are subject to wear or corrosion must be checked regulary. The user must determine the Inspection Intervals and the Inspection procedures land carry out the inspections as a function of the product such that the wall thickness never wears down to below the minimum value. The point where wear is worst is always decisive. ifn doubt, contact the customer service division of HOSOKAWA ALPINE for advice and assistance, ‘Component Classifying wheel Spiral discharge Fines discharge ‘Wear-protection elements (order-spe- cific) Cyclone, fiter, bins and ductings ATP: vane ring AFG: nozzles ZPS: beater disc Permissible wear/corrosion Classifying wheel vanes: max. 25% of their original height. max. 1mm, max, 1mm Untit almost worn through. ‘max. 0.2 mm Until the function is impaired. Until the function is impaired, Beater disc, ie. the beaters: max. 3 ‘mm in height and max. 1.5 mm on each side of the beater or until the function is impaired. ZPS: grinding track The grinding track in the area of the

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