SP MF [PDF]

Citation preview

Multi-function separator SP-MF Type No. 145 04 01



Operating and Service Manual 06/2004 en



This operating and service manual contains information protected by copyright. No part of this operating and service manual may be copied, printed, filmed or reproduced, processed, duplicated or disseminated by any other means, either in whole or in part, without our prior written consent. We are not liable for damage or problems arising from the use of items of special equipment, parts and replacement parts which are not original Trützschler products or replacement parts. The German version is the authoritative version of this operating and service manual.



 2004 Trützschler GmbH & Co. KG, Mönchengladbach All rights reserved



Trützschler GmbH & Co. KG Textile Machinery Manufacturing Company D-41199 Mönchengladbach Postfach 41 01 64 Telephone +49 2166 607-0 Telefax +49 2166 607-405 E-mail [email protected] Internet www.truetzschler.com



Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



7



About this operating and service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purpose of this operating and service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventions employed in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definition of machine sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols employed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety of persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Avoid machine damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



7 7 7 8 8 8 9 9 10 10 10 10 11 13



Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



15



Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



21



Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning messages and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keyboard and display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key-operated switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Malfunctions and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control systematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparation for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . First start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Daily preparations for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



21 21 21 22 22 22 23 24 24 24 25 28 28 28



Constructional layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position within a plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan BR-FD500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Addition of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy part separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metal Separator SP-EM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling level control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



145 04 01 S SP-MF S en S 06/2004



15 15 15 16 16 16 17 17 17 18 19 20 20 20



Switching the machine on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switching the machine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring production data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection, maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing wheeled waste containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring heavy part separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monitoring pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Further tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



29 30 30 30 31 31 31 33 34 34



Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



35



Setting exhaust air output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Purging air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heavy part separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 Working Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Set door locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Enter limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Reset counter EM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Display control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Display scheduled value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Autoleveller to be calibrated? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Change control parameters? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Display ejections EM? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Extraction flap EM service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Selection of language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Network address TKN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Display program numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Set system clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volumetric flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional description of integral action controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Balancing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



35 37 37 38 38 38 38 39 39 40 41 41 41 41 41 42 42 42 42 43 43 44 44 44



Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



45



Dealing with malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Malfunction indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault messages – causes and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire in wheeled waste container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing wheeled waste containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing CO2 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Waste compartment door opened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED indicators in switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



145 04 01 S SP-MF S en S 06/2004



45 45 45



46 50 50 50 51 51 52 53 56 57



Miniature control system/central processing unit KSZ4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I/O module DEA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



58 59



Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



61



Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



79



Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metal detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire extinguishing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



79 79 79 79 79 79 79 80 81 81 82



Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



83



Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning filter sieves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning light barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning comb profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning air ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning extraction flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter pressure controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning volumetric nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning waste compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine panelling, frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional testing of display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional testing of aggregates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Further service operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing CO2 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing fluorescent lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



145 04 01 S SP-MF S en S 06/2004



61 61 61 61 64 64 66 67 67 69 69 70 70 71 71 71 73 74 74 74 77



145 04 01 S SP-MF S en S 06/2004



Introduction



Introduction In this chapter you will find important safety precautions as well as explanations on the structure of this operating and service manual and on the symbols and conventions employed.



About this operating and service manual Purpose of this operating and service manual This operating and service manual familiarises you with the Multi-Function Separator SP-MF and informs you how to operate and service the machine safely and correctly. The initial start-up as well as putting the machine out of operation do not form part of this operating and service manual since only Trützschler’s after-sales service is allowed to perform these operations. Trützschler attaches great importance to you operating the machine safely, correctly and profitably. It is therefore important that you read this operating and service manual carefully before you start to work on or with the machine. This operating and service manual contains important information that will help you to avoid hazards and to increase the reliability and service life of the machine and the attached components.



Further information Should you have any questions about the operation of the machine that are not answered in this operating and service manual, please contact: Trützschler GmbH & Co. KG Textile Machinery Manufacturing Company D-41199 Mönchengladbach Postfach 41 01 64 Telephone +49 2166 607-0 Telefax +49 2166 607-405 E-mail [email protected] Internet www.truetzschler.com



Particularly read the section Safety measures from page 10 onwards. Follow all the instructions precisely so that you do not endanger yourself or others and in order to avoid damage to the machine.



145 04 01 S SP-MF S en S 06/2004



7



Introduction



Conventions employed in this manual



Symbols employed



Bold type



The following symbols are employed in this operating and service manual:



Designations and titles of menus, menu items and buttons are printed in bold type. Italics Cross-references to other points in the text or other chapters are printed in italics. Operating steps Operating steps are marked as follows: 1. Open the flap-type cover (1). 2. Turn the key-operated switch to 0 and remove the key. 3. Unscrew the hexagon screw (2).



DANGER This symbol draws attention to a potential hazard for the operator that could result in serious personal injury or even death. Caution This symbol draws attention to hazards that could result in machine damage or data loss. Note This symbol draws attention to tips and points of particular note that make operation of the machine easier for you. Every safety warning specifies the source of the hazard, the potential hazard and the measures to be taken to avoid the danger.



Lists Lists are marked as follows: – Variant A – Variant B – Variant C



Definition of machine sides The machine sides “left” and “right” in this operating and service manual are defined in accordance with the side definitions for spinning mill machines in DIN/ISO 92. For machines with a material flow in one direction, the machine sides are defined looking against the direction of material flow. Example: The operating unit of the SP-MF is located on the right side of the machine (see arrow).



8



145 04 01 S SP-MF S en S 06/2004



Introduction



Intended use The Multi-Function Separator SP-MF is intended exclusively to be used in spinning mills. The machine serves for separating heavy parts and metal from unprocessed cotton and synthetic fibres. In addition, the machine separates burning or smouldering parts from the material and automatically extinguishes any fire inside the machine. Use in any other way does not constitute an intended use and is expressly forbidden. The intended use also entails reading the operating and service manual and adhering to the inspection and maintenance intervals.



Type plate You will find the type plate allowing precise identification of the machine on the side on which the material leaves the machine. There the type plate is located on the left of the door to the waste compartment of the metal separator. You will need the data on the type plate to allow an unambiguous assignment of individual components to the machine when contacting Trützschler’s after-sales service, for instance. The following data can be found on the type plate:



Tr ützschler GmbH & Co. KG Textilmaschinenfabrik D--41199 M önchengladbach (Germany)



Typ en - Bez . / d es ignation Typ en - N r. / typ e - no.



S P -- M F 1 4 5 -- 0 4 0 1



Kom. - N r. / c om. - n o. Bauja hr / y ear of m anufac ture



– Type designation – Type number – Serial number – Year of manufacture



145 04 01 S SP-MF S en S 06/2004



9



Introduction



Safety measures Organisational measures



Safety of persons



This machine has been built to the state of the art and the recognised safety regulations. If used in an improper manner, however, the machine may pose a danger to the life and limb of the operator or of other persons, or machine functions may be impaired.



The personnel employed for operation and maintenance must be qualified for their work or must have been instructed by qualified persons.



The personnel employed to work on or with the machine must have read and understood this operating and service manual before starting work. This applies in particular to personnel who are only required to work on the machine occasionally, e.g. for maintenance work. The owner of the machine is obliged to ensure that the machine operates safely and does not present a hazard. He can achieve this through the following measures: – Ensuring that the operating and service manual is available on the machine at all times – Carrying out regular training courses – Monitoring the safety and hazard-conscious working of the personnel at regular intervals Warning plates and signs on the machine must always be easy to read and intact and must not be removed.



Qualified persons have sufficient knowledge of the machine as a result of their technical training and experience. These persons are sufficiently familiar with the relevant local and national work safety and accident prevention regulations that they are able to assess the safe working condition of the machine. – Observe the working instructions for your place of work. – Observe the relevant accident prevention regulations. – Observe the safety precautions contained in this operating and service manual.



Avoid machine damage As owner of the machine, you are responsible for the following points: – Use the machine only for applications described as an intended use. – Observe the operating conditions and materials for the machine described in this operating and service manual. – Observe the prescribed service intervals. – Use only original spare parts and process media recommended by Trützschler.



10



145 04 01 S SP-MF S en S 06/2004



Introduction



Safety instructions Read the following safety instructions carefully and observe them. They are given for your own safety, for the safety of your colleagues and in order to avoid any damage to the machine and the attached components. Before switching on the machine As owner of the machine, ensure that only qualified personnel are employed to operate the machine. Also ensure that the machine is inspected by qualified personnel for a safe and hazard-free condition before it is switched on for the first time, after maintenance work and after any technical modifications. In particular, make sure that the fire extinguishing system (spark detector, fire sensor and CO2 cylinder) is properly installed and ready to be triggered every time before switching on the machine. Ensure that the CO2 cylinder is completely filled. As operator of the machine, ensure that you request all persons in the danger area of the machine to leave the area. Electrical installation and control cabinet Ensure that the doors of the control cabinet are kept locked at all times. The key should be kept by a responsible and qualified person, for example the plant electrician.



Maintenance work, servicing and repairs As owner of the machine, ensure that only qualified personnel are employed to carry out maintenance or repair work on the machine. Also observe the instructions and directions for maintenance work contained in the manufacturers’ documentation in the annex to this operating and service manual. Install and/or activate all protection and safety devices correctly after all maintenance work. Work on the machine going beyond the operations described in the chapter Maintenance may only be carried out by Trützschler after-sales service personnel or by persons authorised by Trützschler. Start all set-up and maintenance operations only when the machine has been disconnected from the power supply and has come to a standstill. Secure the master switch in the OFF position by means of a padlock and a warning sign or by other suitable means to prevent unauthorised switching on. This applies in particular for machine combinations and machines that cannot be monitored in all areas at the same time due to their size. Carry out modifications to the machine or its components only after consultation with Trützschler’s after-sales service; otherwise major malfunctions may occur causing serious personal injury and irreparable machine damage.



Ensure that no liquid can enter the control cabinet or other components. Should this nevertheless happen, switch off the machine at the master switch, lock the switch to prevent unauthorised switching on and inform the responsible specialist personnel or the Trützschler after-sales service.



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11



Introduction



Start-up/putting the machine out of operation



Further notes



Only Trützschler’s after-sales service is allowed to start up the machine and to put it out of operation. This also applies in the event of a temporary stoppage and restart at the same owner’s works (e.g. if the machine is moved to another location).



If this machine is moved to another location or sold to another company, this operating and service manual must accompany the machine. It represents an integral part of the machine described therein.



12



Ensure that the floor around the machine is not soiled with oil or grease after maintenance work to avoid the risk of operators or other persons slipping and suffering serious injuries.



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Introduction



Safety equipment Emergency stop



Dangerous spots



The Multi-Function Separator SP- MF does not have any emergency push-button of its own.



There are three dangerous spots on the multifunction separator where injuries due to squeezing, shearing, impact or burns are possible. These are:



In the event of an emergency stop the installation control opens the external emergency stop circuit and causes the different safety circuits operating independently of each other to switch off safely. When the external emergency stop circuit is opened, the quick closing flap of the metal and spark separator is switched off only if in the service mode but not during normal operation. This enables the flap to be actively held in discharge position in the event of a fire.



– the transport fan (1) – the heavy part separator (2) – the metal and spark separator (3)



The emergency stop circuit is automatically opened by the installation control following a fire report. Master switch The red and yellow master switch of the machine is located on the right side of the machine (see arrow). It functions as a mains disconnecting device and serves to shut down the machine in an emergency. If necessary, secure the master switch by means of a padlock, with the machine switched off, to prevent the machine from being switched on again (e.g. during servicing or maintenance operations).



These dangerous spots are monitored independently of each other to allow work in a secured danger area while other parts of the machine continue to operate, e.g. when one of the wheeled waste containers has to be emptied.



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13



Introduction



Safety mechanisms of doors and flaps



Fire warning centre



Access to the fan is prevented by means of an electrical closing mechanism. The flap is released by the control system after the fan has stopped (timing: 3 minutes). The external emergency stop circuit has a disabling effect on a higher level.



The fire warning device works completely selfsufficiently. If the power supply fails, the signalling and extinguishing functions will be buffered and maintained via a built-in battery. In this way a fire can also be extinguished after the end of operation in case heat has been signalled.



The door to the waste compartment of the heavy part separator is secured by a door locking system. The door can be released during operation by pressing the illuminated push-button key next to the door. Opening of the door prevents the separating cylinder from being triggered. At the same time the closing mechanism of the service door on the left-hand side of the machine which leads to the heavy part separator is released. The external emergency stop circuit has a disabling effect on a higher level.



Tripping of a heat detector in the waste compartment is automatically followed by extinguishing with CO2. The door to the waste compartment of the metal and spark separator is locked and only released again by the control system after a waiting time of 5 minutes.



The door to the waste compartment of the metal and spark separator under the quick closing flap is secured by a door locking system. The door is released when the flap is in its initial position and there is no material flow. Releasing of the door can be can be manually requested by pressing the illuminated push-button key next to the door. Opening of the door prevents the quick closing flap of the metal and spark separator from being triggered. DANGER OF INJURY Do not electrically or mechanically override or disable the safety locking devices on doors, maintenance flaps or other openings!



Resetting of the fire warning centre in order that the quick closing flap returns to its initial position is a precondition for opening of the waste compartment door under operating conditions after a spark has been signalled. Warning plates and information signs Warning plates and signs warning of dangerous spots and giving instructions on how to conduct yourself have been affixed to many parts of the machine. These signs must not be removed and must always be easy to read and intact. Poorly legible or damaged signs must immediately be replaced by new signs of the same kind.



Service mode There is a service door on the left-hand side of the machine. The key-operated switch for the service mode is located behind this door. The door is released by the machine control after the fan has stopped (timing: 3 minutes after switchoff). Opening of the service door prevents the quick closing flap of the metal and spark separator from being triggered. When an authorised person has switched on the service mode with the key-operated switch, all door locking systems are released and all safety limit switches overridden. On a higher level the external emergency stop circuit has a disabling effect also in the service mode.



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145 04 01 S SP-MF S en S 06/2004



Description



Description This chapter describes the Multi-Function Separator SP-MF and provides you with an overview of the subassemblies and their functions within the machine. You will find an overview of the most important operating elements and an introduction to the function and operation of the operating unit in the following chapter Operation from page 21.



Constructional layout Subassemblies The Multi-Function Separator SP-MF essentially consists of the following subassemblies (in material flow direction): – Fan BR-FD500 (1) – Heavy part separator (2) – Air separator, optional (3) – Metal and spark separator (4)



Position within a plant The following machines may be located upline of the Multi-Function Separator SP-MF: – Bale Opener BO-A – Waste Feeder BO-R – Mixer BL-FC The following machines may be located downline of the SP-MF: – Mixer MX – Condenser BR-CO When the Mixer MX is used, the Multi-Function Separator is always equipped with an air separator. The Condenser BR-CO can process larger quantities of air than the Mixer MX. If a Condenser BR-CO is used downline of the multi-function separator and the air quantity delivered by the SP-MF does not exceed the maximum capacity of the condenser, the air separator of the SP-MF can therefore be dispensed with.



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15



Description



Functional description Overview



Fan BR-FD500 The Transport Fan BR-FD500 (5) is responsible for transporting air and material from the upline machine (e.g. the Bale Opener BO-A) to the SPMF.



The fan does not have any control system of its own. The machine control or the higher-level installation control switches the fan on or off and controls the rotational speed.



At the feeding end (on the right-hand side of the machine) the fan sucks in material through the suction unit. The material is blown out again through the exhaust pipe located at the top and transported to the feeding end of the heavy part separator. The fan ensures a constant air current. The suction air volume always remains within the ideal range, irrespective of the length of the transport route.



The fan does not have any operating or display elements.



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145 04 01 S SP-MF S en S 06/2004



Description



Addition of waste



Air separator



If necessary, so-called soft waste can simply be added. The soft waste is then drawn in together with the main flow of material (4). The added waste thus passes through the entire machine and is checked for heavy particles, metal particles and fire.



The multi-function separator is equipped with an optional air separator (7). The purpose of the air separator is to adjust the air volume of the main air current for the downstream machine (10) by splitting the air volume of the main air current and discharging one part, depending on the intake capacity of the next downstream machine.



Heavy part separator



The discharged dusty exhaust air is usually led to a filter installation (8).



The heavy part separator serves for separating foreign particles (seeds, dirt or other foreign particles) from the raw material (3) supplied. Thanks to its aerodynamic guiding profile in connection with the constant air current, the heavy part separator attains a very high efficiency while keeping the loss of good fibres down. After having been separated, the particles are fully automatically discharged through a flap (2) and dropped into the wheeled waste container (1). The waste compartment is sealed airtight by means of door seals. The process of discharging the heavy particles takes place without leakage air, thus without the discharging effect being impaired. The heavy part separator does not have any control system of its own. The flap is opened by the machine control at preset intervals.



The exhaust air output can be adjusted by opening or closing a slide gate in the downstream pipeline for dust exhaust more or less wide. The duct height of the air separator decreases uniformly over the whole duct length. This prevents the material flow from slowing down when the partial air current is discharged. A volume-measuring instrument in the air separator serves for measuring the discharged volumetric flow. If a Condenser BR-CO is used downline of the multi-function separator and the air quantity delivered by the SP-MF does not exceed the maximum capacity of the condenser, the air separator of the SP-MF can be dispensed with.



The wheeled waste container can be replaced or emptied during ongoing operation.



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17



Description



Metal Separator SP-EM



Quick closing flap



The Metal and Spark Separator SP-EM separates metal and burning material from the material flow.



The quick closing flap (11) discharges metal and burning material without impairing the air current. The air can escape through a sparkproof sieve in the waste compartment, preventing sudden overpressure or underpressure in the conduit system.



Fire protection Two spark sensors in the air duct (6) downline of the heavy part separator and upline of the air separator detect sparks and burning or smouldering material. The Metal and Spark Separator SP-EM discharges the burning or smouldering material into the fireproof wheeled waste container (13) via the quick closing flap (11). If the material continues to burn there, a heat sensor (14) on the wheeled waste container will detect the fire and automatically cause it to be extinguished with CO2 (12). Separation of metal A metal sensor (9) surrounds the duct in the Metal Separator SP-EM. The sensor detects any kind of metal in the material flow. When the sensor detects metal, the quick closing flap (11) is opened, and the metal is discharged into the wheeled waste container (13).



18



When opening and closing, the quick closing flap is actively moved by pressure cylinders. Therefore it operates very quickly and reliably. Sufficient underpressure in the metal separator ensures trouble-free functioning of the quick closing flap. A pressure gauge in the switch cabinet door on the right-hand side of the machine shows the underpressure in the metal separator, thereby allowing you to check it. The metal separator does not have any control system of its own. The quick closing flap is automatically controlled and triggered by the spark sensor in the air duct (6) or by the metal sensor (9). The waste compartment of the metal separator can be opened upon manual request, allowing the wheeled waste container to be replaced or emptied even during ongoing operation. In the event of a fire in the wheeled waste container the machine is automatically switched off and the door to the waste compartment locked. The fire extinguisher is fully automatically controlled by the fire warning centre.



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Description



Filling level control The filling levels in the two wheeled waste containers, of the heavy part separator and of the metal and spark separator, are monitored by light barriers. When the preset maximum filling level is reached, the light beam is interrupted. A warning is output on the operating unit. The waste compartment doors can be opened and the wheeled waste containers replaced or emptied during ongoing operation. If one of the wheeled waste containers is not emptied within the preset time after the warning has been output, the material supply to the machine is automatically stopped (cf. chapter Malfunctions, page 51 of this operating and service manual).



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19



Description



Switch cabinet The switch cabinet of the SP-MF is located in the middle module on the right-hand side of the machine. The red and yellow master switch of the machine is installed in the door of the switch cabinet. The red warning siren is located above the master switch. A housing fan and a housing filter may be installed in the switch cabinet door, if necessary.



Components Housed in the switch cabinet are: – Electrical main supply line – Electrical connections – Main fuse and other fuses – Transformer with rectifier – Matching transformer if necessary – Motor protection switch – Fixed-time relay for door locking systems – Installation control interface – TKN-2 interface – Supply voltage socket-outlet for service



Further information For further information on the switch cabinet and the electrical installation, please refer to the documentation for the electrical installation. Note A copy of this documentation can be found in the tray on the inside of the switch cabinet door.



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Operation



Operation This chapter gives you an overview of the most important operating elements and an introduction to the function and operation of the operating unit. This chapter describes how to switch the machine on and off as well as all activities during normal operation, e.g. checking the operating status and replacing or emptying the wheeled waste containers. Servicing and maintenance operations are described in the chapter Service from page 61 onwards. The chapter Malfunctions from page 45 onwards describes how to detect and remedy faults.



Operating elements To be entrusted with the operation of the machine, you need to be familiar with and know how to operate the following operating elements: – Operating unit (1) – Push-button for opening the two waste compartment doors (2) – Slide gate for adjusting the exhaust air output of the air separator (3) – Master switch (6) The section Operating unit from page 22 onwards describes how to handle the operating unit. The other operating elements are described in connection with the corresponding activities (e.g. switching on the machine or emptying the wheeled waste container).



Warning messages and faults Warning messages and faults are shown on the display of the operating unit. In the event of a fire in the wheeled waste container of the metal and spark separator, the red warning siren (5) in the switch cabinet door sounds as well.



Other indicators A pressure gauge (4) located above the switch cabinet door on the right-hand side of the machine shows the underpressure in the metal separator area. The indicated value provides information as to whether the transport fan, in conjunction with the exhaust air slide gate and the next machine downstream of the SP-MF, is correctly adjusted.



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21



Operation



Operating unit Description The operating unit of the Multi-Function Separator SP-MF is located in the door to the metal and spark separator on the right-hand side of the machine. The operating unit consists of: – Membrane keyboard with keys and LEDs – Two-line display – Key-operated switch With the keys of the operating unit you can switch the machine on and off, trigger functions, set parameters and acknowledge malfunctions. On the display you see warnings and essential information as well as text messages concerning operating statuses, data and measured values. The key-operated switch serves for switching over between the different operating modes.



Keyboard and display The membrane keyboard consists of keys under a protective membrane. The keys react even to slight pressure. For a better overview the keys are combined to form functional groups. You usually need to press a key just briefly in order to trigger a function or to gradually change a value. The reaction of the machine to inputs into the operating unit is always shown on the display. A new value is displayed, for example, or you see a confirming text or a message requesting further action. Caution Do not exert excessive pressure on the keys, and do not bang on the keyboard or the display to avoid damaging the keys and the display or impairing their functions.



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145 04 01 S SP-MF S en S 06/2004



F1



F2



F3



P



N



S



F4



H



YES



7



8



9



CE



NO



4



5



6



R



0



1



2



3



Operation



General survey



F1



F2



F3



P



N



S



F4



1 Key-operated switch For selecting the operating mode N = Normal operation P = Programming mode S = Service mode (not used)



H



YES



7



8



9



CE



NO



4



5



6



R



0



1



2



3



6 Special key Switches automatic control on/off 7 Special key (not assigned in the SP-MF)



2 Position of key-operated switch When the key-operated switch is on position P or S, the corresponding LED is illuminated. 3 Function keys F1 ... F4 (not assigned in the SP-MF) 4 Operating keys I = Switches the machine on 0 = Switches the machine off



8 Fault message key For acknowledging fault messages, switching off the warning siren and resetting the fire warning centre 9 Numeric keypad For inputting numerical values, for navigation in the menus and for using the menu functions



5 Two-line display shows production data and measured values, information on the operating status, fault messages, warnings and directions for operation



145 04 01 S SP-MF S en S 06/2004



23



Operation



Key-operated switch



Malfunctions and warnings



The key-operated switch serves for switching over between the different operating modes.



When a malfunction has occurred, the LED over the key Fault message is illuminated continuously. When a warning is due to be dealt with, the LED over the key Fault message flashes.



Three positions are possible: N = Normal operation P = Programming mode S = Service mode (not used) In position N the machine is in normal operation. It is possible to navigate in the menus and to read data. You cannot, however, change any settings. In position P the machine is in the programming mode. In the programming mode you can input or change data and trigger certain functions. Faults can also be acknowledged only when the key-operated switch is in position P. The chapter Settings from page 35 onwards describes how to set and change parameters in the programming mode. Caution You can remove the key only in position N. Always remove the key during normal operation to prevent unauthorised intervention.



At the same time a text with further information on the message due to be dealt with is shown on the display. Note When the key-operated switch is in position P, no warnings or faults are shown on the display. The chapter Malfunctions from page 45 of this operating and service manual contains detailed instructions for reacting to faults. There you will also find comments on other instruction texts and status messages on the display.



Display brightness You can adapt the brightness of the display to your requirements and to the lighting conditions of your work environment. 1. Press the key CE and hold depressed. 2. Briefly press the key 1 once or repeatedly. The display brightness increases by one step at each press of the key. 3. Briefly press the key 0 once or repeatedly. The display brightness decreases by one step at each press of the key. 4. When the desired brightness is reached, release the key CE.



24



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Operation



Control systematics



Opening of menu and navigation



With the keys of the numeric keypad you can – open the menu – navigate in the menu structure – select values – change values – input or delete values – correct inputs Some of the individual keys have different functions, depending on the text messages on the display:



0



9



Digits 0 ... 9 for inputting numerical values



H



Opens menu, closes menu or function



R



Selects function directly, scrolls on menu



CE



Scrolls back menu



Note If no key of the operating unit is pressed for some time, the display will switch off automatically. Briefly press a key to switch the display on again. This keystroke with the display switched off will not initiate any further action. When you see the basic display in the display section, you can open the menu and then navigate in the menu . When the machine has been switched on, the basic display shows the most important production data:



When the machine has been switched off, only the message Drives to be switched on is displayed.



YES



Opens input function, confirms input



NO



Cancels and rejects change, scrolls to next function



After you have opened the menu, there are two ways you can select a function: – You can scroll through all functions, one by one. – You can select the function directly by inputting its respective number. When you have selected a function, the display shows the current settings and values. You can then open the function to make changes.



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25



Operation



Scrolling through all functions



Inputting and saving values



You see the basic display.



When a function is shown on the display, you can open this function to adapt the settings. You can input, select or change values. However, values can only be changed on condition that the key-operated switch is in position P.



1. Press key H to open the menu. The first function is shown. 2. Press key R once to scroll to the next function. 3. Press key CE to scroll back to the previous function. 4. Press key R or CE repeatedly to scroll through all functions one by one. 5. Press key H to close the menu again. Selecting specific functions



Some functions only display current measured values (e.g. the volumetric flow rate) that you cannot change. 1. Press key YES to open the function. The display shows the message Values to be changed? =N. 2. Press key YES. The flashing cursor shows which value you can change. 3. Use the numeric keys 0 ... 9 to input the desired new value.



You see the basic display. 1. Press key R once. The display shows the message P-function =. A marker flashes, indicating where to input the desired function number.



4. Press key R to conclude the input and save the new value,



2. Use the numeric keys 0 ... 9 to input the number of the desired function.



5. press key NO to reject the input. The previous value is valid again.



3. Finally press key R once more. The desired function is shown. If the inputted number has not been assigned to any function, the message P-function not available will appear on the display.



26



or



When you press either key R or NO within a function to conclude editing, you automatically get to the next value to be set or to the next function.



145 04 01 S SP-MF S en S 06/2004



Operation



Example



Wrong inputs



The following example describes step by step how you can change the time of the internal calendar clock.



If you have inadvertently input a wrong value, you can simply close the function without saving the change. To this end, press key H.



You see the basic display.



You can repeat or change every input at any time. In each case it is the last input that remains valid.



1. Press key R once. 2. Press the numeric keys 9 and 8 to input the function number 98. 3. Finally press key R once more. The date and the time are shown on the display. 4. Press key R to open the function. The message Values to be changed? =N is displayed. 5. Press key YES. The first value to be set (the date) is displayed. The cursor flashes under the first value (day).



If you have input an invalid value, a corresponding message will be shown on the display. In this case press key R to edit the setting value again. Note Some functions are only available when the machine has been switched on (and the fan is running).



6. Press key R repeatedly. With every press of the key the cursor moves on to the next value. After the year the second value to be set (the time) is displayed; the cursor flashes under the first value (hour). 7. Use the numeric keys 0 ... 9 to change the value for the hour. The cursor moves on automatically and flashes under the next value (minute). 8. Use the numeric keys 0 ... 9 to change the other values (minutes and seconds). 9. If necessary, press key CE to move the cursor back to the previous value. 10. Press key R again. The function is closed. The next function is shown on the display.



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27



Operation



Preparation for operation First start-up The first start-up of the machine and the configuration of all operating parameters are performed by Trützschler’s after-sales service following the erection. The chapter Settings from page 35 of this operating and service manual describes how to set and change the operating parameters.



Daily preparations for operation Before switching on the machine, make sure that all preconditions for safe and trouble-free operation have been met. DANGER Ensure that all in-plant safety equipment works properly. Make sure that all safety and accident prevention regulations are complied with. 1. Perform a visual inspection of the whole machine. Start the inspection on the maintenance scaffold and then continue inspecting the machine by walking around it on the ground. 2. Close all flaps and doors. 3. Remove any dirt and remaining oil or grease. 4. Check the mechanical safety equipment for proper condition, particularly the ladder, trap basket, safety door and the railings of the maintenance scaffold. 5. If necessary, empty the wheeled waste containers. Replace any faulty or damaged parts, if necessary. Service operations are described in the chapter Service of this operating and service manual from page 61. The chapter Repairs from page 74 of this operating and service manual describes repair work on the machine which you may perform yourself. Any other work may only be carried out by Trützschler’s after-sales service.



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Operation



Switching the machine on DANGER Before switching the machine on, make sure that safe operation is possible. Ensure that all safety equipment works properly. Make sure that all safety and accident prevention regulations are complied with. The Multi-Function Separator SP-MF can only be switched on if no malfunction has occurred. The chapter Malfunctions from page 45 of this operating and service manual provides information on malfunctions and their elimination. If necessary, switch on the higher-level installation control and the power supply to the machine before switching on the machine. 1. Turn the red and yellow master switch in the switch cabinet door on the right-hand side of the machine to position I. The power supply is switched on. 2. Watch the display and the LEDs of the operating unit on the right-hand side of the machine. The control system is being initialised. The LEDs over the keys flash simultaneously. The display first shows the designation of the control system (ATC 2) and then the designation of the machine (SP-MF). When the yellow LED over key I (2) flashes slowly, the machine is ready to be switched on. The display shows the message Drives to be switched on. 3. Press key I of the operating unit. The yellow LED over the key flashes fast. The display shows the message Drives are starting. The door locking systems are now de-energised and thereby locked. When all doors have been locked, the fan starts, accelerating until the nominal speed is reached.



F1



F2



F3



P



N



S



F4



H



YES



7



8



9



CE



NO



4



5



6



R



0



1



2



3



After approx. 20 seconds the LEDs over key I (2) and the Control key (3) show a steady yellow light. The machine is now in operation. The display section shows the basic display (1) with the most important production data.



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29



Operation



Switching the machine off



Operation



Use the operating unit to switch off the machine. In an emergency or in the event of a malfunction the machine is automatically switched off by its control system, the higher-level control system or the fire warning centre.



During normal operation check and ensure that the machine works faultlessly and efficiently. This includes the following basic tasks: – Monitor the production data – React to fault messages



1. Press key 0 of the operating unit on the right-hand side of the machine. The fan slows down and is switched off. The display shows the message Drives are slowing down. After three minutes the door locking systems are automatically unlocked, and the doors can be opened.



– Clean the air ducts of dirt – Clean the air separator – Change and empty the wheeled waste containers – Keep the environment clean



2. The display shows the message Drives to be switched on. You can switch the machine back on again at any time.



Note Regular cleaning operations are particularly important for an efficient and cost-effective operation of the machine.



3. If necessary, turn the red and yellow master switch to position 0 to disconnect the machine from the power supply system. DANGER In order to prevent unintentional switching on of the machine, lock the master switch, e.g. with a padlock.



Monitoring production data The most important production data of the machine are shown on the display of the operating unit. The basic display shows the following information: V1



Volumetric flow rate upline of the fan



V2



Volumetric flow rate in the metal separator



n



Fan speed



z



Number of times the quick closing flap in the metal separator opened during the past 60 minutes



Volumetric flow rate/fan speed The setpoints for the volumetric flow rate and the fan speed are adapted to your plant and predefined by the control system. Inform yourself of the range each of those values must remain in. Check regularly whether the indicated values are within the predefined limits. In the event of deviations you may wish to inform a competent person so that any irregularities can be detected at an early stage.



30



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Operation



Flap openings The number of flap openings during the past 60 minutes provides you with an indication of the filling level of the wheeled waste container in the metal separator. This way you can prepare for the next exchange of wheeled waste containers early and plan your work flow accordingly. Note The material flow through the machine must be stopped to allow the wheeled waste container in the metal separator to be replaced. It is therefore important to replace the wheeled waste container without any unnecessary delay.



Malfunctions In the event of a malfunction the machine is automatically switched off. The chapter Malfunctions from page 45 of this operating and service manual contains a detailed description of malfunctions and remedial actions. There you will also find comments on other instruction texts and status messages on the display.



Inspection, maintenance and servicing Different maintenance operations are necessary over the entire service life of the machine. Their purpose is to judge the condition of the machine, to detect and eliminate any deficiencies that may exist and generally to maintain the machine in an optimum condition.



The chapter Repairs from page 74 of this operating and service manual describes repair work on the machine which you may perform yourself. Any other work may only be carried out by Trützschler’s after-sales service.



Replacing wheeled waste containers You have to empty the two wheeled waste containers, i.e. that of the heavy part separator and that of the metal and spark separator, regularly. To this end, you have to take the wheeled waste containers out of the machine, one at a time, and empty them or replace them with empty wheeled waste containers. The two wheeled waste containers are identical and can be pushed into either of the two waste compartments. The filling levels in the two wheeled waste containers are monitored by means of light barriers (cf. page 19). When the preset maximum filling level is reached, a warning is output on the operating unit. The wheeled waste container of the heavy part separator can be replaced or emptied during ongoing operation. The material flow must, however, be stopped to allow the wheeled waste container of the metal and spark separator to be replaced or emptied. If one of the wheeled waste containers is not emptied within the preset time after the warning has been output, the material supply to the machine will be stopped automatically. The material flow is not interrupted for removing the wheeled waste container from the heavy part separator. The material flow must, however, be interrupted for removing the wheeled waste container from the metal and spark separator to prevent any metal particles or sources of fire from being transported any further.



Activities without a fixed time schedule that are part of the daily inspection are described below in this chapter. The chapter Service from page 61 of this operating and service manual describes required maintenance and servicing measures and activities. There you will also find a clearly arranged maintenance and service schedule.



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31



Operation



Removing and emptying a wheeled waste container The wheeled waste container is taken out of and pushed into the two waste compartments of the machine in the same way. 1. Briefly press the illuminated blue push-button key on the left of the door to the waste compartment. The lamp in the push-button starts to flash. 2. When the lamp in the push-button is lit continuously, the door is no longer locked. Now open the door with a suitable key. 3. Open the door fully and pull the wheeled waste container out straight. 4. If necessary, clean the two windows in the waste compartment in front of the light barriers on the right and left of dirt. 5. If necessary, clean the floor in the area of the door so that the door seal can seal airtight again. 6. Clean the two filter sieves in the waste compartment of the metal and spark separator of fibres. 7. Push the empty wheeled waste container straight into the waste compartment until it noticeably touches the back wall of the waste compartment. A magnet on the back wall holds the wheeled waste container in place. 8. Close the door and lock it with the key. The door safety lock is automatically reactivated. The door can only be opened again if it has previously been released by pressing the illuminated push-button key again. Note If the door has been open too long, a fault message is output (see chapter Malfunctions from page 45).



32



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Operation



Monitoring heavy part separator The inspection windows on either side of the heavy part separator make it possible to monitor the material, the material transport and the separation of foreign particles. A lamp on the lefthand side of the machine lights this part of the air duct. Regularly check the condition and the function of the heavy part separator by inspecting the air ducts and the material flow through the inspection windows. This will also show you whether the material flow is being obstructed, e.g. by larger foreign particles such as remaining material handling equipment or packaging material residues.



Other inspection windows Depending on the design of the machine, other inspection windows that are accessible from the outside may be located – in the flap over the comb in the heavy part separator (2), – in the flap over the waste compartment of the heavy part separator (3), – in the flaps of the air separator (1). Cleaning is possible through different flaps. Further details are described in the chapter Service of this operating and service manual from page 61.



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33



Operation



Monitoring pressure gauge The pressure gauge over the switch cabinet door on the right-hand side of the machine shows the underpressure in the area of the metal and spark separator. The indicated value provides information as to whether the transport fan, in conjunction with the exhaust air slide gate and the next machine downstream of the SP-MF, is correctly adjusted. There must always be underpressure in the area of the machine that is monitored by the pressure gauge, as otherwise the function of the extraction flap (quick closing flap) of the metal and spark separator can no longer be ensured. The pressure gauge must always indicate a value of approx. 150 Pa with the machine running. If the value shown is considerably less, this may indicate a possible malfunction. In this case inform a qualified staff member that can check the machine. The chapter Settings from page 35 of this operating and service manual describes how to set and change operating parameters.



Further tasks The chapter Service from page 61 of this operating and service manual describes further inspection, maintenance and service activities. There you will also find a clearly arranged maintenance and service schedule.



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Settings



Settings This chapter describes all the settings you can make on the machine. This concerns manual settings on mechanical components on the one hand and machine control settings you can make on the operating unit on the other hand. Caution Perform only the work described below. Any further changes to the machine configuration may cause damage to the machine or material defects. In any case of doubt please consult Trützschler’s after-sales service. Note The chapter Operating unit from page 22 of this operating and service manual describes the operating unit as well as basics on working with the menu structure.



Setting exhaust air output The multi-function separator is equipped with an optional air separator. The purpose of the air separator is to adjust the air volume of the main air current to the next downstream machine by splitting the air volume of the main air current and discharging one part, depending on the intake capacity of the next downstream machine. The exhaust air output can be adjusted by opening or closing the slide gate in the pipeline for dust exhaust more or less wide. A volume-measuring instrument in the air separator serves for measuring the discharged volumetric flow. The volumetric flow downline of the air separator is calculated.



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35



Settings



The machine control keeps the volumetric flow rate in the inlet upline of the fan constant by adapting the fan speed. The two volumetric flow rates are shown on the display of the operating unit: V1



Volumetric flow rate upline of the fan



V2



Volumetric flow rate in the metal separator



The pressure gauge over the switch cabinet door on the right-hand side of the machine shows the underpressure in the area of the metal and spark separator. The indicated value provides information as to whether the transport fan, in conjunction with the exhaust air slide gate and the next machine downstream of the SP-MF, is correctly adjusted. The pressure gauge must always indicate a value of approx. 150 Pa with the machine running. In addition, take into account the minimum output air volume for the material transport to the next downstream machine when adjusting the exhaust air output. The air volume needed to exhaust the upline machine must be assured before the slide gate in the pipeline for dust exhaust is set. You have to set this value on the operating unit (cf. function Autoleveller to be calibrated, page 43). The slide gate of the pipeline for dust exhaust downline of the air separator can be reached from the maintenance scaffold. The slide gate is not secured. 1. Pull the slide gate out to increase the exhaust air output. 2. Push the slide gate in to decrease the exhaust air output.



36



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Settings



Purging air supply The air separator has a slide gate for the purging air supply. With the purging air you can blow out deposits of sand and similar substances at the bottom of the air separator. The purging air supply should normally be shut off and be opened only if required and as wide as necessary. The purging air can be set at the bottom on the outside of the air separator. 1. Loosen the locking screw with a 5 mm hexagon socket screw key. 2. Move the lever up to open the purging air supply. 3. Move the lever down to shut off the purging air supply. 4. Tighten the locking screw again.



Heavy part separator No manual setting operations are necessary on the heavy part separator. Make all settings concerning the heavy part separator (e.g. volumetric flow rate, flap opening intervals) on the operating unit (see the following section Machine control).



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37



Settings



Machine control Machine control parameters can only be set when the key-operated switch of the operator’s panel is in position P. All functions can be directly selected by inputting their function number.



Overview of functions The following functions can be selected via the operating unit of the multi-function separator: 00 Working Memory



BR-FD = 70 With this function you can adjust the setpoints for volumetric flow control. The first parameter of the function indicates the basic speed of the fan. Fine adjustment can be made using the function 60 Autoleveller to be calibrated? (see page 41). 1. Input the new value with the numeric keys.



35 Set door locking system



2. Press key R to display the next parameter.



39 Lamp test



Volumetric flow =6500m3/h



40 Enter limits 41 Reset counter EM



The second parameter shows the setpoint for the volumetric flow rate upline of the fan. The value is determined by the technical specification of the plant and of the machine.



49 Configuration 50 Display control 51 Display scheduled value



1. Input the new value with the numeric keys.



60 Autoleveller to be calibrated?



2. Press key R to exit the function.



61 Change control parameters? 78 Display ejections EM?



35 Set door locking system



79 Extraction flap EM service?



Adjust door locking EM =N



80 Selection of language 87 Network address TKN 89 Display program numbers 98 Set system clock In the following the functions are described in the order of numbering. The first figure always shows the display after the respective function has been selected.



38



00 Working Memory



This function can only be used while the machine is at a standstill. The function serves for testing the safety circuit of the door locking systems. You can check the locking devices of the two waste compartment doors and of the maintenance flap of the fan one after the other.



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Settings



The first parameter concerns the waste compartment door of the metal and spark separator. 1. Press key YES to check the locking device. The display indicates the status of the locking device. Door locking OFF or Door locking ON The message Door locking OFF indicates that the safety circuit is not closed. Door locking ON indicates that the safety circuit is closed. 2. Press key R to display the next parameter. The second parameter concerns the waste compartment door of the heavy part separator. Adjust door locking SP-H =N 3. Press key R to display the next parameter. The third parameter concerns the maintenance flap of the fan.



40 Enter limits With this function you can define different specifications in connection with the extraction flaps. EM door unlocking after = 30 The first parameter concerns the time (in seconds) that passes before the waste compartment door of the metal and spark separator is released after the illuminated blue push-button key next to the door has been pressed. When setting this time interval, make sure that by the time the door is released there is no more material passing through the machine. 1. Input the new value with the numeric keys. 2. Press key R to display the next parameter. EM monitoring time Doors =2 This parameter indicates how long (in minutes) the waste compartment door of the metal and spark separator is allowed to be open. When this time has passed, the control system automatically triggers a fault. 3. Input the new value with the numeric keys. 4. Press key R to display the next parameter.



Adjust door locking BR-FD =N



EM carriage change Extractions =1



39 Lamp test



With this function you can check the display elements of the display screen and the LEDs over the keys of the operating unit.



The filling level of the wheeled waste container in the metal and spark separator is monitored by light barriers. When the maximum filling level has been reached, the display shows a warning, and the corresponding carriage must be emptied.



1. Press key R. All elements of the display must light up. All LEDs over the keys of the operating unit must light up. 2. Press key R again to exit the function.



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39



Settings



With this parameter you define how many ejections are still possible after the monitored maximum filling level has been reached. When this value is reached, the control system automatically triggers a fault.



With this parameter you define how long (in minutes) ejections are still possible after the monitored maximum filling level has been reached. When this value is reached, the control system automatically triggers a fault.



5. Input the new value with the numeric keys.



11. Input the new value with the numeric keys.



6. Press key R to display the next parameter.



12. Press key R to display the next parameter.



EM extraction time =1.0



SP-H flap interval = 30



With this parameter you can set the opening period (in seconds) of the quick closing flap of the metal and spark separator. The flap will open immediately when the metal sensor has detected any metal and close automatically after the time set here has passed. The time interval must be set such that the detected metal will definitely be discharged. 7. Input the new value with the numeric keys. 8. Press key R to display the next parameter. SP-H monitoring time Doors =2



With this parameter you set the time interval at which the extraction flap in the heavy part separator is to open. The time period depends on how dirty the material is. It must be chosen so as to avoid too much waste collecting in the waste container over the flap and possibly being blown into the clean material flow again. 13. Input the new value with the numeric keys. 14. Press key R to exit the function.



41 Reset counter EM Reset counter EM? =N



This parameter indicates how long (in minutes) the waste compartment door of the heavy part separator is allowed to be open. When this time has passed, the control system automatically triggers a fault.



With this function you can reset the value z in the basic display to 0. The value z indicates the number of ejections in the metal and spark separator within the past 60 minutes (cf. page 30).



9. Input the new value with the numeric keys. 10. Press key R to display the next parameter. SP-H carriage change =2 The filling level of the wheeled waste container in the heavy part separator is monitored by light barriers. When the maximum filling level has been reached, the display shows a warning, and the corresponding carriage must be emptied.



40



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Settings



49 Configuration



51 Display scheduled value V1:6514m3/h ASU:2537m3/h



With BR-FD? =Y This function serves for selecting the machine components at the initial start-up. You can activate (key YES) or deactivate (key NO) a component with every parameter. The first parameter concerns the fan BR-FD. 1. Press key R to display the next parameter. With SP-H?



4.81V 1.05V



This function displays the current volumetric flow rates upline of the fan and downline of the air separator (discharged air volume). This display is only provided for your information; you cannot change anything here.



60 Autoleveller to be calibrated? V1:6500m3/h + 0.2% n=75%



=Y The second parameter concerns the heavy part separator. 2. Press key R to display the next parameter. With BR-ASU? =Y The third parameter concerns the air separator. 3. Press key R to display the next parameter. Configuration to be set? =N



With this function you can configure closed-loop control of the volumetric flow rate (fan). The display shows the setpoint for the volumetric flow rate upline of the fan, the volumetric flow deviation in per cent and the basic speed of the fan in per cent. You will find a description of the closed-loop control system and the balancing operation from page 44 of this operating and service manual.



61 Change control parameters?



With the last prompt you can confirm and import (key YES) or reject (key NO) the configuration you have just set.



Amplification factor =0.5 With this function you can change the control parameter and adapt it to your requirements. The parameter concerns the amplification factor.



50 Display control



1. Input the new value with the numeric keys.



nom.6500m3/h n=75.0% act.6514m3/h n=74.3%



2. Press key R to exit the function.



This function displays the volumetric flow rate measured upline of the fan (nom. = preset nominal value, act. = actual value). This display is only provided for your information; you cannot change anything here.



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41



Settings



78 Display ejections EM?



80 Selection of language



Discharges EM z=1234567



Language English? =N



This function displays the total number of ejections by the metal and spark separator since the initial start-up of the machine. This display is only provided for your information; you cannot change anything here. This counter cannot be reset.



With this function you can select the language in which text messages are to be displayed. The available languages are shown one after the other. 1. Press key YES to select the indicated language. 2. Press key NO for the next language to be displayed.



79 Extraction flap EM service Service interval EM 100,000 / 123456z



87 Network address TKN With TKN?



This function allows the preset service interval and the current count of ejections by the metal and spark separator to be displayed. When the preset value is reached, the control system automatically triggers a fault message reminding you of the required maintenance. The value for the service interval is fixed and cannot be changed here.



With this function you can select whether to connect the machine to the data network of the higher-level control system. Once this is the case, you can set the network address with the second parameter.



With the second parameter of this function you can reset the counter to 0 after completing maintenance.



1. Press key YES to confirm connection to the network. The second parameter is automatically displayed.



1. Press key R to display the next parameter.



=N



2. Press key R to exit the function. TKN address = 1



Extraction flap EM serviced? =N With this parameter you can reset the count of ejections by the metal and spark separator to 0 after completing maintenance. Caution Only reset the counter content if servicing has really been performed. Exceeding of the preset service intervals may cause damage to the quick closing flap and to the machine.



Here you can set the network address of the machine. The address is predefined by the higherlevel installation control. 1. Input the network address with the numeric keys.



2. Press key YES to reset the counter to 0.



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Settings



89 Display program numbers Program number 401-45.800.400aa The first parameter of this function shows you the version number of the control software. Use this information when consulting Trützschler’s aftersales service. The second parameter indicates the version number of the keyboard. 1. Press key R to display the next parameter. ATC 2 495-08.800.001 2. Press key R to exit the function. If you keep the YES key depressed when the first parameter is shown, the current cycle values will temporarily be displayed: min: 17ms max: 45ms



act: 24ms mea: 22ms



This message is provided for the information of Trützschler’s after-sales service. You cannot set or change anything here.



98 Set system clock 19.04.2004 08:30:00 With this function you can set the internal calendar clock. Setting of the calendar clock is described in detail on page 27 of this operating and service manual.



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43



Settings



Volumetric flow control Functional description of integral action controller After the machine has been switched on, the fan speed is increased without any influence of the closed-loop control system until reaching the basic speed. The closed-loop control system is then activated to determine the proportional deviation of the volumetric flow. After averaging (smoothing of the measured values) the fan speed is adapted: Fan speed = current rotational speed (%) – amplification factor × volumetric flow deviation (%) The rotational speed is only adjusted up to the rotational speed limit (basic speed +30%/–15%).



Balancing operation Caution Only qualified persons are permitted to balance the closed-loop control system. Wrong settings may cause damage to the multi-function separator, to other machines and to the material. Set the setpoint for the volumetric flow rate with the function 00 Working Memory (cf. page 38). You can adjust the individual control parameters with the function 61 Change control parameters? (cf. page 41). Balancing integral action controller The integral action controller can only be balanced with the closed-loop control system switched off. This function is disabled while the closed-loop control system is switched on. – Display the setpoint for the volumetric flow rate and the deviation with the function 60 Autoleveller to be calibrated?. – Correct the basic fan speed until the volumetric flow deviation is as small as possible. Conclude every input by pressing key R so that the value is imported. Each change becomes visible after approx. 2 seconds. – Finally press key R to end the balancing operation.



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Malfunctions



Malfunctions Dealing with malfunctions Malfunction indication If a condition necessitating an interruption of operation occurs while the machine is running, this is considered to be a malfunction. The machine or installation control automatically reacts to a malfunction, switching off the machine and, if necessary, other machines of the plant. Malfunctions are always indicated on the operating unit: – The LED over the fault key (2) lights up in red.



F1



F2



F3



P



N



S



F4



– The display shows a fault text (1).



H



YES



7



8



9



CE



NO



4



5



6



R



0



1



2



3



In the event of a fire in the wheeled waste container of the metal and spark separator, the warning siren in the switch cabinet door on the right-hand side of the machine sounds as well (cf. page 21). Note The chapter Operating unit from page 22 of this operating and service manual describes how to handle the operating unit.



Basic procedure When a fault has occurred, you can basically proceed as follows: 1. Read the fault text on the display of the operating unit. The text gives you initial information about the cause of the fault. 2. Try to eliminate the cause of the fault (close an open waste compartment door, for instance). 3. Restore the machine to a safe and troublefree condition if necessary (e.g. close all maintenance flaps and doors).



F1



F2



F3



P



N



S



F4



H



YES



7



8



9



CE



NO



4



5



6



R



0



1



2



3



4. Then press the fault key (2) to acknowledge the malfunction. The red LED over the key goes out. 5. Press the start key I (1) to switch the machine back on again.



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45



Malfunctions



Fault messages – causes and remedies The following table gives you an overview of possible fault messages of the Multi-Function Separator SP-MF. The possible cause of each fault message is briefly described, and you are given instructions for the recommended procedure.



every fault message has a number, which is shown on the display of the operating unit together with the fault message.



To allow unambiguous identification (e.g. for questions for Trützschler’s after-sales service),



Note Below the table individual procedures, e.g. how to react to a fire in a wheeled waste container, are described in greater detail.



Fault message



Cause



Recommended remedy



150 Fault existed in operating unit



No power supply; connecting cable defective or operating unit defective.



Check power supply and connecting cable; replace operating unit if necessary.



158 Fuse monitoring



24 V AC or 220 V AC automatic circuit breakers have tripped.



Switch automatic circuit breaker -F020 or -F030 on again.



163 Fault TKN network



TKN network cable defective.



Check TKN network cable.



200 Safety circuit emergency stop



Emergency stop circuit in installation control interrupted.



Reset and/or acknowledge emergency switch or other comparable device in installation control.



202 Safety circuit fault in installation



Emergency stop circuit in installation control interrupted.



Reset and/or acknowledge emergency switch or other comparable device in installation control.



207 Motor protection switch has Motor protection switch of fan tripped has tripped.



Check reactor (-L100) and frequency converter 2 (-A100). Check current setting on motor protection switch -Q100 and switch motor protection switch on again.



210 Fault compressed air



Check compressed-air supply to machine. Check setting (6 bar) of pressure control switch -S756.



46



Not enough compressed air available in main supply system of machine.



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Malfunctions



Fault message



Cause



Recommended remedy



211 Fault in I/O-modules



I/O module is not recognised by main module.



Check connecting cable between main module and I/O module. Replace controller.



221 Frequency converter



Frequency converter of fan is not ready for operation.



Check power supply to fan.



655 Door middle left



Door on left-hand side of machine (middle frame) is not closed.



Close door; check door locking system -A201 if necessary.



661 Safety loop SP-H



Doors of heavy part separator could not be locked.



Close doors; check door locking systems -A720 and -A721 if necessary.



670 Left-hand door SP-H



Door on left-hand side of heavy part separator is not closed.



Close door; check door locking system -A721 if necessary.



671 Door SP-H waste compartment



Door to waste compartment of heavy part separator is not closed.



Close door; check door locking system -A720 if necessary.



672 Door EM waste compartment



Door to waste compartment of Close door; check door locking metal and spark separator is not system -A751 if necessary. closed.



673 Extraction SP-H



Extraction flap in heavy part sep- Check extraction flap. arator has not reached the required positions.



690 SP-H wheeled waste container full



Wheeled waste container of heavy part separator is full.



691 EM wheeled waste container full



Wheeled waste container of Empty wheeled waste container; metal and spark separator is full. clean light barriers -A754 and -V754 if necessary.



692 Metal detector



Metal detector detects metal Check and clean material duct over an extended period of time. of metal detector.



145 04 01 S SP-MF S en S 06/2004



Empty wheeled waste container; clean light barriers -A724 and -V724 if necessary.



47



Malfunctions



Fault message



Cause



693 Pushbutton EM waste compartment



Illuminated push-button key next Acknowledge fault; to door to waste compartment check push-button. of metal and spark separator has been pressed too long (20 seconds).



694 Safety installation EM



Safety system of metal and spark separator has been interrupted.



Have safety system checked by qualified personnel.



695 Metal initialization



Metal detector is not ready for operation.



Check metal detector -A740. Check automatic circuit breaker -F030.



696 Compressed air Preventing



Preventing pressure control switch does not switch.



Check compressed-air supply to machine; possibly check setting (1 bar) of pressure control switch -S755.



697 Safety loop EM



Safety circuit of metal and spark separator has been interrupted.



Have safety circuit checked by qualified personnel.



699 Extraction flap EM



Extraction flap in metal and Check extraction flap. spark separator has not reached the required positions.



700 Extraction flap EM Maintenance



The extraction flap in the metal and spark separator must be serviced within the next few days.



701 Extraction flap EM Output



Output of extraction flap in metal Have output checked by and spark separator has ocqualified personnel. curred too late or not at all.



714 Pushbutton SP-H waste compartment



Illuminated push-button key next Acknowledge fault; check to door to waste compartment of push-button. heavy part separator has been pressed too long (20 seconds).



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145 04 01 S SP-MF S en S 06/2004



Recommended remedy



Service extraction flap.



Malfunctions



Fault message



Cause



Recommended remedy



715 Fire protection



Fire warning centre is not ready for operation.



Check power supply to fire warning centre; acknowledge fault on fire warning centre.



716 Fire detected



Heat detectors in waste compartment or spark detector signal fire.



Wait until fire has been extinguished, then empty wheeled waste container of metal and spark separator and acknowledge fault (also see sections Fire in wheeled waste container and Spark detection from page 50).



717 Maintenance flap BR-FD



Maintenance flap of fan is not closed.



Close maintenance flap; check closing mechanism -A103 if necessary.



718 Safety loop BR-FD



Maintenance flap of fan could not be locked.



Close maintenance flap; check closing mechanism -A103 if necessary.



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Malfunctions



Fire in wheeled waste container When the heat sensors detect a fire in the waste compartment of the metal and spark separator, the fire warning centre triggers a fault. The fault is also indicated on the display of the operating unit, and the warning siren sounds. The machine is switched off immediately. The fire warning centre usually transmits the fire alarm to the higher-level installation control, which then also switches off all the other machines of the line. The extinguishing operation starts immediately and automatically. The contents of the CO2 cylinder are completely emptied into the wheeled waste container in the process. The CO2 extinguishes the fire, and the contents of the wheeled waste container cool down rapidly to the point of freezing. All doors of the multi-function separator are kept closed by the control system for about 5 minutes to prevent any injuries in connection with the extinguishing operation. Afterwards you can open the waste compartment door of the metal and spark separator, empty the wheeled waste container and replace it with an empty wheeled waste container.



Replacing wheeled waste containers The machine can only be switched on again after the wheeled waste container has been replaced. FROSTBITE HAZARD The extinguishing operation causes the waste compartment, the wheeled waste container and its contents to cool down enormously. Extended contact may lead to frostbites. Wear protective clothing (heavy gloves) as an insulation.



3. When the lamp in the push-button is lit continuously, the door is no longer locked. Now open the door with a suitable key. 4. Open the door fully and pull the wheeled waste container out straight. 5. Push the empty wheeled waste container straight into the waste compartment until it noticeably touches the back wall of the waste compartment. A magnet on the back wall holds the wheeled waste container in place. 6. Close the door and lock it with the key. The door safety lock is automatically reactivated.



Replacing CO2 cylinder DANGER OF FIRE Never operate the multi-function separator without a filled CO2 cylinder. If the CO2 cylinder has been emptied, replace it immediately with a new, completely filled cylinder. If the extinguishing operation has been triggered by the fire warning centre, the CO2 cylinder will have been completely emptied in the process. In this case remove the empty cylinder and replace it immediately with a new, filled cylinder. The chapter Repairs from page 74 of this operating and service manual describes in detail how to replace the CO2 cylinder.



1. Press the fault key on the operating unit to acknowledge the fault. The warning siren is switched off, and the fire warning centre is reset. 2. Briefly press the illuminated blue push-button key on the left of the door to the waste compartment of the metal and spark separator. The lamp in the push-button starts to flash.



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Malfunctions



Spark detection When the spark sensors detect a spark or a smouldering fire in the air duct, the fire warning centre triggers a fault. The fault is also indicated on the display of the operating unit. The machine is switched off immediately. The fire warning centre usually relays the detection of a spark to the higher-level installation control, which then also switches off all the other machines of the line. The quick closing flap of the metal and spark separator opens immediately whenever a spark has been detected. The flap remains open; therefore the door to the waste compartment is kept closed by the control system to prevent any injuries in connection with the quick closing flap. The door is only released again after the fire warning centre has been reset. That reset is triggered by acknowledgement of the fault on the operating unit of the machine. A reset is possible after approx. three minutes. After resetting the fire warning centre open the waste compartment door of the metal and spark separator, empty the wheeled waste container and replace it with an empty wheeled waste container. DANGER OF FIRE Empty the wheeled waste container whenever a spark has been detected to avoid any fire developing later in the wheeled waste container. After the detection of a spark empty the wheeled waste container in such a way that any danger of fire is ruled out. Ensure that the material contains no source of fire.



1. Press the fault key on the operating unit to acknowledge the fault. The fire warning centre is reset after approx. three minutes. 2. Briefly press the illuminated blue push-button key on the left of the door to the waste compartment of the metal and spark separator. The lamp in the push-button starts to flash. 3. When the lamp in the push-button is lit continuously, the door is no longer locked. Now open the door with a suitable key. 4. Open the door fully and pull the wheeled waste container out straight. 5. Push the empty wheeled waste container straight into the waste compartment until it noticeably touches the back wall of the waste compartment. A magnet on the back wall holds the wheeled waste container in place. 6. Close the door and lock it with the key. The door safety lock is automatically reactivated.



Waste compartment door opened The doors to to the waste compartments are usually opened to remove one of the wheeled waste containers and to replace it with an empty wheeled waste container. The door then has to be closed again immediately. If no more than 3 minutes pass between the opening and the closing of a waste compartment door, operation will not be interrupted, and/or the fan will start again automatically. If one of the doors remains open longer, the machine control will trigger a fault, and the machine must be switched on by hand after closing of the respective door and acknowledgement of the fault.



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Malfunctions



Warning messages The following table gives you an overview of possible warning messages of the Multi-Function Separator SP-MF. The possible cause of each warning message is briefly described, and you are given instructions for the recommended procedure. Warning message



Cause



Recommended remedy



Change wheeled waste container SP-H



Wheeled waste container of heavy part separator is full and must be emptied.



Empty wheeled waste container immediately and replace it with an empty wheeled waste container. If the wheeled waste container is not emptied within the preset time, the machine control will automatically trigger a fault, thus stopping the machine (see function 40, page 39).



Change wheeled waste container EM



Wheeled waste container of metal and spark separator is full and must be emptied.



Empty wheeled waste container immediately and replace it with an empty wheeled waste container. If the wheeled waste container is not emptied within the preset time, the machine control will automatically trigger a fault, thus stopping the machine (see function 40, page 39).



Metal recognized



Having detected metal, the metal sensor automatically triggers the quick closing flap of the metal and spark separator. The flap is opened and closed again.



Metal and fibres are automatically discharged into the wheeled waste container. Operation is not interrupted. The operator need not intervene.



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Malfunctions



Notes The following table gives you an overview of possible instruction texts of the Multi-Function Separator SP-MF. Those texts give you information about the status of the machine or about individual components or functions (e.g. open doors). Intervention by the operator is usually not necessary. Nevertheless, pay attention to the displayed texts to inform yourself about the condition of the machine. Instruction text



Cause



Comment



TKN network not active



TKN network not switched on (P87).



Switch on TKN network if necessary (P87).



Drives on installation switched off



Drives of higher-level installation switched off.



Stop switching off drives of higher-level installation if applicable.



Installation to be switched on



Higher-level installation not switched on.



Switch on higher-level installation if necessary.



Drives to be switched on



---



Machine is ready to be switched on. Drives of machine could be switched on.



Drives are starting



---



The fan is running up to its speed setpoint. This acceleration takes approx. 15 seconds.



Drives are slowing down



---



The drives have not yet stopped; the doors cannot be opened. It takes the fan approx. 3 minutes to come to a stop; then the doors can be opened, if desired.



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53



Malfunctions



Instruction text



Cause



Comment



Drives slowing down SERVICE on



Service has been switched on, but the machine has not yet come to a standstill.



Error in the safety system. The service switch is located behind a closed door and can only be operated after the machine has stopped.



SERVICE OFF Please wait



The service mode has been terminated; the drives have not yet come to a standstill.



Wait until the drives are stationary.



Enable door SP-H of waste compartment



Door locking system for waste compartment of heavy part separator has been deactivated.



The door can now be opened.



Waste compartment --door EM please wait



Release of the door has been re- Wait until the material flow is quested by pressing the illumiinterrupted and the door locking nated blue push-button key next system is deactivated. to the door to the metal and spark separator.



Enable door EM of waste compartment



Door locking system for waste The door can now be opened. compartment of metal and spark separator has been deactivated.



Activation metal detector



The metal detector is being checked for its proper operational condition.



Wait until the instruction text disappears. If the metal detector is not ready for operation, a fault message will be displayed.



Metal detection deactivated!



The metal detector has been deactivated by connecting 24 V DC (L+1) to input Z10 (-A031:X10/3).



Any metal in the material will be neither detected nor discharged.



Fire Warning Centre deactivated!



The fire warning centre has been deactivated by connecting 24 V DC (L+1) to input Z11 (-A031:X10/4).



No sparks will be detected; any fire in the waste compartment of the metal and spark separator can be neither detected nor extinguished.



Maintenance flap BR-FD



Maintenance flap of fan is open.



Close maintenance flap.



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Malfunctions



Instruction text



Cause



Comment



Door middle left



Door on left-hand side of machine (middle frame) is open.



Close door.



Left-hand door SP-H



Door on left-hand side of heavy part separator is open.



Close door.



Door SP-H waste compartment



Door to waste compartment of heavy part separator is open.



Close door.



Door EM waste compartment



Door to waste compartment of metal and spark separator is open.



Close door.



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55



Malfunctions



LED indicators in switch cabinet The LEDs of the electronic modules in the switch cabinet can provide additional indications of faults or malfunctions to aid in trouble shooting.



Generally speaking, red lamps indicate a fault. Green lamps indicate normal operation of a component.



1



3



1 Frequency converter 2 Miniature control system/central processing unit KSZ4 3 I/O module DEA1



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Frequency converter The frequency converter serves to control the fan motor. It has six LEDs (1), which are arranged one below the other and can assume different states. The respective combination of illuminated and flashing LEDs provides Trützschler’s aftersales service with important information on operating states or possibly even malfunctions.



1



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57



Malfunctions



Miniature control system/central processing unit KSZ4 The miniature control system/central processing unit KSZ4 is the basic module for the machine control of the Multi-Function Separator SP-MF.



58



L1



KSZ4 in operation



L2



KSZ4 out of order



Z1



---



Z2



---



Z3



---



Z4



---



Z5



“Machine OFF” from EGS



Z6



“Machine ON” from EGS



Z7



“Material transport active” from EGS



Z8



Metal detector ready for operation



Z9



Metal detector: no metal



Z10



Metal detector not available



Z11



Fire warning centre not available



Z12



Fire warning centre ready for operation



Z13



Fire warning centre: no fire



Z14



Fire warning centre: no sparks



E0



Air current upline of BR-FD



E1



Exhaust air downline of AS



E2



---



E3



---



E4



---



E5



---



E6



---



E7



---



A0



Setpoint for BR-FD



A1



---



A2



---



A3



---



A4



---



A5



---



A6



---



A7



---



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Malfunctions



I/O module DEA1 The I/O module DEA1 is located on the central processing unit KSZ4 and switches the inputs and outputs of the Multi-Function Separator SPMF.



E5.0 Safety system OK E5.1 Normal operation E5.2 Left-hand middle door open E5.3 “Ready for operation” from EGS E5.4 Door of EM waste compartment closed E5.5 EM safety system OK E5.6 EM discharging sparks or metal E5.7 EM quick closing flap closed E6.0 EM quick closing flap open E6.1 EM wheeled waste container full E6.2 Door of EM waste compartment open E6.3 Button for unlocking EM door E6.4 EM preventing pressure control switch E6.5 Pressure control switch for main supply system of EM E6.6 --E6.7 Fuse monitoring E7.0 IH safety circuit OK E7.1 Revolving cylinder of IH closed E7.2 Revolving cylinder of IH open E7.3 IH wheeled waste container full E7.4 Door of IH waste compartment open E7.5 Button for unlocking IH door E7.6 IH: Left-hand door open E7.7 --E8.0 BR-FD safety circuit OK E8.1 BR-FD motor protection E8.2 BR-FD maintenance flap open E8.3 BR-FD drive stopped E8.4 BR-FD frequency converter ready for operation E8.5 BR-FD frequency converter: Nominal frequency reached E8.6 --E8.7 ---



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Malfunctions



A1.0 Reset fire warning centre A1.1 EM discharging sparks or metal A1.2 EM preventing valve A1.3 --A2.0 BR-FD power supply frequency converter A2.1 BR-FD frequency converter for controller enabling A2.2 EM door locking system A2.3 IH door locking system A2.4 --A3.0 Revolving cylinder of IH: discharging A3.1 Safety system impulse A3.2 EM door unlocking lamp A3.3 EM safety system impulse A3.4 IH door unlocking lamp A3.5 BR-FD door unlocking A4.0 “Fault” to EGS A4.1 “Replace wheeled waste container” to EGS A4.2 “Drives ON” to EGS A4.3 “Ready for operation” to EGS A4.4 “Material flow permitted” to EGS Fail



60



DEA1 out of order



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Maintenance



Maintenance This chapter describes measures intended to maintain or restore the nominal condition of the machine. Maintenance includes inspections, servicing and repairs.



Service Service mode There is a service door on the left-hand side of the machine. The key-operated switch for the service mode is located behind this door. Through the service door you get into the interior of the machine, where further flaps for cleaning the air ducts above the quick closing flap and in the heavy part separator are located and from where the metal detector and the quick closing flap of the metal and spark separator can be reached. Opening of the service door prevents the quick closing flap of the metal and spark separator from being triggered. When an authorised person has switched on the service mode with the key-operated switch, all door locking systems are released and all safety limit switches overridden. On a higher level the external emergency stop circuit has a disabling effect also in the service mode.



All the required inspection and service measures must be performed in accordance with the national regulations applying to the installation site.



Maintenance schedule The maintenance schedules on the following pages provide you with a quick overview of the maintenance and cleaning operations to be performed regularly on the machine. The purpose of this work is to preserve the safety and optimum operating state of the machine. Therefore be sure to perform these operations with utmost care. Note Below the maintenance schedule individual operations are again described in detail.



General instructions The Multi-Function Separator SP-MF must regularly be serviced by competent personnel so that it will permanently and cost-efficiently function as intended under the conditions that can be expected on the basis of the intended mode of operation. The operating company has to lay down the required service and inspection measures in the form of working instructions, depending on operating conditions and experiences.



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Maintenance



Items on left-hand side of machine Every 6 months Every months Every week



Every week Driving motor (1)



Clean motor ventilation cowl



Filter sieves (2)



Remove fibre accumulations



Light barriers of wheeled waste containers (3)



Clean lenses and acrylic glass with soft cloth



Comb profile (4)



Clean



Every month Frame wall, interior (5)



Clean



Flap seal of heavy part separator (6)



Clean



Waste compartment area (7)



Clean and inspect visually



Outer machine panelling



Clean



Every 6 months Spark detector, heat detector, fire extinguishing system (8)



(See annex: manufacturers’ documentation)



Filter screen cartridge (9)



Wash



Extraction flap (10)



Clean



Driving motor, gearing (11)



(See annex: manufacturers’ documentation)



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Maintenance



Items on right-hand side of machine Every 6 months Every months Every week



Every week Switch cabinet (12)



Clean (qualified personnel)



Filter pressure controller (13)



Drain condensate



Light barriers of wheeled waste containers (14) Clean lenses and acrylic glass with soft cloth Every month Frame wall, interior (15)



Clean



Outer machine panelling



Clean



Every 6 months Spark detector, heat detector, fire extinguishing system (16)



(See annex: manufacturers’ documentation)



Metal detector (17)



(See annex: manufacturer’s documentation)



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Maintenance



Cleaning fan Chips or metal particles may be deposited in the fan casing. The drive shaft may also become dirty. The fan has a maintenance flap secured by one knurled screw. In addition, the maintenance flap is protected against opening during operation (running fan) by a safety locking device. After switching off the machine you can open the maintenance flap as soon as the fan has come to a standstill. 1. Loosen the knurled screw by hand. The screw is secured to prevent it from falling out. 2. Open the flap and fold it over to the side. 3. Clean the fan interior and the fan wheel and check them for damage. 4. Remove any dirt from the drive shaft. 5. Clean the flap seal. 6. Close the flap and tighten the knurled screw by hand.



Cleaning filter sieves Filter sieves are located on either side of the air separator and in the waste compartment of the metal and spark separator. The air separator is accessible only from the maintenance scaffold and from the top side of the machine. Removing fibres The filter sieves in the metal and spark separator are visible and freely accessible after the door to the waste compartment has been opened. The filter sieves on either side of the air separator are accessible from the outside through maintenance flaps. Usually there are inspection windows in the flaps through which you can see the filters and judge the degree of clogging.



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Maintenance



Each of the flaps is secured by means of two knurled screws. The flaps can be opened during ongoing operation. 1. Loosen the knurled screws by hand. The screws are secured to prevent them from falling out. 2. Open the flap fully. 3. Clean the filter sieve. 4. Clean the flap seal. 5. Close the flap and tighten the two knurled screws by hand. Washing filter screen cartridges You have to wash the two filter screen cartridges if too heavily clogged. To this end, it is necessary to remove the screen cartridges completely and to install them again after cleaning. Caution The filter screen cartridges may only be removed and installed with the machine switched off. Be sure to always put down and secure the heavy side walls and the filter sieves in such a way that they cannot fall over or fall off the machine. To get to the filter screen cartridges, you have to remove two side walls of the air separator.



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Maintenance



Each of the side walls is secured by means of 10 screws. 1. Loosen the screws with a 5 mm hexagon socket screw key without screwing them out. 2. Push the side walls up, take them off and put them on the floor so that they cannot fall over. 3. Take the filter screen cartridges out of the air separator and put them on the floor so that they cannot fall over. 4. Fit the cleaned or new filter screen cartridges into the air separator. 5. Clean the side walls and then from above, by means of the slotted holes, hang them up on the screws again. 6. Tighten all the screws with the hexagon socket screw key.



Cleaning light barriers Light barriers monitoring the filling levels in the wheeled waste containers are installed in the two waste compartments of the machine. If the lenses of the light barriers or the round windows in the side walls of the waste compartments are dirty, the light beam will be obstructed. This may trigger faults. You can clean the round acrylic glass windows from inside the waste compartments after taking out the wheeled waste containers. The outsides of the windows and the lenses of the light barriers are accessible from the left and right-hand side of the machine behind the four lateral doors. Caution Only use a soft cloth for cleaning the lenses and the windows. Take care not to scratch the lenses and the windows.



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Maintenance



Cleaning comb profile The comb profile of the heavy part separator is accessible from above through the flap over the inlet duct of the heavy part separator. You can reach this flap from the maintenance scaffold. Usually there is an inspection window in the flap through which you can see the comb and possibly also foreign particles (e.g. fents, transport material). The flap is secured by means of one knurled screw. The flap can be opened during ongoing operation. 1. Loosen the knurled screw by hand. The screw is secured to prevent it from falling out. 2. Open the flap and fold it over completely. 3. Clean the comb profile. 4. Clean the flap seal. 5. Close the flap and tighten the knurled screw by hand.



Cleaning air ducts Outside maintenance flap A maintenance flap allowing access to the air duct below the comb profile is located above the waste compartment of the heavy part separator. This flap is usually provided with an inspection window through which you can judge the degree of soiling. The flap is secured by means of two knurled screws. The flap can be opened during ongoing operation. 1. Loosen the two knurled screws by hand. The screws are secured to prevent them from falling out. 2. Open the flap and fold it down until it rests on the frame. 3. Clean the air duct. 4. Clean the flap seal. 5. Close the flap and tighten the two knurled screws by hand.



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Maintenance



Inside maintenance flaps Through the service door on the left-hand side of the machine you can enter the interior of the machine. There two further maintenance flaps are located. Through these flaps you can reach the air ducts of the heavy part separator and of the metal and spark separator and clean them. Heavy part separator The flap leading to the air duct of the heavy part separator is secured by means of one knurled screw. The flap can be opened during ongoing operation. 1. Loosen the knurled screw by hand. The screw is secured to prevent it from falling out. 2. Open the flap and fold it down. 3. Clean the air duct. 4. Clean the flap seal. 5. Close the flap and tighten the knurled screw by hand. Metal and spark separator The flap leading to the air duct of the metal and spark separator is located in the wall of the air duct between the metal detector and the quick closing flap. The flap is secured by means of eight screws. 1. Loosen the screws with a 5 mm hexagon socket screw key without screwing them out. 2. Push the flap up, take it off and put it on the floor. 3. Clean the air duct. 4. Clean the flap and then from above, by means of the slotted holes, hang it up on the screws again. 5. Tighten all the screws with the hexagon socket screw key.



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Maintenance



Cleaning extraction flaps The heavy part separator and the metal and spark separator are each equipped with a large extraction flap. Fibres and waste residues collect on the extraction flaps and on the housing walls around the flaps: They must be removed to ensure the proper function of the flaps. The flaps are accessible from the outside through the respective waste compartment. 1. Open the door of the waste compartment and fully pull out the wheeled waste container. 2. From the waste compartment clean the extraction flap and the area around the flap. 3. If necessary, clean the flap seal and the area around the seal. Note The flap seal can only be cleaned with the flap open. Opening of the flaps in the service mode is described in the section Functional testing of aggregates, page 71.



Filter pressure controller Condensate from the compressed-air piping tends to collect in the filter pressure controller of the quick closing flap. You need to drain this condensate from time to time. The filter pressure controller is located on the right-hand side of the machine behind the door in which the operating unit is installed. A short end of plastic tubing sticks out of the bottom of the filter pressure controller. 1. Briefly push this end of plastic tubing into the filter pressure controller. Any air and condensate are blown out. 2. If necessary, repeat this procedure until no more condensate is blown out.



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Maintenance



Cleaning volumetric nozzles A volumetric nozzle is located both in the air duct upline of the fan and in the exhaust air duct downline of the air separator. Two transparent plastic hoses leading to the pressure sensors in the machine are connected to each of the volumetric nozzles. At the connections fibres or dirt may be deposited in the hoses. In this case you have to blow the hoses through with compressed air from the pressure sensors. The pressure sensors are located on the right-hand side of the machine behind the door with the operating unit. 1. Check the hose connections to the volumetric nozzle for dirt. 2. If necessary, pull the hoses carefully off the pressure sensors, one at a time, and blow them through with compressed air. 3. Carefully slide the hose back on again.



Cleaning waste compartments Clean both waste compartments thoroughly using a vacuum cleaner, cleaning the floor near the doors in particular. The seal fitted to the bottom edge of each door must provide an airtight seal between the door and the floor. Also clean the door seals in the door frames and in the bottom edges of the doors.



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Maintenance



Machine panelling, frame



Functional testing of aggregates



Clean the machine panelling (walls, doors and floor panels) of dirt. This includes all parts that are accessible from the outside, the inner surfaces of the two waste compartments and the interior of the machine, which is accessible through the service door.



You can energise the aggregates of the multifunction separator (extraction flaps and fan) individually. In this way you can test their functions and perform service or maintenance operations.



Clean all parts with a soft cloth, water and a mild cleaning agent. Caution Do not use any abrasive or aggressive cleaning agents, as they may damage lacquer coats and seals.



Functional testing of display You can check the function of the display of the operating unit. It is important that all display elements function properly so that texts and above all numerical values are reproduced correctly. You see the basic display. 1. Press key R once. 2. Press numeric keys 3 and 9 to input function number 39. 3. Finally press key R once more. All elements of the display must light up. All LEDs over the keys of the operating unit must light up. 4. Press key R again. The function is terminated. If any of the luminous elements in the display or any of the LEDs is defective, please inform Trützschler’s after-sales service immediately.



For manual energization of the aggregates the machine must be in the service mode. DANGER OF INJURY In the service mode all door locking systems are released and all safety limit switches overridden. Secure the machine, e.g. by means of barriers, to prevent unauthorised access. Put up danger signs wherever a hazard may occur (e.g. at the fan and at any access to an extraction flap). Make sure that nobody can open or close the flaps with the operating unit while a person stands near one of the flaps or performs any work there. Secure the operating unit, e.g. by removing the key, to prevent unauthorised access. On a higher level the external emergency stop circuit has a disabling effect also in the service mode. The key-operated switch for the service mode is located behind the service door on the left-hand side of the machine. During normal operation this door can only be opened while the machine is at a standstill. 1. Switch off the machine and wait for the door locking systems to be released. 2. Open the middle door on the left-hand side of the machine. The key-operated switch for the service mode is located on the left side wall. 3. Switch the key-operated switch to service mode (position I).



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On the operating unit you can now successively select the two extraction flaps and the fan for energisation. To this end, you have to press keyYES each time. If you press key NO, the next service step will be displayed for selection. To change to normal operation you have to switch off the service mode with the key-operated switch. Only after that all automatic safety functions will be active again. You can then switch the machine on again. 1. Set the key-operated switch to position 0 to terminate the service mode. 2. Remove the key and close the service door. Extraction flap of metal and spark separator 1. The message Check extraction flap EM? is shown on the display of the operating unit. 2. Press key YES. The display shows the text Extraction flap EM. The red LED over key 0 lights up; the yellow LED over key I flashes. 3. Press key I: The extraction flap is opened and remains open. The red LED over key 0 flashes; the yellow LED over key I lights up. 4. Press key 0: The extraction flap is closed again. The red LED over key 0 lights up; the yellow LED over key I flashes. 5. Press key R to switch to the next service step.



Extraction flap of heavy part separator 1. The message Check extraction flap SP-H? is shown on the display of the operating unit. 2. Press key YES. The display shows the text Extraction flap SP-H. The red LED over key 0 lights up; the yellow LED over key I flashes. 3. Press key I: The extraction flap is opened and remains open. The red LED over key 0 flashes; the yellow LED over key I lights up. 4. Press key 0: The extraction flap is closed again. The red LED over key 0 lights up; the yellow LED over key I flashes. 5. Press key R to switch to the next service step. Or press key CE to switch to the previous step. Fan 1. The message Check BR-FD? is shown on the display of the operating unit. 2. Press key YES. The display shows the text BR-FD 0%. The yellow LED over key I flashes. 3. Press key I and hold depressed (inching mode): The power supply for the frequency converter is switched on. The yellow LED over key I lights up. After a ready-to-operate message from the frequency converter the fan is enabled and the fan setpoint activated. The readout on the display switches from 0% to 100%. 4. Let go of key I: The setpoint for the fan is cancelled. The yellow LED over key I flashes. 5. Press key R to switch back to the first service step. Or press key CE to switch to the previous step.



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Further service operations Further service operations on individual machine components which are not described here must be performed in accordance with the instructions contained in the respective manufacturer’s documentation. This comprises: – spark detector – heat detector in waste compartment – fire extinguishing system – metal detector – driving motor of fan – fan gearing You will find the respective original documentation with all the information about maintenance and service in the Annex to this operating and service manual or in the tray on the inside of the switch cabinet door. Use it to inform yourself about the work to be carried out.



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Repairs General instructions Any defective element of the machine must no longer be used and must be replaced with an equivalent one. For example, this applies to: – worn, cracked or bent screws and locks, – damaged nuts or threads, – bent clamps or bows, – damaged seals, – damaged danger signs and instructions. All the required repair measures must be performed in accordance with the national regulations applying to the installation site. DANGER Any repair work not described in this operating and service manual may only be carried out by Trützschler’s after-sales service. Improper repair work may cause hazards to people and serious damage to the machine.



Replacing CO2 cylinder The fire extinguishing system of the Multi-Function Separator SP-MF uses CO2. If an extinguishing operation has been triggered by the fire warning centre, the CO2 cylinder will have been completely emptied in the process. In this case remove the empty cylinder and replace it immediately with a new, filled cylinder. Note Always keep an operational, filled CO2 cylinder on stock to avoid prolonged downtimes of the machine. EXPLOSION HAZARD Protect the steel cylinder from direct solar radiation!



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Removing empty cylinder The CO2 cylinder is located behind the middle service door on the left-hand side of the machine. This door is locked and can only be opened while the machine is at a standstill. 1. Loosen and completely screw off the nut of the binding screw (1). 2. Pull the screw out completely and remove the tripping device (2). 3. Deposit the screw, nut, washer and snap ring in a clean place nearby. 4. Fully loosen the union nut of the extinguishing agent hose (3) and take the hose off the cylinder. 5. Turn the lever (4) of the ascending pipe valve up to close the valve again. 6. Put the safety pin, which is fastened to the valve with a chain, through the bore (5) and secure it, e.g. with a ring, to prevent it from falling out. 7. Loosen the two safety straps of the cylinder and take the cylinder out. The ascending pipe must remain fitted in the cylinder to allow the cylinder to be filled. Caution Check the ascending pipe for secure mounting before having the cylinder filled again. Note Read the section Preparing new cylinder on page 77 on how to prepare a new cylinder for filling without an ascending pipe having been fitted.



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Mounting filled cylinder DANGER OF INJURY Use only CO2 cylinders conforming to the technical specifications (see from page 81 of this operating and service manual). The use of non-conforming cylinders may cause serious injuries and damage to the machine. During the installation you have to cock the stud of the tripping device. The clamping tool is located behind the cylinder on the housing wall of the machine. 1. Put the cylinder in the machine, turn it to the right position and secure it with the two safety straps to prevent it from falling over. 2. Join the extinguishing agent hose (6) to the thread of the valve; put on and tighten the union nut. Make sure that the nut does not jam, damaging the thread. 3. Fully screw out the screw of the clamping tool. 4. Put the clamping tool on the tripping device, over the stud (2), and lock it with the bayonet catch. 5. Screw in the screw of the clamping tool as far as it will go, overcoming the resistance of the stud, so that the stud is completely pushed into the housing of the tripping device. 6. Push in the pin (3) on the back of the tripping device and slowly unscrew the complete screw of the clamping tool again. The stud remains in the tripping device.



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7. Remove the clamping tool and put it back in the mount in the housing wall of the machine, behind the cylinder. 8. Put the tripping device on the ascending pipe valve and secure it with a screw, a washer, a snap ring and a lock nut. 9. Finally pull out the safety pin (5). DANGER OF FIRE The safety pin prevents the valve from opening. The fire extinguisher will only work if the safety pin has been pulled out.



Replacing fluorescent lamp A damp-proof luminaire lighting the material flying through the air duct of the heavy part separator is installed inside the heavy part separator on the left-hand side of the machine. ELECTRIC SHOCK HAZARD Do not perform any work on electric lines or electrical connections. Work on electric lines may only be performed by trained specialist personnel complying with all regulations. Access to the luminaire is through the service door on the left-hand side of the machine. This door is locked and can only be opened while the machine is at a standstill.



Preparing new cylinder DANGER OF INJURY Use only CO2 cylinders conforming to the technical specifications (see from page 81 of this operating and service manual). The use of non-conforming cylinders may cause serious injuries and damage to the machine. If you want to use a new CO2 cylinder, you will first have to install the ascending pipe included in the scope of supply of the machine.



1. Open and remove the cover of the luminaire. 2. Take out the defective lamp and replace it with a new lamp. 3. Carefully put the cover back on the luminaire again, making sure that the cover does not become canted and that the seal is not damaged. 4. Lock all closing devices of the cover again.



The ascending pipe is located in the position of the CO2 cylinder when the machine is delivered. Use a suitable sealing tape when installing it. After installing the ascending pipe, have the cylinder filled in accordance with the technical specifications (see from page 81 of this operating and service manual).



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Annex



Annex Technical data General notes Dimensions



see drawing in section Machine dimensions



Inner frame width



1,000 mm



Total weight



3,800 kg



Specific floor load



6,314 N/m2



Surface pressure per pedestal



max. 158 N/cm2



Compressed air requirements



74 Nl/h



Material quantity in permanent production



max. 1,500 kg/h



Fan Model



BR-FD 500



Type



three-phase A.C. motor



Drive



direct drive with frequency control



Operating voltage



400 V, 82 Hz



Rating



9.0 kW



Continuous power consumption



max. 6.5 kW



Speed range



800–2,240 min --- 1



Torque



36 Nm



Output capacity (air volume)



max. 7,500 m3/h



Output capacity (material)



max. 1,500 kg/h



Material feed Material quantity



max. 1,800 kg/h



Air intake rate



5,500 m3/h – 7,300 m3/h



Material suction Material quantity



max. 1,800 kg/h



Air intake rate



4,000 m3/h – 6,500 m3/h



Dust extraction Exhaust air output



1,500 m3/h – 3,300 m3/h



Dust throughput



max. 0.3 kg/h



Metal detector Detector coil



Mesutronic Metron 05 PowerLine



Electronic evaluation system



Mesutronic AMD 05



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Annex



Machine dimensions



80



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Annex



Fire extinguishing system Spark detector



Minimax FUX 3001



Heat sensor



Minimax WMX 1000 F60



Tripping device



Minimax EM 24 V DC



Fire warning centre



Minimax FMZ 4100 GAB 6



Horn



multi-function warning siren B/SM 28 UP



(For further technical data see manufacturers’ documentation in annex to this operating and service manual)



Gas cylinder Medium



CO2



Steel cylinder



to directive 1999/36/EC, labelled according to TRG 270, No. 8 (German Code of Practice for Compressed Gas Cylinders)



Surface



RAL 7011 or RAL 7037



Cylinder valve



type K85-20.0-S9



Collar, base



DIN 4664



Protective cap



DIN EN 962



Valve thread



DIN EN 962-1, 25E



Cap thread



DIN EN 962, W80



Cylinder filling



filled according to German Pressure Vessel Code



Cylinder pressure



approx. 60 bar



Test pressure



250 bar



Filling tolerance



in accordance with legal provisions



Nominal volume



13.4 l



Filling quantity



10 kg



Weight without filling



17 kg



Weight with filling



29 kg



Dimensions (L × ∅)



1,220 × 140 mm



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Annex



Gas cylinder dimensions



82



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Index



Control software, 43 Counter Extraction flap, 42 Maintenance, 42



A



D



Accident prevention regulations, 10 Addition of waste , 17



Dangerous spots , 13



Air separator, 15 , 17 , 21 , 35 Autoleveller to be calibrated (function), 41



DEA1, 56 , 59 Display , 22 Display brightness , 24



B



Display control (function), 41



Basic display, 25



Display program numbers (function), 43



Basic speed, 38



Display scheduled value (function), 41



Brand, 50



Display test, 39 , 71 Door locking system (function), 38 Draining condensate, 69



C Calendar clock, 43 Change control parameters (function), 41 Cleaning Air ducts , 67 Comb profile , 67 Extraction flaps, 69 Fan, 64 Filter pressure controller , 69 Filter sieves , 64 Frame, 71 Light barriers, 66 Volumetric nozzles, 70 Waste compartments , 70 Cleaning air ducts , 67 Cleaning comb profile , 67 Cleaning extraction flaps , 69 Cleaning filter sieves , 64 Cleaning light barriers , 66



E Electrical connections , 20 EM carriage change extractions (function), 39 EM door unlocking after (function), 39 EM ejections (function), 42 EM extraction time (function), 40 EM monitoring time doors (function), 39 Emergency stop , 13 Enter limits (function), 39 Exhaust air output , 36 Extinguishing operation, 50 Extraction flap EM service (function), 42



F



Cleaning waste compartments , 70



Fan, 15 Clean, 64 Testing , 71



Autoleveller to be calibrated, 41



Fan speed, 30



Condenser , 15



Fault number, 46



Configuration, 28



Filling level control, 19



Configuration (function), 41



Filter pressure controller , 69



Control cabinet, 11



Fire extinguishing system, 74



Control functions, 26



Fire warning centre, 14



Control parameter, 41



First start---up, 28



Cleaning volumetric nozzles , 70



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Flap openings , 31



LED indicators , 56



Fluorescent lamp , 77



Left side, 8



Frequency converter , 56 , 57



Lighting, 77



Function number, 38 Functional testing of aggregates , 71 Functional testing of display , 71 Further information, 7



G Gas cylinder Installing new cylinder , 77 Mounting, 76 Removal , 75 Replacement, 74



M Machine control , 38 Machine control parameters, 38 Mains disconnecting device, 13 Maintenance, 31 Maintenance flap Comb profile , 67 Fan, 64 Heavy part separator, 68 Metal and spark separator, 68 Maintenance schedule , 61



H Heavy part separator, 15 , 17



Maintenance work, 11 Malfunction indication , 45 Malfunctions, 24 , 45



Housing fan, 20



Master switch, 13



Housing filter, 20



Material flow, 16 , 33



I I/O module , 59 Injuries, 13



Menu , 25 Metal separator, 15



N



Inputs/outputs, 59



Network address TKN (function), 42



Inspection, 31



Number of fault message , 46



Inspection windows, 33 Instruction texts, 53



K Key---operated switch Operating unit, 24 Service, 14 , 61 Keyboard, 22 Keys, 25 KSZ4, 56 , 58



L Lamp, 77 Lamp test (function), 39



84



O Operating and service manual Conventions, 8 Further information, 7 Purpose, 7 Symbols, 8 Operating unit, 21 , 22 Operating unit navigation , 25 Operation , 30 Overview Fault messages , 46 Function, 16 Function numbers, 38 Instruction texts, 53 Maintenance and servicing, 62 Operating elements, 21



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Operating unit, 23 Subassemblies, 15 Warning messages, 52



Service mode , 14 Servicing, 11 , 31 , 74 Set system clock (function), 43



Overview of functions, 16



Setpoints, 38 Setting example , 27



P



Setting exhaust air output , 35 Settings Change, 26 Example, 27 Machine, 35 View, 25



P---functions, 38 Pipeline for dust exhaust, 36 Position, 15 Preparation for operation, 28



Slide gate, 35



Preparation for operation , 28



Slide gate for exhaust air, 21



Pressure gauge, 21 , 34 , 36



Software version , 43



Production data , 30



SP---H carriage change (function), 40



Purging air, 37 Putting the machine out of operation, 12



Spark sensor, 18 Start---up, 12



Quick closing flap, 18 Extraction time, 40



Status messages, 53 Subassemblies, 15



R



Switch cabinet, 20 , 56



Remedies in the event of malfunctions, 46 Repairs, 11 , 74 Replacement of wheeled waste container, 31 Replacing wheeled waste containers , 31 Right side, 8



SP---H monitoring time doors (function), 40 Spark detection, 51



Q



Reset counter EM (function), 40



SP---H flap interval (function), 40



Switching off, 30 Switching on, 11 , 29 Symbols, 8 System clock, 43



T Test of display and LEDs, 39



S Safety equipment, 13 Safety measures , 10 Screen cartridges, 65 Selection of language (function), 42



Testing aggregates, 71 Testing extraction flaps, 71 TKN address (function), 42 Transport fan, 16 Trouble shooting, 56 Type plate, 9



Separation of metal, 18 Service, 61 Manufacturers’ instructions , 73



U



Service door, 61



Underpressure, 34



Service interval EM (function), 42



Use, 9



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V Version number of software, 43 Volumetric flow (function), 38 Volumetric flow rate, 30 Volumetric flow rates, 36



W Warning messages, 52 Warning plates, 10 Warnings, 24 Waste compartment door , 51 Waste compartment doors , 31 Wheeled waste containers, 19 Work safety regulations, 10 Working memory (function), 38



86



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Trützschler GmbH & Co. KG Textilmaschinenfabrik D-41199 Mönchengladbach Postfach 41 01 64 Telefon +49 2166 607-0 Telefax +49 2166 607-405 E-Mail [email protected] Internet www.truetzschler.com