DOCUMENTATION Designation: sample extractor type SP05-K-F
Operating- and MaintenanceInstructions
DOCUMENTATION Designation: sample extractor type SP05-K-F
Index
1. 2. 2.1 3. 3.1 3.2 4. 5. 6. 7. 8. 9. 10. 11. general safety precautions lawful directions for customer liability- and warranty-guarantee delivery specification technical data state of material as supplied mounting instruction operation description trial run trouble shooting card maintenance activities and its intervals list of spare and wear parts drawing/driving data wiring diagram
DOCUMENTATION Designation: sample extractor type SP05-K-F
1. general safety precautions
Besides the safety precautions in this operation instruction there have to be observed the general and local safety- and for prevention of accident rules. !" has to be ensured, that each person who is ordered with mounting, operating and It maintenance of the machine, has read and understood these operating instructions before starting activities. !" machine has been constructed according to the newest state of art and is The reliable in operation. If a person, who is not trained, handles the machine incorrectly, danger can be originated from it. !" machine is exclusively intended for the use and specified loose material The agreed with the manufacturer. In case of non-observance, the manufacturer is not liable for arise damages. !" personnel authority has to be defined for mounting, putting apparatus into The operation, operation and maintenance in order that safety will not be endangered during handling the machine. !" only permitted that the machine runs in original state. Unauthorised It’s requipments and alterations of the machine by user, that can endanger its safety, are not allowed. !" maintenance- and adjustable activities have to be done on principle when the All machine is in stillstanding. Before starting these activities it has to be ensured, that the machine can not be switched on erroneously or by an unauthorised person. !" manufacturer recommends to peruse the operation instructions, because he is The not liable for damages, that result from non-observance the operation instructions. !" difficulties arise, that can not be cleared by user, he should contact the If manufacturer. !" Alterations within the meaning of technical improvement are subject to change without notice.
DOCUMENTATION Designation: sample extractor type SP05-K-F
2. Lawful directions for customer
!" manufacturer exerted itself, that all information, contained in this operation The instruction, is complete, precise and actual. !" far as legal allowable, the manufacturer is not liable for any damages, that As result from non-observance the operation instructions. !" addition the manufacturer is not liable for deliberately and gross negligence. In !" rights are reserved including the right to reproduce this operation instruction All completely or partially in any form. !" Changes of the content without preceding announcement are reserved. !" Technical alterations of the product without preceding announcement are reserved.
DOCUMENTATION Designation: sample extractor type SP05-K-F
2.1 Liability and warranty guarantee
All information and hints for operation and maintenance the machine happen in consideration of our previous experiences and knowledge to the best of a person’s knowledge. We are liable for possible mistakes or omissions, out of question further claims within the scope of guarantee-obligations entered into the main-contract. Claims to extensive compensation are excluded, equal form which legal argument these claims are derived from. Likewise translations are made to the best of a person’s knowledge. We can’t take the liability for mistakes in the translation; even then we can’t take the liability if the translation was made by us or made by order of us. Competent is the german documentation exclusively. Liability or warranty is out of question: !" hints and instructions of the operation instruction are not observed if !" machine, equipment including, is handled incorrectly respectively their if operation doesn’t correspond to the instructed work cycle !" machine will be used in opposition to for purposes other than originally if intended !" protective equipment will not be used or will be put out of function if !" any changes in function will be made without our written agreement if !" respective safety regulations will not be observed (see adequate chapter in this if operation instruction) !" machine, equipment including, will be maintained incorrectly (temporal and the if way of execution; that also includes the use of specified spare parts) Electric wires are parts subject to wear and therefore not liable to the manufacturer’s guarantee. If parts have to be changed respectively providing for replacements, only original spare parts have to be used that have been released by manufacturer. In case of non-observance liability and warranty-guarantee become cancelled.
DOCUMENTATION Designation: sample extractor type SP05-K-F
3. Delivery specification
3.1 Technical data
over all length pipe-diameter of screw sampler mounting flange diameter gross weight slot width slot length drive: worm geared motor manufacturer type voltage frequency power rate of revolutions protection class insulation class : approx. 1080 mm : 60,3 mm : 70 mm : approx. 27 kg : 15 mm : 250 mm
: Danfoss : BS03-34V/D05LA4/SP : 415 V : 60 Hz : 0,18 kW : 35,0 min-1 : IP65 :F
3.2 State of material as supplied
The sample extractor will be delivered as a complete mounted apparatus with mounting flange. This sample extractor has to be stored in dry rooms until he will be mounted at its destination.
DOCUMENTATION Designation: sample extractor type SP05-K-F
4. Mounting instructions
First it has to be fixed a suitable point of insertion for the sample extractor. Following criterion’s have to be considered for the selection of point of insertion: 1. The conveying-system must work without internal pressure at its point of insertion. The material mustn’t get additional air in order to improve its flowability. The point of insertion should be good accessible for the change of sample container later. At the point of insertion should be enough space for correctly mounting and maintenance of the sample extractor. The point of insertion should guarantee that sample extractor can not be damaged by falling material. It has to be ensured that the flow of material will be registered by the sample extractor at the point of insertion.
2. 3.
4.
5.
After chosen the point of insertion under observing the previously criterion’s an aperture has to be brought in with a diameter of 70-72 mm into the funnel, chute, gravity tube or similar. After finish the aperture put the sample extractor out of the packing. If you unscrew the 4 pieces hexagon bolts DIN 931 M12x80 the mounting flange can be dismounted from the screw sampler. The mounting flange has a standard length of 250 mm. It depends on the mounting situation whether the mounting flange has to be cut. Insert the mounting flange into the aperture that was brought in (∅ 70-72 mm). The mounting flange has not be installed succinctly with the housing of the funnel, shut or similar. Nevertheless it has to be observed, that after installation of the sample extractor the sample slot will be not covered by the mounting flange that extends into. The mounting flange may only be pushed in the aperture so far that a correctly screwing up of the 4 hexagon bolts DIN 931 M12x80 is guaranteed. After fixing the position of the mounting flange, adjust the mounting flange into the horizontal line by using a water balance. Now connect the mounting flange with the housing by using a weld apparatus. Check the fixed position and if need be, readjust the mounting flange. Now the mounting flange can be welded tightly at the housing with the suitable amperage. Please notice, that this procedure happens by having no appreciable time delay.
DOCUMENTATION Designation: sample extractor type SP05-K-F
Before putting the sample extractor into the mounting flange, the mounting flange has to be cooled down to normal ambient temperature. Take care that, during pushing the sample extractor into the mounting flange, the direction of the sample slot is above. After putting the sample extractor into the mounting flange, slide the mounting flange with plastic cone ring over the worm pipe of the sampler up to the flange of the mounting flange. Should this procedure not be pitched, detach through slight impacts by a plastic hammer the flange of the cone ring. Is the mounting flange fixed with the cone ring and the through bores are adjusted to each other, put the 4 pieces hexagon bolts DIN 931 M12x80 into the respective bore holes. At first screw the flange connecting by hand. Take care that there is a constant space between the flanges. Now fix the screws uniformly by a suitable tool (ring spanner box and wrench, fixed spanner or ratchet drill in each case width over flats of hexagonal nut 19). For each screw and operation apply a quarter turn. Check by hand through twisting turning the screw sampler if the setting is adequate strong. At this is valid: Only as strong as necessary in order to avoid a damage or a destruction of the plastic cone ring. The plastic cone ring is at the same for sealing the flange connection.
DOCUMENTATION Designation: sample extractor type SP05-K-F
5. Operating description
The screw sampler type SP05-K-F is for sampling of fluid materials out of pressureless funnels, silos, chutes, gravity tubes and similar components which convey materials. The sample extractor is constructed for reversing operating. Before each sampling, the sense of rotation of the sample worm has to be switched to reject (counter clockwise running of the worm shaft). Through this procedure, the non-actual material, which is in the sampler, will be conveyed back into the main-material-flow over the aperture at the face of the pipe of the sampler. This prevents a adulteration of the sample. At the end of sufficient time the sense of rotation of the worm shaft will be returned into clockwise running. In order to protect the drive, it should be made a break about 2 sec. between the change of sense of rotation. Formula for calculation of the minimal necessary reject running time: 1.2 x length of sampler up to sample outlet [800mm] x 60 seconds pitch of the worm (40 mm) x rate of revolutions/minute (35 min-1)
The single sample quantity will be destined through the period of the running time in clockwise direction. For getting a representative sample profile as possible, this procedure should be repeated in several successively following intervals. If there is an electric control in the arrangement of our supply, it contains all above mentioned functions. The periods of reject-running-time, sampling-running-time and also sampling interval are variable at any time and for user comfortable adjustable. At the screw-sampler type SP05-K-F the adjusted maximum filling level is asked via a capacity actuated proximity switch at the sample container. When having achieved the filling level, the sample taking is stopped . Now the sample container must be changed. For that the ball valve has to be closed and the sample container has to be unscrewed from the container connection of the sample discharge. In the following an empty sample container has to be connected with the container connection at the sample discharge and the ball valve has to be reopened. To start the sampling in the automatic mode you have to quit the changing of the sample container at the relating button at the electric control.
DOCUMENTATION Designation: sample extractor type SP05-K-F
6.
Trial run
The trial run is for examination the mechanical and electrical installation. Before delivery, all functions of the sampler will be tested by a trial run in our manufactory.
1.)
Before connecting the power supply check that supply voltage agrees with the operating voltage. Make sure that a motor protection switch is installed with adapted power in the electric control. Make sure that the active sense of rotation of the drive agrees with the required sense of rotation (otherwise phase reversal) Take care of strong background noises (a slight crackling of the worm shaft in the sampler is subject through one-sided bearing). If there appear strong background noises, they can be caused probably by distortion of the tube through external strain. Choose the necessary sampling running time and the necessary interval time at the electric control.
2.)
3.)
4.)
5.)
DOCUMENTATION Designation: sample extractor type SP05-K-F
7. Trouble shooting card
Fault Sampler doesn’t convey material although drive is running Cause False sense of rotation Clear faults phase reversal
sample running time is too short choose a longer sample running time sample slot is clogged Mounting flange covers the sample slot drive doesn’t start sampler is clogged clean up sample slot cut mounting flange or push sampler further clean up the sampler, examinate cause, coarse grain possible open the ball valve and take out the pressed material remove foreign body, replace damaged parts pull the sampler out of the mounting flange, put it into new position and fix it again
the ball valve is always closed while the sampling is running too large foreign body in sample tube (e.g. grinding ball) drive doesn’t work during the reversal operating reject material can’t be pushed out of the sampler at the end of the pipe because there is not enough space
DOCUMENTATION Designation: sample extractor type SP05-K-F
8.
Maintenance activities and intervals
The screw sampler type SP05-K-F functions almost maintenance-free. The ordered maintenance-intervals essentially apply to the total drive unit with gear. Please take the necessary instructions from the included operation and maintenance instruction of the manufacturer. It depends on the sample material if there is an increased wear of the seal ring. By this, a functional influence doesn’t generally happen.
9.
List of spare and wear parts
Printed in bold = wear parts. pieces 1 1 1 1 1 1 1 1 4 8 4 4 1 9 4 4 1 4 1 1 1 1 1 2 1 1 1 1 part no. 640012 640015 640016 640019 640023 640042 640043 641907 640183 640184 640185 640201 640189 640186 640187 640094 640242 640091 640188 640046 640241 640240 640010 640087 640316 641809 641808 640250 description packing sleeve mounting flange cone ring washer to fasten the worm shaft worm shaft seal ring 47.22x3.53 ARP Norm parallel key 6x6x30 worm gear motor, 415 V, 60 Hz, 35 min-1, IP65, Iso F hexagon bolt M12x80 A2 flat washer d=13 A2 single coil spring washers A12 A2 hexagon nut M12 A2 hexagon socket head cap screw M6x18 A2 flat washer d=6.4 A2 single coil spring washers A6 A2 hexagon nut M6 A2 retaining ring for bores DIN 472 ∅ 20 mm hexagon socket head cap screw M6x35 hexagon socket set screw M6x10 A2 hexagon nut DIN 431 2“ A2 housing of sampler AT061309 slot 250x15 mounting flange sample container connection sample container 2 Litre contents ball- valve 2“ stainless steel proximity switch for level measuring frame sheet of the proximity switch double nipple hexagonal
DOCUMENTATION Designation: sample extractor type SP05-K-F