ccs centralised conveying systems...

Manual

R2466

CCS – Centralised Conveying Systems

Labo-Scan

Serial No....................

ISO 08.01.02.058.GB LT nr.: 986891

Rev. 01

Rev.00 CCS-Centralised Conveying Systems – Labo-Scan of 42

1.0 CONTENTS

2.0 GENERAL INFORMATION ............................................................................. 4

2.1 Application ......................................................................................................................... 4

2.2 Restrictions......................................................................................................................... 4

2.3 Design ................................................................................................................................ 4

2.4 Relevant standards, instructions, directives etc. .................................................................... 8

2.5 Operating principles ............................................................................................................ 8

2.6 Certificates ....................................................................................................................... 12

3.0 TECHNICAL DATA......................................................................................... 13

3.1 Type plate ........................................................................................................................ 13

3.2 Dimensioned drawing of vacuum station, example ............................................................. 14 3.3 Capacity ........................................................................................................................... 14

4.0 ASSEMBLY ....................................................................................................... 15

4.1 Fitting the main components ............................................................................................. 15

4.2 Connections ...................................................................................................................... 16

5.0 USERS MANUAL ............................................................................................. 17

5.1 System setup..................................................................................................................... 17

5.2 Operating the system......................................................................................................... 25

5.3 Alarms ............................................................................................................................. 31

5.4 Start ................................................................................................................................. 32

5.5 Stop.................................................................................................................................. 33

5.6 Screen overview ............................................................................................................... 34

6.0 ACCESSORIES ................................................................................................. 35

7.0 MAINTENANCE .............................................................................................. 36

7.1 Maintaining the Labo-Scan control .................................................................................... 36

7.2 Maintaining the central filter, WAM .................................................................................. 36

7.3 Maintaining the vacuum blowers and the valves ................................................................ 36

8.0 TROUBLESHOOTING .................................................................................... 37

8.1 Troubleshooting generally ................................................................................................. 37

8.2 The system stops short ...................................................................................................... 38

8.3 Reduced or stopped conveying of raw material to several or all vacuum receivers .............. 39 8.4 Reduced or stopped conveying of raw material to some of the vacuum receivers ................ 40

9.0 REPAIRS ........................................................................................................... 41

9.1 Replacing the bottom flap vacuum receiver PGT ............................................................... 41

9.2 Replacing the bottom flap vacuum receiver SVR (stainless) ............................................... 42


NB! All electrical diagrams can be found in the pocket in the back of the manual.


2.0 GENERAL INFORMATION

2.1 Application

Labotek’s conveying system is a computerized, in-plant system designed for handling the raw

materials optimally at all levels. The system is fitted with a central blower and a control to ensure

supply of raw materials to each processing machine as required.

The system is designed, dimensioned and customised in accordance with the individual customer’s

machine layout, requirements and requests.

The system is suitable to convey all types of free-flowing granules. An integrated central dust filter

system protects the environment against pollution.

The individual vacuum receivers (PGT or SVR) can be mounted at or combined with Labotek’s

drying or dosing equipment.

2.2 Restrictions

The system may only be used for the purposes specified.

The system cannot be used for powders or liquids, or for living creatures.

The system must be used by qualified operators only, following the correct procedures.

The system may not be located in areas where there is any danger of explosion.

2.3 Design

The design of the system is based on the basic principle of suction air conveying and may consist of the following main components (see the above drawing).

R2618


1. Vacuum station

Used to generate the vacuum necessary to convey the plastic materials.

The vacuum station is supplied as a compact unit consisting of a vacuum blower with motor

protection, a central self-purifying dust filter and piping and valve arrangement.

Alternatively, the central self-purifying filter may be substituted for a built-in return air valve which

is reversing the air flow in the system and by air cleaning the filters fitted in the vacuum receivers

(pos. 2).

2. Vacuum receivers (PGT or SVR) To be mounted on the processing machinery. The capacity of the vacuum receivers corresponds to

the hourly capacity of each processing machine.

3. Labo-Scan control

Used to collate and coordinate all processes of the system.

4. Line clearing valves

To be fitted by the silo(s) / drying hopper(s) to ensure that the material lines are completely cleared

after each conveying cycle so to avoid plugging effectively.

Alternatively, pneumatic slide valves may be fitted under the silo(s) / drying hopper(s). They are

used to clear the material lines and to ensure that an equal amount of material is conveyed in each

cycle.

The system is designed to incorporate Labotek’s other range of equipment such as:

5. Hot air dryer type CD (not shown on drawing) Used to dry and condition non-hygroscopic raw materials.

6. Dry air dryer type DDL, DFD and MDFD (MDFD shown on drawing)

Used to dry hygroscopic raw materials.

To ensure a reliable production it is recommended to install dry air dryers in areas where the R.H.

(relative humidity) varies according to season or is constantly high even though the material is

categorized as less hygroscopic.

7. Dosing and mixing equipment type Gravimix or RS (RS type IDV shown on drawing)

Gravimix is especially designed for gravimetric blending of main materials, regrind, master batch

and other additives.

The Ratio-Selector type RS is designed for mixing two main materials or a main material with

regrinds.

8. Mobile dryer type DDM (not shown on drawing)

Adds to the flexibility of the production process as the unit can be moved about as necessary.

9. Self-purifying filter WAM

The filter is located between the vacuum station and the vacuum receivers and is cleaned after each

conveying cycle.


2.3.1 Vacuum station

The vacuum station unit is as standard supplied with a control cabinet, a filter, not less than one

vacuum blower and all connecting pipes necessary to make the unit fully operational.

The control cabinet, which is made of japanned metal plate, contains all electrical components

required for start and operation of the vacuum station. The electrical motor for each vacuum blower

is fitted with a contactor with thermal overload relay.

The electrical motor of the vacuum blower is supplied with across-the-line starting as standard.

Systems incorporating more than one vacuum blower are fitted with a delay module to minimize

start current for the whole vacuum station.

The front of the cabinet serves also as a door on which a combined safety cut-out and main switch

is fitted. The type plate of the vacuum station is located at the cabinet.

To avoid several successive power consuming starts-ups of the vacuum blower the control is fitted with a time delay function allowing the blower to run on for 20 to 120 seconds after the conveying

has stopped.

Fresh air valve The vacuum blower is equipped with a fresh air valve which opens when the blower is running

without admitting air for material conveying. Valve shut off time is adjustable between 60-120

seconds.

The vacuum station base support is designed to allow location detached or against the wall. It may also hang on the wall, if the wall is strong enough. The base support is equipped with holes for

fastening. The triangular supporting leg may be dismantled if the vacuum station is to hang on the

wall.

Safety valve

To prevent overloading of the blower e.g. by blockage of the vacuum pipe, a safety valve, which

opens automatically if the vacuum exceeds a certain level, is fitted at the inlet side of the blower.

Frequency converter Option. The frequency controller is set in % air speed hereby each station may have its individual

air speed setting depending on the character of the material being conveyed. Raw materials are

gently conveyed and piping system/hoses has increased lifespan. Energy is saved as well.

Filters

The vacuum station may be supplied with one of the following type of filters:

Self-purifying filter

The filter is located between the vacuum station and the vacuum receivers and is cleaned after each conveying cycle. The self-purifying filter may only be used for cleaning vacuum air in the plant in

which it is fitted.

For information on WAM filters, see separate manual.

Blow-back valve

The valve is used to reverse the air flow from the vacuum blower and by air to clean the filter in the

vacuum receiver between conveying cycles.


Cyclone

Filters the air continuously.

2.3.2 Vacuum receivers

The vacuum receivers are made of cast aluminium or stainless steel and come ready-fitted with

bottom flap arrangement (level control) and vacuum valve. The vacuum valve is operated by

compressed air and is activated by a solenoid valve (for 24 VAC).

Type of vacuum valve is identical with the line clearing valve mentioned in section 2.3.4.

2.3.3 Labo-Scan control

The Labo-Scan control consists of a Siemens PLC with a TP 177 MICRO control panel.

R2627

2.3.4 Line clearing valve

The line clearing valve is a single-acting, normally closed 2-way seat valve fitted with a solenoid

valve.

The line clearing valve opens by means of compressed air and, via a return spring, it closes up at

release of pressure (see section 2.3.5).

The closing movement of the valve is controlled by throttling the ventilating side of the solenoid

valve. The valve arrangement is made of plated steel and aluminium.

The valve is fitted at a Ø50mm pipe branch by compression of an O-ring.


2.3.5 Piping system

Labotek’s specially designed piping system is made of aluminium pipes as standard with fittings

made of stainless steel.

Standard diameters of the system are: Ø38 and Ø50mm.

2.3.6 Non-return flap in vacuum receiver

The non-return flap consists of a silicone gasket (52) and a non-return flap (51) fitted at the inlet

pipe (50) of the vacuum receiver.

A non-return flap is fitted in either of the following two cases:

1. The piping system incorporates a coupling station.

2. A common material pipe is used for several machines.

3. If the vacuum station is fitted with blow-back valve.

The non-return flap ensures that false air is not admitted to the system from several vacuum

receivers. At worst it may cause material to be sucked from one vacuum receiver to the other

through the entire piping system.

R1805

2.4 Relevant standards, instructions, directives etc.

Directive no. 2006/95/EU (the Low-voltage Directive).

Directive no. 2004/108/ (the EMC directive).

Directive no. 2006/42/EU (the Machinery Directive).

2.5 Operating principles

2.5.1 Conveying

The vacuum receivers are fitted with a bottom flap. The bottom flap acts as level control and

controls the raw material level continuously.

The Labo-Scan control registers the level in any of the connected vacuum hoppers and at the indication of low level the vacuum station is activated.

The conveying cycles take place in a pre adjusted time corresponding to the time it takes to fill the

vacuum receiver.

To ensure an easy and unobstructed material flow the line clearing valves open (if fitted), and the

pipe lines are cleared so to prevent material from piling up.


2.5.2 Design

Conveying of raw material is, in principle, based on a number of conveying cycles. Each processing

machine is fitted with a vacuum receiver designed to meet both the required capacity and the

requirement for quick change of material and colour.

2.5.3 Conveying cycle

See also section 2.5.4 for the operational sequence of each conveying cycle:

1. When the vacuum receiver (21) is empty the bottom flap, which is also acting as a level

control, will close up against the outlet and by it activating a micro switch. This is registered

in the Labo-Scan control (10) via an electrical signal.

2. Via the bottom flap in the vacuum receiver the system registers all empty vacuum receivers

that are in line for conveying. Each vacuum receiver is activated and filled according to the

principle of first in / first out.

3. The vacuum blower (18) is activated, and the vacuum valve (23) opens in the pre adjusted

time (menu 3.2)

4. A vacuum is generated in the piping system and the raw material (27) is conveyed to the

vacuum receivers according to the time adjusted for each vacuum receiver.

5. When the filling has been completed the line clearing valve (25) opens (if fitted), and air is

admitted into the system via the material suction pipe (menu 3.2). If a slide valve is fitted it

will shut off when the filling has been completed, and by it clearing the piping system.

6. The vacuum valve (23) shuts off and by it vacuum is neutralized in the vacuum receiver (21).

7. The weight of the raw material sucked into the vacuum receiver (21) will cause the bottom

flap to open and the material to fall into the material hopper.

8. When the bottom flap is released against the outlet it automatically indicates to the control,

via the bottom flap switch, that a new conveying cycle will be started only when the level of

the material has dropped sufficiently to allow the bottom flap to close up against the outlet.

9. The Labo-Scan control switches to the next vacuum receiver in the conveying line, and the

conveying cycle is repeated now activating the channel associated to this receiver.

10. When all active vacuum receivers have been filled, the blower will run on for an adjusted time

(20-120 seconds.) (Menu 3.1) keeping the fresh air valve (12) open to avoid overloading the

blower.

The fresh air valve will close according to an adjusted time (menu 3.2) after the blower has

stopped.


R2628

The drawing shows a system equipped with blow-back valve (14).

Equipment shown in the drawing may be optional.


2.5.4 Sequential diagram

The operational sequences of the components of the system are illustrated in the sequential diagram

below:

R1918_GB


2.6 Certificates

2.6.1 IQ-Net Certificate


3.0 TECHNICAL DATA

3.1 Type plate

The identification number consists of a code (A), a type number (B) and a serial number (C).

(A) The first and last digit (A) of the code identify the year in which the machine was manufactured. Example: 16 = 2016.

(B) The digits in the middle (B) of the code identify the machine. The type number consists of

two/three digits characterising the machine type:

MSC Labo-Scan Control: 25

(C) The serial number is a four/five-digit number referring to the individual manufacturing

number of the machine.


3.2 Dimensioned drawing of vacuum station, example

All dimensions in mm.

R2617

The drawing shows 3xLT6 SVS with blowback-valve and filter.

3.3 Capacity

Labotek’s wide range of vacuum stations, vacuum receivers, piping systems etc. and the modular-designed Labo-Scan control make it possible to meet almost any requirements to capacity and

design.

All systems are customised according to information on capacities, number of processing machines

and conveying distances, and the design will always allow for future extension.


4.0 ASSEMBLY

4.1 Fitting the main components

All main components that form part of the system are designed for individual fitting according to

requirements.

4.1.1 Vacuum station

The vacuum station is placed detached. The unit has to be fastened by bolts in the predrilled holes.

The capacity of the vacuum station is calculated on basis of the conveying distances as informed to Labotek; therefore, before altering the machine layout we recommend you to contact Labotek.

To connect the vacuum station follow electrical diagram 202318 placed in the pocket in the back of

the manual.

4.1.2 Labo-Scan control

The Labo-Scan control can be placed either on the wall or in the production area together with other

control units so to make it easily accessible.

To connect the Labo-Scan control follow the electrical diagram placed in the pocket in the back of

the manual.

4.1.3 Vacuum receivers

The vacuum receivers can be fitted either on a machine hopper, a dryer, a mixer or a dosing unit

directly.

4.1.4 Line clearing valve

Filtered, compressed air (5-10 bar (500-1000 kPa)) is to be connected to the connecting branch of

the line clearing valve.

4.1.5 Blow-back valve


the blow-back valve.

4.1.6 Slide valve


the slide valve.

R1763


4.1.7 Central filter, WAM

The central filter is connected to the vacuum station using pipes or hoses.

4.2 Connections

4.2.1 Piping system

Please consider to arrange material pipes and vacuum pipes so to limit the number of bends as much

as possible to ensure minimum loss of vacuum.

4.2.2 Wiring the cables

A four-wire main power cable (3 phases + earth) is connected to the terminal block in the control

cabinet of the vacuum station(s). The internal cable connections interconnecting control cabinet,

vacuum station and blowback valve (if fitted) are performed by Labotek. (See electrical diagram

202318 in the pocket in the back of the manual).

The Labo-Scan control is fitted with single-phase voltage to the terminals. Cables are wired

according to the attached electrical diagram.

4.2.3 The compressed air system

The vacuum valves are fitted on the vacuum pipe, alternatively on top of the vacuum receivers. The

pneumatic controlled valves are connected to a compressed air system supplying filtered and dry

compressed air (5-10 bar (500-1000 kPa).

Compressed air of the required pressure is usually available from the processing machines and

compressed air for the vacuum valves can be supplied from there.

From the compressed air system an air hose is installed to each of the pipe clearing valves and is

connected to the connecting branch.

4.2.4 Central filter, WAM (see also separate manual)

Required supply of compressed air: maximum 10 bars


5.0 USERS MANUAL

The system is operated via the TP 177 MICRO touch panel incorporated in the front plate of the control cabinet.

5.1 System setup

To start the setup press “Service menu”. (See fig. below)

Operating the system.

(See point 5.2.1)

Service menu. (See point 5.1.1)

Start / Stop of the

transport system.

To start the system press

”ON”. When the system

has started the button

will be dark shaded.

To stop the system press

”OFF”. When the

system is stopping the

button will be dark shaded.

To transport to each

channel activate this.

(See section 5.2.2)

Status shows which

channel is being transported to including

the channel’s name.

Shows whether conveying has: Started, is Stopping or has

Stopped.

”Started” the conveying system is activated.

“Stopping” the system is shutting down. Conveying to vacuum

receivers that are already in line will be completed ”Stopped” conveying has stopped. There is no transport and no

further channels can be feed.


5.1.1 SERVICE MENU

Access to this menu requires a user name and password.

User name: Admin

Password: 1001

Press ECS to return to Main screen.

Press HOME to go to Main screen.

The following need to be setup before using the system points. (See section 5.1.2, 5.1.3, 5.1.4, 5.1.5

and 5.1.6)

Setup of channel name

and type. (See section

5.1.2)

Setup of blowers and

alarm. (See section

5.1.3)

Contrast adjustment up

for the touch panel.

Contrast adjustment down for the touch

panel.

Activate this when

cleaning the panel so no

unwanted adjustments

occur.

Puts the panel into

Transfer mode when

loading new software.

Choose language.

Shows amount of channels and slide

valves of the Labo-Scan system, and

SW version of panel and PLC.

Please notice that the slide valves are

always placed on the first channels.

Calibrates the panel

Alarm list. All alarms will be logged

here so they can be seen later. (See

section 5.3.1)

Adjust date and time.

(See section 5.1.5)

Choice of frequency

converter. (See section

5.1.6)


5.1.2 Channel name and type set-up

Press ECS to return to section 5.1.1

Press HOME to return to Main screen.

Forward to the rest of

the pages.

Choose between the

following:

NONE

DH

MACHINE

Touch the field

area”Name” to input the

name. Each channel

must have a unique

name (max. 8 symbols)

and type.


5.1.3 Blower and alarm set-up



Setup of run-on time

for blower. (10-120 sec)

(See section 5.1.3.2)

Setup of the cleaning

method. Choose between:

Cyclone.

Central filter.

Blow-back valve. (See section 5.1.3.3)

Setup of the blow-back

time at start and stop. (0-10 sec)


Setup of frequency

converter speed, if this

option is used. (10-100 %)

(See section 5.1.6)

Setup of delay time for

automatic reset of alarm

lamp.

(20-600 sec)



5.1.3.1 Alarm reset time

When an alarm is activated this timer starts. When time runs out the alarm is deactivated. The alarm

is not confirmed it has to be done manually.

Time can be set from 20 – 600 sec.

5.1.3.2 Run-on time for blower

Used to enter the time the blower is to keep running after a conveying cycle has been completed and

no vacuum receivers are short of material.

The function is created to reduce the number of starting and wear and tear of the blower if a vacuum

receiver becomes short of material just after the blower has stopped. Energy is saved as well.

The optimal run-on time can be adjusted only when the plant has been put into full operation. Due

to different transport distances and number of receivers.

Time can be set from 10 – 120 sec.

5.1.3.3 Cleaning type

Purifying filter, cyclone or blow-back valve.

5.1.3.4 Blowback time at start & stop

Blow-back start indicates blow-back before transport. Blow-back stop indicates blow-back after

transport. (See section 2.5.4)


5.1.4 DH and Machine set-up

To set-up transport and pipe cleaning times on DH and Machines are described in section 5.2

Operating the system (See section 5.2.2.1 and section 5.2.3.1)


5.1.5 Time & date

Note: When the operator opens this screen it updates to current date, time and day.

To show the correct time in the alarm list, the time must be set.



Current date, time and

day.

Set date and time by

pressing each number.

Set day by pressing

current day.

Press ”Set” to activate

changes.


5.1.6 Option



Press here to

choose frequency

converter.


5.2 Operating the system

5.2.1 Overview of the various DH / machines

Press ECS to return to Main Screen.

Pages forward to the

various DH / machines.

Name of the DH/machines

Indicates if the

DH/machine is active,

can show:

OFF: Not active

ON: Active

F/F: In queue for transport

Pushing a DH/machine

icon brings you forward

to setup of this particular

DH (See section 5.2.2)/

Machine (See section

5.2.3).


5.2.2 Overview of the DH

Press ECS to return to section 5.2.1.


Adjustments are not required during normal operation. It may be necessary to adjust the suction probe, and the time of conveying and line clearing when changing to a material of different pellet

size or dust level.

As the operation is fully automatic and no manual attendance is required, only ordinary monitoring

of the operation and functioning of the system are required. Ordinary monitoring includes:

A: Checking the supply voltage and voltage for solenoid valves.

B: Checking the pressure and filters of the compressed-air system.

C: Checking and emptying the central dust/WAM filter daily or at regular intervals according to

requirement. It is recommended to register each time emptying has been carried out.

D: Checking the Labo-Scan control.

Filters (if fitted) in the vacuum receivers are to be checked regularly and cleaned as required, or

replaced if damaged.

Push to activate /

deactivate transport to DH.

Button text shows the

current election, for

example. "ON" that the

chosen transport for this

channel.

Push to adjust transport

time for this DH. (See

section 5.2.2.1)

Bottom flap active.

Transport is active on this DH.

Press here to toggle

between channels.


5.2.2.1 Adjustment of DH



Adjusting conveying

time.

Adjusting line clear

time.

Setup of the speed on

the frequency converter

for this DH if option is

used. (20-100%)


between channels


5.2.3 Overview of machine



Push to activate / deactivate transport to

machine.

Button text shows the

current selection, for

example "ON" that

transport is chosen for

this channel.

Push to adjust transport

time for this machine


Bottom flap active.

There is no active transport to this

machine.


between channels.


5.2.3.1 Adjusting the machine



To ensure an optimal throughput all adjustments and test commissioning may be performed prior to

commencement of operations.

The processing machine located farthest off the raw material silo(s) should be adjusted and

commissioned first:

1. Disconnect all vacuum receivers but the one located farthest off (conveying distance).

2. Set the conveying time of this vacuum receiver to 999 seconds and the line clearing time to 0 seconds.

3. Now register the conveying time by observing when the material flow to the vacuum receiver

stops. This occurs when the vacuum receiver has been completely filled.

4. Enter this time in “Conveying Time”.

5. Register the time of line clearing during the next conveying cycle by lifting the suction pipe out of the material and register the time it takes clear out the probe.

6. Enter this time in “Line Clear.

For vacuum receivers equipped with a non-return flap the conveying time must be adjusted so not to

overload the vacuum receiver, as this may hinder the functioning of the non-return flap.

Adjusting the

Conveying time.

Adjusting the Line Clear

time.

Push to select suction

address. (See section 5.2.3.1.1)

Setup of the speed on

the frequency converter

for this Machine if

option is used

(20-100%)


between channels.


5.2.3.1.1 Overview of the suction addresses

You can select the suction addresses, which are defined as DH container in the configuration of the

channel name. If channels are defined as "machines" or "None", these are not shown because it is

not possible to convey from these. Only channels selected as “DH” allows for slide valves selection.

Press ECS to return to section 5.2.3.1


Select suction address.

The sign ”” indicates

the choice of channel.

After selecting address

by pressing the

requested field the

screen returns to the

previous screen.

Forward to the rest of

the pages. (Becomes

visible when more than

7 slide valves.)


5.3 Alarms

5.3.1 Alarms:

This control is exclusively associated with transport alarms.

A transport error can occur on all channels. The fault is activated if

transported to a channel 3 times without the bottom flap of the vacuum

receiver remains open due to filled receiver.

Transport error disappears again when the bottom flap of the vacuum

receiver remains open for 20 sec. This means that the receiver is full.

The error also disappears if the channel is turned off (set to OFF).

When an alarm occurs, this icon will appear, and flash as long as there are active alarms.

The number indicates active alarms.

Tap the icon, and a list of active alarms will appear.

(For alarm history, see section 5.3.1)

List of all active alarms.

In the presence of an

alarm, this picture is

displayed in front of the

screen. An active alarm

is indicated with a "C”

after the alarm time (18-

03-2009 10:26:55) and

alarm number (7). The alarm text (Chan. 1

CONVEYING ERROR)

is shown under the time.

By pressing "!" in the

bottom right of the

window, acknowledge

the alarm, and you then

press "CA". If the user

does not acknowledge

the alarm before this has

disappeared, the display will show "CG".

"C" = Come

"A" = Acknowledge

"G" = Gone

It is not possible to

operate the panel until

the alarm window is

closed again. This is

done by pressing the

“X” at the top right corner.

When an alarm occurs, this button will appear.

By pressing the button, the alarm lamp will turn off

and the button disappears again.

The alarm is automatically reset after a given time

(default 60 sec.) By this the button disappears again.

To adjust this see section 5.1..3.


5.3.2 Alarm list

Press ECS to return to section 5.2.1.


5.3.3 Main switch on vacuum station

The main switch is an ON/OFF switch to START/STOP the vacuum blower. Normally the main

switch should be positioned at ON, as the blower function is controlled by the Labo-Scan control.

5.4 Start

1. IMPORTANT! Check that a filter cartridge is fitted in the filter housing.

2. Check that the voltage available corresponds to the voltage specified on the type plate at the control cabinet of the vacuum station.

3. Check that control signals to the line clearing valve and the vacuum valves are 24 VAC, and

24 VDC to the bottom flaps of the vacuum receivers.

4. Check that the compressed-air supply for valves for vacuum, line clearing and blow-back (if

fitted) is connected to the conveying equipment.

5. Check that the vacuum station is bolted properly.

6. Check that all activated vacuum blowers revolve arrow-directed (in case of reverse rotation,

two phase leads have been switched when connecting the main cable).

7. Check that the central/WAM filter is connected, if fitted.

The alarm list shows

active alarms and alarms

witch has occurred with

time and date.

Alarms coming, alarms

witch are acknowledged and alarms witch

disappears are logged.


5.5 Stop

To stop the system press “OFF” on the screen (See section 5.1). Conveying already in line will be completed (status: Stopping).

At status: “stopped” no further conveying will be executed.

Now the system may be disconnected on the main switch.


5.6 Screen overview


6.0 ACCESSORIES

Customised control units are available according to requirements.


7.0 MAINTENANCE

Maintenance is limited to regular control of filters, fuses and contactors for vacuum blowers.

7.1 Maintaining the Labo-Scan control

The Labo-Scan control is checked regularly to ensure that all functioning’s are operative.

Filters, if fitted, in the vacuum receivers should be replaced at least every three months.

7.2 Maintaining the central filter, WAM

See separate manual

Please notice!

When checking or replacing dust filters the scanning system must be shut off.

7.3 Maintaining the vacuum blowers and the valves

Vacuum blowers, line clearing valves and the functioning of the blow-back valve, if fitted, should

be checked once a week. Check the functioning of the compressed-air system including the free

flow of compressed air to-and-from the valves.

At one or more of the following conditions it may be necessary to adjust the stroke speed of the line

clearing valves using the throttle valve:

A: The pressure in the compressed-air system has been changed.

B: Change of material.

C: The system has been modified or extended.

As to dimensioning and calculation of capacity contact the supplier of the system before making

any modifications or extensions.


8.0 TROUBLESHOOTING

Malfunctions in the system usually appear by one of the following observations:

- Irregular operation or total stop of the vacuum station.

- Lack of material, wholly or partly, at one or more processing machines.

8.1 Troubleshooting generally

Prior to initiating a comprehensive troubleshooting check the mains supply, the compressed air

system and the raw materials as follows:

1. Power supply:

Connecting fuses

Phase and mains voltage

Thermal relays

Contactors and power switches

Fuses

Cabling

2. Compressed-air:

Compression Flow

Filter

Valves

Pipe joints and pipes

3. Supply of raw material:

Level of raw material in silos, obtains or the like.

Position of telescopic suction probe in raw material.

Pile up of material in the pipes.

8.1.1. Operational malfunctions

Operational malfunctions may be one of the following:

1. The system stops short

2. Conveying of raw material is reduced or stopped to several or all vacuum receivers.

3. Conveying of raw material is reduced or stopped to one vacuum receiver.

Before initiating any troubleshooting activity check that the conveying time, the line clearing time

and the telescopic pipe have been properly adjusted.

Note! At the change of material it may be necessary to readjust the settings if the bulk density and/or

shape of replacement material vary considerably.


8.2 The system stops short

Should the system stop short it is usually caused by an electrical error. If the power supply is connected we recommend that you check:

Error Check Remedy

Total stop of the

whole system

The position of the main switch at the Labo-Scan control.

Turn the main switch to position 1.

The position of the main switch at the control cabinet for the

vacuum station

Turn the main switch to position 1.

Control voltage for vacuum station.

Re-establish bad connections, replace defective fuses.

Control voltage 24 VAC for

vacuum station.

Replace fuse, if defective.

Cabling and wiring to the

vacuum station

Re-establish bad connections, replace

defective cables and wires.

Control voltage for the Labo-

Scan control.

Re-establish defective

connections/defective fuses replace

according to diagram

Fuses. Replace defective fuses, if any.

Important!

When defective fuses are replaced the cause of error should always be

established and remedied accordingly.


8.3 Reduced or stopped conveying of raw material to several or all vacuum

receivers

Error Check Remedy

Conveying reduced

or stopped to several

or all the vacuum

receivers.

Level of raw material in silo, octabin, bag or like.

Supply new/more material

Position of telescopic pipe in silo,

octabin or bag.

Adjust position and e.g. telescopic

suction probe by dislocating inner

and outer pipe proportionally

Line clearing valves

Do the valves close tight? Remove any impurity between valve seat and piston.

Have the piston gaskets become leaky?

Replace the piston gaskets.

Has the return spring become slackly or has it gone?

Replace the return spring

Do the piston and the piston rod work sluggishly?

Replace piston/piston rod

Condition of filter at cylinder

cover?

Replace or clean filter as required.

The mechanical functioning of

the solenoid valve of the line

clearing valve?

Replace the solenoid valve if it flaps.

The supply of compressed air to

the solenoid valve?

Repair any leaks. Clean filter and

check compressed-air system. Adjust

pressure and flow.

The vacuum valve does not pick

up the electric signal connections.

(24 VAC) from the control.

Re-establish wires and Replace the

fuse.

No or reduced

conveying in general.

Check the blow-back valve if

fitted

Repair the blow-back valve (see list

of spare parts.)

Check control signal (24 VAC) for coil at the relay

Replace fuse according supplementary to diagram. Replace

vacuum valve.

Check the mechanical functioning of fresh air valve

Repair fresh air valve. (see list of spare parts).

Control signal 24 VAC for coil at solenoid valve of fresh air valve

Replace fuse in the system. Replace vacuum valve

Conveying capacity

reduced

One or more of the non- return

flaps are open or worn

Check functioning of non-return

flaps, if fitted. Check adjustment of

conveying time (the vacuum receiver must not be filled to overflowing).

Replace defective non-return flaps.


8.4 Reduced or stopped conveying of raw material to some of the vacuum

receivers

Adjust conveying time of the individual vacuum receivers in accordance with conveying distances

and capacity of the hopper making sure that material is not able to pile up in the piping system.

At reduced conveying to one processing machine first check that the conveying time, the telescopic

suction pipe and the line clearing valve have been correctly adjusted. Then check as follows:

Error Check Remedy

Conveying to one

vacuum receiver has

stopped

Whether the vacuum receiver has been activated in the Labo-Scan control

Activate the vacuum receiver in question at the TP 177

MICRO panel.

The disc filters in top of the vacuum receiver (fitted only if the system is

supplied with blow-back valve).

Clean or replace filter as required.

Central, self-purifying filter, if fitted Replace cartridge filter and empty dust collector.

Leakiness between vacuum receiver and filter on side of the vacuum receiver

Clean the contact surfaces and replace the filter.

The bottom flap of the vacuum receiver

(its closing mechanism and the micro switch).

Adjust or repair the bottom

flap as required

The spring controlled bottom flap must

close up properly when conveying to the associated vacuum receiver.

A “click” must sound from the micro

switch when the bottom flap is

approximately half-open.

Replace a defective micro

switch.

Leaks in the vacuum receiver, the piping system and the vacuum piping system.

Repair hopper and/or piping systems.

The mechanical functioning of the vacuum valve which is fitted on top of

the vacuum receiver

Clean off any impurity at the vacuum valve which may

cause leaks or hinder a free

and unobstructed movement of

the piston or the piston rod.

Replace gaskets.

Replace vacuum valve.

Control signal (24 VAC) to the supplementary relay for vacuum blower.

Replace fuse Replace vacuum valve

In case a malfunction in a channel cannot be located or remedied immediately the vacuum receiver in question can be transferred electrically via the Labo-Scan control to an available channel, if any,

until spare parts can be procured.


9.0 REPAIRS

9.1 Replacing the bottom flap vacuum receiver PGT

1. Clear the vacuum receiver.

2. Disconnect the vacuum receiver by pressing OFF at the TP 177 MICRO operator panel.

3. Unplug the vacuum receiver to disconnect the power supply.

4. Dismantle the vacuum receiver from the processing machine.

5. Turn the machine upside down or sideways and remove the bottom flap by removing screw

and disc (66).

6. Remove dust and impurity from the mounting cylinder (67).

7. Fit the bottom flap (51) on the maundering cylinder (67).

Adjust the bottom flap by dislocating it in the oval hole so that the discharge branch is

covered completely.

At vacuum receivers Scanning PGT 4 the bottom flap is to be located as near to the edge as possible.

At vacuum receivers Scanning PGT 61 and PGT 9 the bottom flap is to be pushed back

completely.

8. Adjust the spring function of the bottom flap, if necessary. See separate manual

9. Mount the vacuum receiver on the processing machine and plug in the vacuum receiver to reconnect the power supply.

10. Connect the vacuum receiver by pressing ON at the TP 177 MICRO operator panel.

R1512


9.2 Replacing the bottom flap vacuum receiver SVR (stainless)

1. Clear the vacuum receiver.

2. Disconnect the vacuum receiver by pressing OFF at the TP 177 MICRO operator panel.

3. Unplug the vacuum receiver to disconnect the power supply.

4. Dismantle the vacuum receiver from the processing machine.

5. Turn the machine upside down or sideways and remove the bottom flap by removing the split pin (77).

6. Remove the magnet (79) and the balance weight (78) from the bottom flap.

7. Fit the magnet (79) and the balance weight (78) at the bottom flap.

8. Remove dust and other impurity from the mounting fixture.

9. Fit the bottom flap (51) in the mounting fixture using the split pin (77).

10. Adjust the proximity switch if necessary. See separate manual

11. Fit the vacuum receiver on the processing machine and plug in the vacuum receiver to

reconnect the power supply.

12. Turn on the vacuum receiver by pressing ON at the TP 177 MICRO operator panel.

R1979

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