air conveyor manual

8/13/2019 Air Conveyor Manual

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OPERATION

and MAINTENANCE MANUAL

AIR CONVEYORC.17217


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Presentation

While thanking you for choosing one of our products, we wish toinform you that this manual is the outcome of long and careful

research carried out by our technicians, aiming at improving

your knowledge and use of the system we supplied to you.

In order to help us achieve the best results from our long and

patient work, we advise you to read the preliminary remarks to

this manual, on Ch. Safety.

We are firmly convinced that something started well leads tobetter results and hence to a long and profitable collaboration

which will help us improve our work and, consequently, yours.

We are confident that you will agree and appreciate the quality

and type of work that emerges from the pages that follow and

we are pleased to have the opportunity to thank you and wish

you all the best in your work.

Offices and Plant: S.r.l.Via Scodoncello N. 41 - 43044 COLLECCHIO (PARMA) - ITALIA

Tel.: (0039 - 0521) 541.011 (5 linee r.a.); Fax: (0039 - 0521) 802.149 (ITALIA)

Sito WEB: http://www.lanfranchi.it; E - mail: [email protected]

Branch house: Nord Europe SA

109 bis Av. J. Lebas - 59100 ROUBAIX (FR)

Tel.: 0033 - 320.689.620; Fax: 0033 - 320.689.621

E - mail: [email protected]

Branch house: North America Inc.8190 Woodland Center blvd. - Tampa FLORIDA 33614 (U.S.A.)

Tel.: +813-901.5333; Fax: +813-901.5518

E - mail: [email protected]

The PresidentLanfranchi Lino


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Table of contents

TITLE - CH.Machine identification - Ch. A

Safety - Ch. B

Trasportation and installation - Ch. C

Preliminary operations - Ch. D

Components and operations - Ch. E

Control panel - Ch. F

Maintenance - Ch. G

Pneumatic - Ch. H

Size change - Ch. I

Spare parts - Ch. J


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Copyright

This OPERATION and MAINTENANCE MANUAL has been designed and drawn

up by the Engineering Department of LANFRANCHI S.r.l.

This manual and any information contained in it may not be reproduced,

copied or transmitted in any form or by any electronic, mechanical or other

means, unless otherwise specified and, in any case, not without the prior

written authorization of LANFRANCHI S.r.l.

Any violation of the above regulation or of the Copyright legislation

currently in force in Italy and in the countries of destination of the manual

will be punishable according to the law.

The software Adobe PageMaker 7 was utilized in the realization of this

publication.

Collecchio on, _____________

Via Scodoncello, 41 - 43044 COLLECCHIO (PARMA) ITALIATel.: (0039 - 0521) 541.011 (5 linee r.a.); FAX: (0039 - 0521) 802.149 (ITALIA)

Sito WEB: http://www.lanfranchi.it; E - mail: [email protected]

EXPORT: M 562694; C.C.I.A.A.: 17534; Iscr. TRIB.: PR 20681; P. IVA Cod. FISC.: 01713170346


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1

AIR CONVEYOR - Machine identification

Par. Title Page

Identification machine

1 Documentation 2

1.1 Warranty and inspection 2

1.2 Reproduction and copyright restrictions 2

1.3 CE Declaration of conformity 2

2 Tecnichal information 5

2.1 Technical characteristics 5

2.2 Environmental conditions 6

2.3 Vibrations 6NOISE 6

Reading points 7

2.4 Weights 8ELECTRIC CONTROL CABINET 9

ABSOLUT FILTER 9

2.5 Power and consumption 10

2.6 Connection and consuption 10


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43044 Collecchio (PARMA) ITALIA - Via SCODONCELLO, 41

Tel.: (0039 - 0521) 541.011 (5 linee r.a.) - FAX: (0039 - 0521) 802.149

EXPORT: M 562694 - C.C.I.A.A: 173534 - COURT REG. NO.: PR 20681

TAX CODE & V.A.T. NO.: 01713170346

SYMPAK BOTTLING & CANNINGGesellschaft Bahngasse, 25 A-2700 WIENER NEUSTADT AUSTRIA

Our order N: C17217

Your order N: 0842Z07_CO of 07/12/2007

Subject: Air conveyor (Bottle release mechanism)

Machine applications: TRASPORT of EMPTY and LOOSE PLASTIC BOTTLES

COMPOSITION

Subject: Air conveyor (Bottle release mechanism)

Model: NA

Serial N: 17217-07

MARK

PATENT --

MODEL NA

SERIAL N 17217-07

YEAR of MANUFACTURE 2007


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Machine identification - AIR CONVEYOR

I, signatory of this document, hereby

DECLARE

on my own responsibility that the system mentioned above as subject of this declaration

IS IN CONFORMITY

- with the provisions of EEC directive

for Italy

93/68/CEE and subsequent revisions

for abroad


- with the previsions of Low Voltage Directive


- with the provisions of the Electromagnetic Compatibility directive:



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2 Tecnichal information

2.1 Technical characteristics

The pneumatic conveyors supplied by us have been designed to perform best in environments

with a low relative humidity count (maximum acceptable humidity is 30%) and with temperatures

ranging from a minimum of 20 and a maximum of 40.

When processing food products, in order to guarantee the maximum inalterability and hygiene

of the product treated, the entire line of pneumatic conveyors must operate in a clean isolated

environment, ideally with the above described characteristics.

Under no circumstances should oily or volatile products be present in such environments.

Additionally, there must not be sugary substances present in the air as these deposit harmful

films on the suction and air intake components (aspiration filters, electric motors or any other

kind of rotating mechanical element).

The presence of these substances in the working environment can damage beyond repair seals or

protections designed to insulate the wiring of the electrical system, thereby jeopardizing their

safety and reliability.

Regular maintenance and preventive cleaning are not always sufficient to guarantee the good

performance of the entire conveying system if the system is operating in an environment that is

not perfectly protected from harmful agents which, over the course of time, can also be corrosive.

The company LANFRANCHI S.r.l. will not, therefore, be held responsible for damage to, or

malfunctioning of, the system it has installed if the above listed criteria are not adhered to when

the system is effectively installed on the clients premises.


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2.2 Environmental conditions

To ensure top machine performance, operating temperatures must be within acceptable limits

i.e. not less than + 4C and not exceeding+ 90C .

The internal temperature of the electric control cabinet must not exceed + 45C.

To satisfy this condition, the electric control cabinet is constantly ventilated and forced ventilation

is used, if required.

2.3 Vibrations

The machine has been designed and constructed according to existing standards and accepted

vibration levels.

NOISE

On the basis of readings taken using a System of the same type, we can safely say that the

maximum operating noise levels of the machine we supply do not exceed 82 Db.

The above stated values were measured according to the method described in the following

page in compliance with the current standards in force.

This value can, however, only be considered as approximate given the fact that, in order to

obtain an accurate reading for daily exposure to noise, a further test should be run once the

system has been completely installed on the clients premises.

This test must take into account the following factors:

- shape and architecture of the work place;

- acoustic characteristics of its walls;

- operational cycle rhythms with reference to the standard values;

- type of bottle treated.


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Reading points

1 m.

1 m.

1 m.

1 m.

1,6 m.

MANDATORY

THE ACOUSTIC

PROTECTIONS


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2.4 Weights

Components Weight in kg

Rectilinear section 20 kg/ m

Curve 90 30 kg

Hinge with 2 hand - wheel L = 3000 110 kg




Releasing mechanism section 12 kg

Fixed foot h = 2000 13 kg

Adjustable foot h = 2000 20 kg

Combiner

- asymmetrical 60 - 80 kg

- simmetric 190 kg

Blower with motor 80 kg


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ELECTRIC CONTROL CABINET

Models Weight in kg

STANDARD 150 kg

2 DOORS 450 kg

3 DOORS 750 kg

4 DOORS 1050 kg

5 DOORS 1350 kg

VERTICAL PANEL 115 kg

ABSOLUT FILTER

Components Weight in kg

Collector 150 kg

Single cannister 450 kg

Double cannister 750 kg


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2.5 Power and consumption

Voltages:

Main 400V- 50Hz

Auxiliary 24V DC

Installed electric power:

In order to calculate the total power installed only on the air conveyors, it is necessary to carry

out this operation:

2.2 kW (power of a single motor for each fun)

x

total number of the motors installed on the conveyors

2.6 Connection and consuption

Connection:Compressed air supply G 1/2"

Compressed air operational pressure 6 - 7 Bar


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AIR CONVEYOR - Safety

Par. Title Page

Safety

1 Preliminary remarks 2

2 How to consult this manual 3

3 Revisions 4

4 Connections to be made by the client 4

5 Requesting technical service 5

6 Instructions for ordering spare parts 5

7 Machine applications 6

8 Danger zones 6

8.1 Danger zone 6 EXPOSED PERSON 6

8.2 Operator 6

9 Personnel safety devices 7

9.1 Main switch 8

9.2 General emergency button 10

9.3 Special keys 10

9.4 Electromechanical safety devices 11SAFETY DISCONNECTING SWITCH 14

9.5 Precautions for the operator 15OPERATOR GUARDS 15


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Safety - AIR CONVEYOR

1 Preliminary remarks

This manual has been drawn up as a guideline to the correct use of the machine you have

purchased and is intended exclusively for operators and qualified personnel.

It is, therefore, of essential importance that the employer should undertake to inform the latter

on the following topics relative to operational safety in the use of the machine:

- risk of accident;

- operator safety devices;

- general accident-prevention regulations or those laid down by international directivesand by the legislation of the country in which the machine is to be installed.

Before starting work the operator must read, with due care and attention, the entire contents of

this manual in order to understand the machine layout, the functions of its various controls and

its characteristics.

We, as manufacturers, undertake to provide, in a clear, detailed but simple manner, the following:

- explanations to ensure that the machine supplied is correctly installed;

- a detailed description of the machines principle of operation and each of its component;

- rules for setting up and start-up;

- a thorough scheduled maintenance program;

- strict adherence to the accident-prevention and safety regulations.


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2 How to consult this manual

In order to facilitate consultation of the manual, there is a GENERAL TABLE OF CONTENTS

on the first page by means of which you can immediately localize the topic you wish to consult.

The chapters are structured hierarchically for easy reference.

Each chapter is preceded by its own TABLE OF CONTENTS.

The operator will note the use of various symbols below to which he must pay very careful

attention.

To facilitate consultation, their meanings are explained below:

For the operator security it is absolutely compulsory to observe whats hereby

described: !You will find the references to the OBLIGATION signs situated in the

dangerous areas!

For the operator security it is absolutely forbidden to carry out the following

operations: !You will find the references to the PROHIBITION signs situated inthe dangerous areas!

MANDATORIES

DANGER

Presence of risks (wastes) for the operator.

!You will find the references to the DANGER signs situated in the dangerous areas!

PROHIBITIONS


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3 Revisions

If any modifications or functional replacements are carried out on the machine, revised copies of

the manual will be sent to replace the previous version.

4 Connections to be made by the client

Connections to be made by the client:

- loose bottle feeding;

- compressed air network connection;

- main electric panel connection;

- grounding system;

- any consumable materials additional to those already supplied by us.

For the information required to make these connections and wiring arrangements correctly,please consult the Ch. "Preliminary operations".

The company LANFRANCHI S.r.l. reserves the right to modify the OPERATION and

MAINTENANCE MANUAL for the machinery it manufactures whenever it deems fit and

without prior notice.


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5 Requesting technical service

Requests for assistance from the Client Technical Assistance Service should be sent via fax to

the following address:

LANFRANCHI S.r.l.

Via Scodoncello 41 - 43044 Collecchio (PARMA)

Fax (0039 - 0521) 802.149

Tel. (0039 - 0521) 541.011

and must contain the following details:

- machine type, serial number and year of installation;

- nature of the problem;

- your complete address and, if different, the exact address of the site where your machine

is installed;

- contact person.

6 Instructions for ordering spare parts

All spare parts requests should be sent via fax to the following address:

LANFRANCHI S.r.l.

Via Scodoncello 41 - 43044 Collecchio (PARMA)

Fax (0039 - 0521) 802.149

Tel. (0039 - 0521) 541.011

To make spare part identification faster and more precise, always include the following

information:

- machine serial number;

- drawing number and exact position in which the part is found, description and quantity.


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7 Machine applications

The machine has been designed and constructed to transport large and small empty bottles

obtained by through the blow-moulding of plastic materials.

Should the machine be used for any application other than that for which it was designed and as

described in this manual, the manufacturer declines any and all responsibility regarding the

machine.

8 Danger zones

Please note the following definitions as laid down in the EEC Machinery Directive 89/392.

8.1 Danger zone

Any area within and/or around machinery in which an EXPOSED PERSON is subject to a risk to

his or her safety.

EXPOSED PERSON

Any person wholly or partially in a danger zone.

THE OPERATOR DEDICATEDTO THE AUTOMATIC OPERATION OF THE

EQUIPEMENT IS COMPELLED TO BE IN FRONT OF THE CONTROL

CONSOLLE DURING THE PRODUCTION

8.2 Operator

The person or persons given the task of installing, operating, adjusting, maintaining, cleaning,

repairing or transporting the machinery.

NO ENTRY TO ANY PARTS OF THE EQUIPEMENT (A PART OF QUALIFIED

STAFF)


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9 Personnel safety devices

MANDATORY TO OBSERVE THE INDICATIONS DESCRIBED IN THE

FOLLOWING PARAGRAPH

Most accidents and injuries in the work place are due to human error.

For this reason great care must be taken by personnel when carrying out the operations. It is

therefore necessary to:

- strictly adhere to the accident-prevention and safety regulations of your own country and

that in which the factory is located;

- entrust the running of the plant to physically and psychologically responsible personnel

who do not operate under the effects of alcohol, drugs or similar substances;

- use suitable personal means of protection for eyes, hands, feet, etc.

For the unit operator:

- report any failures encountered, especially those involving safety.

- never disable the safety devices and do not remove guards or housings installed to protect

the machines moving parts;

- do not make adjustments or activate switches, valves, sensors, photocells or controls if

you do not understand their principle of operation and/or unless specifically authorized to do s;

- follow cleaning and disinfecting schedules;

- adhere scrupulously to the temperatures and times indicated.

MANDATORY TO OBSERVE THE ACCIDENT PREVENTION RULES TO

ASSURE MAXIMUM SAFETY


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OPERATION CONDITION

9.1 Main switch

Tha main safety of the equipment is represented by the main switch (verify the kind of switch

placed on your supply).

Pos. OFF

Pos. ON

Pos.

ON

Pos.

OFF

Pos. ON

Pos. OFF

Pos. ON

MERLIN GERIN

SIEMENS

KLOEKNER MOELLERMod.: NZM

KLOEKNER MOELLER

Mod.: PKZ

ALLEN BRADLEY

Pos. ON

Pos. OFF

Pos. ON


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SAFETY CONDITION

Before performing any operations of an electrical or mechanical nature, cut off the voltage by

turning off the main switch, which is located on the electric control cabinet.

The main switch may then be padlocked in (verify the kind of switch placed on your supply)

order to ensure the safety of the personnel responsible for all operations, repairs and maintenance

work to be performed on the machinery.

MERLIN GERIN

SIEMENS

KLOEKNER MOELLERMod.: NZM

KLOEKNER MOELLER

Mod.: PKZ

ALLEN BRADLEY

Pos. ON

Pos. OFF

Pos. OFF

Pos. ON

Pos.

OFF

Pos. OFF

Pos. OFF

Pos. ON

Pos. OFF


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9.2 General emergency button

There is a mushroom-head emergency button on the control board.

It can be easily identified by its colour (below). Its function is to immediately stop the entire

unscrambler unit.

RED

YELLOW

MANDATORY TO PRESS THE

EMERGENCY BUTTON

ONLY IN CASE OF

NECESSITY

THIS SIGN SHOWS THAT

THERE IS A GENERAL EMER-

GENCY BUTTON IN THE

NEAR BY

To isolate this section, cut off the electric current by switching off the main switch on the main

power supply unit for the entire bottling system.

The feed cable must be connected up line of the main switch and marked with the symbol below:

9.3 Special keys

The access doors to the control board are locked with special keys which may only be kept by

authorized personnel.


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Part. B

Part. 1

Part. A

Part.

B

Part. A

9.4 Electromechanical safety devices

Some components (Combiner) which can be installed on the air conveyors lines, are closed in a

structure composed by some fixed parts and some mobile parts placed so as to enter easily the

zones that need maintenance or some other intrerventions to re-establish the machine production

cycle; these mobile parts are called ports (part. A and B below).

These doors are controlled by electromechanical safety device consisting of:

- a Key for safety position switch (det. A below), located on the mobile part of the guard

(door);

- a Safety position switch (det. B below) generally placed on the fixed part of the guard

(machine structure). The upper part (det. 1 below) of which is positionable (360) and depending

on assembling requirements, is.


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Pos. 1

Pos. 2

A

Ex.: LOWER protection door

B

The purpose of these keys is to place the machine in EMERGENCY conditions immediately one

of the doors controlled by these devices is opened.

The machine can proceed with its normal cycle of operation;

- if the door is closed, i.e. the key has been inserted into the switch, (Pos. 1 below);

- if the door is opened, the key is disconnected (Pos.2 below) and the machine enters

EMERGENCY conditions, and the relevant alarm is displayed.


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YELLOW

RESET

ECURITY

DEVICE

ORANGE

START

COMBINER

These devices may be subject to malfunctioning for a variety of reasons; should this be the case,

they must be removed by means of suitable wrenches and either replaced or repaired.

Before proceeding to remove these devices, the voltage to the machines electric switchboard

must be cut off by turning the main switch to OFF and padlocking it.

After completing any operations requiring the opening of doors controlled by a safety key, proceed

as follows in order to restore normal operating conditions:

- re-close the door of the guard;

- press the SAFETY DEVICE RESET button on the main control panel (below);

- or if the operator is near the port it is enough to press the keyn START COMBINER

(below).


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These devices are very simple to use:

when the disconnecting switch is turned from ON to OFF (below), the motor associated

with the disconnecting is automatically isolated thereby allowing the operator to perform all the

required operations in safe conditions.

These disconnecting switches can be installed either internally or externally to the machine

but they must always be in the immediate vicinity of the motor to which they are associated,

easily identifiable (YELLOW/RED), and easily accessible for immediate use.

SAFETY SISTEMS ARE EFFICIENT

SAFETY DISCONNECTING SWITCH

Among the various safety devices on the LANFRANCHI S.r.l. machinery, there are SAFETY

DISCONNECTING SWITCHES (below).

These disconnecting switches may be installed, on all parts of the machine where a drive unit is

likely to be installed or where personnel could be at risk.


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OPERATOR GUARDS

The accident prevention gear to be used as a personal means of protection is illustrated in the

drawing below and in the following pages.

9.5 Precautions for the operator

Under normal working conditions (automatic mode) there are no danger zones for the operator;

the unscrambler unit is well-protected against risk of injury.

This paragraph provides some basic information relative to operator personal safety.


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A: Always wear gloves to protect your hands so that they do not come into contact with

materials and/or other substances considered to be particularly dangerous.

MANDATORY TO USE

DANGER OF REMAINING RISKS IN SPITE OF THE ACCIDENT

PREVENTIONS PROTECTIONS. PAY THE MAXIMUM ATTENTION DURINGEVERY OPERATION

B: Always wear a suitable accident prevention helmet to protect your head from any unstably

positioned small objects that might fall.

MANDATORY TO USE

C: Always wear suitable glasses to protect your eyes against splinters, dust or remains of the

acidic-chemical products used for cleaning the machine.

MANDATORY TO USE

D: Always wear protective footwear with reinforced toecaps to safeguard your feet from falling

tools and objects in general (always within limits of weight and size).

MANDATORY TO USE


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E: Always wear work overalls in good condition. The overalls must be of the right size, so

that they are close-fitting and comfortable without impeding movement.

MANDATORY TO USE

E.1: The overalls must have close-fitting legs and sleeves with elasticized hems to avoid the

risk of becoming caught up in the machinery.

NO KIND OF JEWELLERY

ALLOWED

NO ENTRY WITH METAL

OBJECTS


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AIR CONVEYOR - Transport and installation

Par. Title Pag.

Transport and installation

1 Transportation 2

1.1 Maintenance safety rules 2

1.2 Section 3

1.3 Bottles release section 4

1.4 Combiner section 6

1.5 Absolute filter 8TRANSPORTATION 8

PLACING 9

2 Adjustments 10

2.1 Feet 10

2.2 Bottles release section 11

2.3 Side guides 12

2.4 Combiner section 13

2.5 Air delivery valve 14

3 Bolts and nuts tightening 18


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Transport and installation - AIR CONVEYOR

THIS CHAPITER IS EXCLUSIVELY DEDICATED TO THE QUALIFIED STAFF

1 Transport

The air conveyorsmust be handled usingpolyester straps .

1.1 Maintenance safety rules

OVERHUNG DANGER

NOT AUTHORIZED STAFF IS NEAR THE EQUIPEMENT

CRUSH DANGER

MANDATORY THE PROTECTIVE HELMET

MANDATORY THE GLOVES

MANDATORY THE SHOES


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Having ensured that the straps are securely positioned, proceed with the lifting of the section of

conveyor and its positioning on the production line taking the utmost care and attention to

avoid sudden movements or jolts that could result in the conveyor being damaged.

The fans that feed the air conveyor arrive disconnected at the clients premises in order to

facilitate the handling of the conveyor and must only be reconnected to the conveyor once it has

been positioned.

In order to avoid possible accidents to personnelat work during the handling of the conveyor

sections, it is good practice, for the purposes of safety, to warn all those who are in the vicinity

that a dangerous operation is underway and to be aware of the movements .

Part. 2

Part. 1

1.2 Section

Irrespective of the total length, these conveyors are always split into lengths of 3 metres eachto

facilitate their handling.

The strapsused must under no circumstances be passed under the side guides or between one

guide and another because this could cause them to be damaged thus endangering production.

In order to avoid damage to the conveyor or to any of its components, the straps should be

passed beneath the brackets that support the side guides (part. 1 below) and then positioned

onto the forks of a normal forklift truck (part. 2 below).


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1.3 Bottles release section

This section has a variable lenght (beetween 700 mm. and 1000 mm.) and is handled using some

chains.

- on the back, on the discreption of the operator, or to the cross beam A (Fig. 1 below) or

directly to the camera (Fig. 2 below).

The chain are hooked:

- frontally to the levers frame (det. 1 below);

1

1 2

A


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part. 1

After making sure that the chains are fixed, you can go on with the conveyor lifting and its

positioning on the outfeed supports (part. 1 below), being careful not to carry out hard movements

that can damage the conveyor.

In order to avoid that during the section movement some problems to the staff happen, its

aways a good antiaccident norm to inform everybody near the machine that dangerous operation

is carried out and its necessary attention to movements.


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part. A

1.4 Combiner section

This section is moved by using some polyester bands

The bands pass around the Combiner frame as you can see here below, paying attention not to

damage the frame.

Lift the Combiner section (below) selecting one of the systems described here below:

- bringing the extremities of the bands until the hook of a crane (part. A below);


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- passing the extremities of the bands around the forks of a lift (below).

In both the cases, keep the structure in balance in order to avoid damages to the persons and to

the gears.


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Part.1

1.5 Absolute filter

TRANSPORTATION

Absolute filters carriage takes place by means of polyester ropes and overhead.

Put the ropes at the basis of the filters (part. 1 below), so that during the carriage they dont

move, damaging the filter it self and eventually someone near the machine. People must be

careful not to stay in places that may be dangerouas for personal safety

WARNING! THE DEEPING OF THIS PARAGRAPH HAS TO BE CARRIED OUT

ONLY IF ON THE SUPPLY SOME ABSOLUTE FILTERS HAVE BEENINSTALLED


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Part. 1

Part. 2

Part. 3

A

B

C Part. 4

PLACING

Lining up tajes place on pedestals (part. 1 below) specially mades in order to be fixed to the

filters support (part. 2 below).

These pedestals avoid the absolute filter a to be an obstacle for the slide of the bottles and can

however be reached by the operator for eventual maintenance.

During thre placing it is very important thet the head of exit of the filter and collector of the

conveyor B are correctly connencted (part. 3 below).

After the placing of teh absolute filter A, take palce connenction with the fire fan C, wich

is moved to using polyester ropes. After that fire fan is leaned and fixed to the filters head (part.4 below).


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2 Adjustments

2.1 Feet

To position the air conveyors on a level plane, proceed as per the unscrambler unit, placing the

spirit level on the belt itself while adjusting the support feet of the conveyor belt (det. 1 below).

Part. 1


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PIANO DI SBARCO

Part. 1

Anello di presa (BAGA)

Part. 2

C

B

B

2.2 Bottles release section

In order to adjust the bottle processing transfer guides to the correct height, it is necessary to

take into consideration the transition points from one element to another of the various sections

of which the unscrambler unit is composed.

The air conveyor guides (below) must be capable of receiving a bottle without the bottle neck

becoming trapped between the guide and the conveyor.

In order to make the adjustment, a bottle of the same type as that to be processed must be used.

Place the base of the bottle on the unloading surface (det. A below) and regulate the 4 screws B

of the support belt (det. 1 below) so that the ring (Bottleneck ring), under the screw neck of the

bottle is approx.1 mm. higher than the air conveyor guides (det. C below).

In det. 2 shows a standard bottle with pick-up measurement Hi.e. the distance between the

base of the bottle and its upper part with the ring (bottle neck ring).

The measurement H - 1 corresponds to the exact position in which the air conveyor guides must

be placed in order to ensure that the bottles to be removed are successfully picked up.


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2.3 Side guides

The regulation of the guides must be checked every 1000 hours of operation.

The vibrations provoked by the blowing fans (installed on the conveyor chambers) could cause

some of the guide blocking clamps to loosen, after a long operational cycle.

The procedures for adjusting and tightening the support clamps are described as follows:

- loosen the knob A to enable the free sliding of the stem that supports the side guides;

- adjust the guides so that the bottle moves along smoothly without it rotating on itself, so

that the distance is around 5/6 mm. (det. 2 below);

- once the smooth passage of the bottle along the conveyor has been checked, turn the knob

A again to secure the guide support rod B in the pre-set position.

B A

Part. 2

5/6 mm.

Part. 1


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Fig. A Fig. B

Fig. C

2.4 Combiner section

In order to place the Combiner section on the production line it is necessary to place side by side,

according to the position it has to take, the air conveyor chamber section (Fig. A) to the devio-

combiner section (Fig. B) and tighten the two parts with autothreated bolts (Fig. C).

This operation has to be carried out keeping aligned the two sections to be joined.


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A

2.5 Air delivery valve

Between the central body of each fan (shell) and the chamber of the pneumatic chamber there is

a manifold for the regulating of the air flow (det. A below).

Inside the collector you can find a regulation valve for the air flow becoming from the valve; it

can be manually ruled as described in the following paragraphs.

BEFORE CHEKING THE OPENING OF TWO FLOW VALVES, ENSURE THAT

THE BLOWING FAN IS ROTATING IN THE RIGHT DIRECTION, IF THIS

ROTATING IN THE WRONG DIRECTION, CHECK THAT THE POWER CABLES

ARE CORRECTLY HOOKED UP IN THE WIRING OF THE TERMINAL BOARD

INSTALLED ON THE ELECTRIC MOTOR OF THE FAN ITSELF


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B

APart. 1

The air pressure should only be regulated if a considerable drop in the pushing pressure of the

bottles is encountered.

The regulating of the manifold with the system enabled should be carried out as follows.

If there are any Electric Motors controlled by INVERTER installed on the conveyor:

- loosen the knob B, located on the slide of the manifold A, so as to enable the smooth

movement of the slide along the regulation groove (below);

- move the two slides to a point halfway along the groove marked -(Det. 1 below);

- using the inverter keypad (located inside the systems Electric Panel) it is possible to set

various frequencies so as to have more than one speed per fan.


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Usually 3 frequencies are used and these are set as follows:

- MINIMUM frequency (at rest) which is activated automatically (after a given pre-set

programmed period) as a result of a prolonged stand-by stoppage of the production cycle of thesystem;

- INTERMEDIATE frequency (in dynamic operation) which enables each individual blower,

to keep an entire pack of bottles moving (the number of bottles contained in the pack must be

slightly greater than than normally moved by the conveyor during the normal production cycle);

- MAXIMUM frequency (static surge) that conveys the Maximum Peak to each individual

blower at a high enough level of power to move, from a static situation, an entire pack of bottles

(the number of bottles contained in the pack must must be slightly greater than normally moved

by the conveyor during the normal production cycle) after a stoppage during the accumulationphase or after a forced stop.

B

APart. 1

Should the air flow set by the various frequencies programmed be too great or not enough to

move the bottles along smoothly, adjust the manifold A increasing + or decreasing - the

opening of the two blades of the manifold (Det. 1 above).

Once the correct adjustment has been made (for all 3 speeds) lock the 2 regulating slides by

screwing down the knobs B (above).


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B

APart. 1

If there are no Electric Motors controlled by INVERTER installed on the conveyor:

- loosen the knob B, located on the slide of the manifold A, so as to enable the smooth

movement of the slide along the regulation groove (below);

- move the two slides to the end of the groove onto the mark - (Det. 1 below);

- now adjust the slides, making them move slowly and gradually towards the + sign (Det.

1 below).

In the area of the fan to be adjusted, there should already be a certain number (or pack) of

bottles in contact with one another (the number of bottles contained in the pack must be slightly

less than that normally moved by the conveyor during the normal production cycle).

When the pack of bottles start moving and, gradually accelerating, reach an acceptable speed,

lock the 2 regulating slides by screwing down the locking knobs B.

This operation must be repeated for each fan installed along the pneumatic conveyor.


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PRELOADS AND TIGHTENING TORQUES

BOLT DIM. CLASSES(METRIC THREADING - TRIANGULAR SECTION - LARGE PITCH)

Friction coefficient

Pre load Tightening

torque


Pre load Tighten ing

torque


Pre load Tightening

torque

Pitch

3 Bolts and nuts tightening

AFTER HAVING UNPACKED THE EQUIPEMENT, CONTROL THE

SCREWING UP

FOR THE SCREWING UP COUPLES, REFERES TO THE FOLLOWING TABLES


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AIR CONVEYOR - Preliminary operations

Par. Title Page

Preliminary operations

1 Connections and wiring 2

2 Grounding system 2

3 Connection to the main grounding installations 3

3.1 Mass linkage 4

4 Electrical connections 44.1 Documentation 5

5 Pneumatic connections 6

6 Setting up and initial start up 6


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Preliminary operations - AIR CONVEYOR

2 Grounding system

The grounding of the system is the responsibility of the client.

This system has been built according to the precise characteristics specified in the standard EN

60204-1.

This standard dictates that in each user system the protective grounding of all parts of the

system and all of the groundings required for the operation of the circuits and used equipmentmust be carried out by connecting the parts involved to a single ground system.

1 Connections and wiring

The mains of the electrical and pneumatic systems must be calculated to be able to withstand

the machines maximum absorption levels, as shown in the Output and consuption table (Ch.

C - Technical informations).

The electric switchboard is already in conformity with the standards while the feeding line placed

behind the switchboard has to be suitably sized and conformed to the electric switchboard to be

feeded.

THE WHOLE CHAPITER IS EXCLUSIVELY DEDICATED TO THE QUALIFIEDSTAFF


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3 Connection to the main grounding

installations

The figure below demonstrates how to connect the grounding of the System to the main grounding

installation which should already exist in the building in which the system is being installed.

BE SURE THAT THE GROUNDING IS SUITABLE FOR THE WHOLE

INSTALLATION, AND KEEPING WITH THE RULES OF THE SECTOR

Machine component connection point

Component: mains connecting cable

Grounding mains

Coupling the parts of the machine


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3.1 Mass linkage

As already mentioned on the previous pages ,the various connecting points between the blocks

making up the machine must be interconnected (symbol ) so that the electricity can

arrive at the main grounding point (par. Connection to the main grounding installations).

In order to guarantee this electrical conductivity, each contact point to which the stranded wire

connecting jumper or direct contact is mechanically fastened must be thoroughly cleaned of any

kind of deposit (paint, wax, non conductive metal etc.) and dirt (grease, oil and dirt in general).

In brief, at the contact point between the two components of the machine there must be clean

metal alone.

4 Electrical connections

For this operation, follow general installation standards for the preparation and start-up ofelectrical systems.

The electrical connection is made at the control panel of the machine, the position of which will

depend on the overall general layout of the bottling system installation.

CONNECTION FORBIDDEN IF THEN VOLTAGE DOES NOT CORRESPOND

THE THE EQUIPEMENT ONE

FOLGURATION DENGER


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4.1 Documentation

The electrical diagrams, like the manuals of the electrical componentry used in this supply, are

integrating part of this manual.

Our long experience in the field of automatic machines and the numerous suggestions of our

Customers, led us to insert this important documentation directly in the Electrical Switchboard

in order to allow an easier consultation by your technicians.

With this purpose a pocket (below) where you can lodge the documentation has been inserted.

If our supply only concerns air conveyors, after this page you will find a further copy of their

electric diagram, but if the conveyors are coupled with an unscrambler, their electric diagram is

together with the unscramblers one.


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6 Setting up and initial start up

5 Pneumatic connections

With a view to preventing errors and accidents, the pneumatic connections of the machine are

carried out by LANFRANCHI personnel, using the connections already prepared by the client.

BEFORE THE EQUIPEMENT START UP BE SURE THAT:



NO ENTRY WITH METAL OBJECTS

THE BOLTS AND NUTS, AND THE SCREWS WILL BE CORRECTLY

TIGHTENED

FOR THE TIGHTENING COUPLES YOU HAVE TO REFER TO THE TABLE AT

CH. C PAR. BOLTS AND NUTS TIGHTENING

A series of preliminary checks are also run before the machine is started up for the first time with

a view to detecting any damage which the machine might have suffered during transportation,

handling and setting in place.


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AIR CONVEYOR - Component and operation

Par. Title Pag.

Component and operation

1 Convering along the line 2

2 Unloading surface 2

3 Bottles release to the unscrambler 3

4 Brake 4

4.1 Single brake 4

4.2 Double brake 5

5 Intermediate bottles release 6

6 Combiner 7


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Component and operation - AIR CONVEYOR

1 Convering along the line

Once the bottles have been straightened, they are picked up by the unscrambler and conveyed to

the air conveyors which transfer them to the subsequent phases of operation (below).

2 Unloading surface

At the outfeed of the extractor star wheel there is a surface which always acts as a reference

for the bottle base outfeeding height; this is called the unloading surface (below).

Unloading surface


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3 Bottles release to the unscrambler

At the air conveyor infeed there is a special release system that comes into operation when

deformed bottles are picked up or when bottles are picked up incorrectly.

In the Figure below the release system is described in detail.

As can be clearly seen, a defective is removed by the conveyor (det. 1), when the sensor positioned

on the conveyor detects the bad positioning and sends a signal to the PLC which responds by

activating the cylinder, positioned in the upper part of the conveyor (circled below), that in turn

opens the guides thus allowing the bottle to fall (det. 2).

Part. 2

Part. 1


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4 Brake

This component is used to regulate some phases of the bottles transport along the conveyor and

it can be single (Fig. A) and double (Fig. B).

4.1 Single brake

It is installed before the intermediate release (following par.) and through its blades locking (pos.1 below) and opening (pos. 2 below), it allows to the release to open or close according to the

requirements.

It is used also to form the bottles packages (bottles trains) in order to allow their better sliding

along the conveyor line.

Fig. A Fig. B

Pos. 1 Pos. 2


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4.2 Double brake

It is installed before the combiner (par. 6) and through its alternate blades locking (pos. 1 below)

and opening (pos. 2 below), it avoids that the bottles slide towards the devio combiner while it

is moving.

In this way the brake allows also the bottles package formation (bottles train).

The brake movements are the following:

Pos. 1 - if the brake A is closed the bottles stop allowing the brake B locking;

Pos. 2 - if the brake A is opened the bottles move and lean to the brake B closed, in

the meanwhile the bottles package forms (bottles train).

Freno B Freno A

Pos. 1

Pos. 2


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5 Intermediate bottles release

This particular release system (Fig. A) which is started in order to allow to the bottles to fall into

a second storage tank, that is needed to feed a supplementary line, or as provisional storage for

the bottles waiting to come back on the same production line.

In the picture below you can find the system according which the bottles arrive near the release;

if it is colsed, it allows them to go on along the same line, while if it is open (Fig. B) they fall into

the supplementary tank.

This release is always coupled with a brake (previously paragraph).

Fig. A Fig. B


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6 Combiner

This component is installed to distribute, or collect according to the requirements, the bottles

from one or more than one conveying lines.

It is always advanced by a double brake (par. 4) which assures the lack of bottles during its

movement.

Through the movement of a rotating frame (below) the bottles flow is modified according to

the requirements (Pos. 1 and 2 below).

Pos. 1 Pos. 2


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AIR CONVEYOR - Control panel

Control panel

WARNING: THE AIR CONVEYORS SUPPLY OF THIS PROJECT IS COUPLED

TO AN UNSCRAMBLER.

THE AIR CONVEYORS ARE CONTROLLED BY THE UNSCRAMBLER

CONTROL PANEL, SO THE CONTENTS OF APPLICATIONS PAGES AND

OF THE ALARMS IS DISCUSSED IN THE SPECIFIC Ch_F - CONTROLPANEL CHAPTER INSIDE THE UNSCRAMBLER MANUAL.


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Control panel - AIR CONVEYOR


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1

AIR CONVEYOR - Maintenance

Par. Title Pag.

Maintenance

1 Maintenance 2

1.1 Maintenance safety rules 3

2 Air conveyor 4

2.1 Cleaning 4BOTTLE NECK GUIDE 4

AIR FILTER 5

FAN 9

2.2 Combiner 12GREASING 12

Where should the machinery be lubricated? 12

When should the machinery be lubricated? 12

How should the machinery be lubricated ? 13

What is necessary to lubricate ? 13

3 Absolute filter 14

3.1 Three steps filtration check 14MEASURING INSTRUMENT DESCRIPTION 15

Instrument assembling and calibration 16

DEFINITIVE INSTRUMENT INSTALLATION 17

Manometer fixing and levelling: 17

Manometer gauging 18

Tubes connection to the manometer 19

Differential pressure measuring 20

SUMMARY 24

MAINTENANCE 25


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2

Maintenance - AIR CONVEYOR

1 Maintenance

A regular check of all the systems running and an eventual correct maintenance and, if necessary,

an immediate replacement of any damaged element before it breaks, become necessary for the

good functioning of the whole installation.

Respect always the indicated periodicity for the maintenance interventions.

All the operations which require the regulating interventions or the eventual replacement of the

pneumatic conveyors components have to be carried on only by LANFRANCHI qualified staff.

THIS CHAPITER IS EXCLUSIVELY DEDICATED TO THE QUALIFIED STAF

LANFRANCHI COMPANY DOES NOT ANSWER, IN ANY WAY, ABOUT

INADEQUATE USE OF A WRONG MAINTENANCE OF THE EQUIPEMENT.


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1.1 Maintenance safety rules

MANDATORY TO TURN OFF THE ELETTRIC SWITCH BOARD POWER

AND THE LOCKED ELECTRIC SWITCHBOARD

TO INSULATE THE MOTORS WITH THE SAFETY DISCONNCTING

SWITCH (below).

MANDATORY THE GLOVE


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Part. 1

In particularly dirty environments with sugary

residues (syrups), cleaning should be carried out

using a clean cloth dampened with denatured

alcohol at 90.

Rub the cloth repeatedly along the guides (Det.1

Figure alongside) until the film which has

deposited during the systems operating hours

has been completely removed.

On the other hand, for environments with

systems exclus ively pro cessing still or

carbonated water or oils, this operation should

be performed at least once a month.

Regular cleaning in this way will ensure the smooth transiting of the bottle trains along the

entire length of the pneumatic conveyor.

BOTTLE NECK GUIDE

The bottle neck slideways (Det.1 below) must be cleaned (at the contact points) at least every

10 operating hours.

2 Air conveyor

2.1 Cleaning

If the air pressure results suddenly changeable or insufficient, even after the delivery valves

regulation on the collector and the frequency modification on the inverter, it will be necessary

the disassembling and the following accurate cleaning of the impellers and the filters installed

on the blowers.


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A

B

AIR FILTER

If the pneumatic conveyor system is operating in particularly saturated in sugar solutions (syrups

and such like) combined with a very high degree of humidity, deposits of foreign substances

could build up (within a very short period of time) both on the impeller (Det. B below) of the fan

and on the exterior of the (Det. A below) air filter installed on the shell of the blower.

Run a check on all the filters installed on the blowers at least once every 10 hours of operation.

The build-up of these detrimental deposits can hamper the correct functioning of the blower fan

and the resulting drop in pressure necessary for moving the bottle trains through the system.


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Part.1

The disassembling of the air filter does not involve any special operations and is quick and easy

to perform.

At the two ends of the container A of the air filter there are two quick release clips (Det.1

below).

Press down slightly with your index finger to release the two gripping levers of the clips and free

the eyelet B from the retaining hook C (Det. 1 below).

Part. 1

A


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Repeat this operation 2 or 3 times for a few minutes, shaking the filter under the running water

(below).

If this is not sufficient to remove the film which has formed, wash the filter with a steam jet at

100C.

Hold the hot water jet (the temperature of which must be between 40 and 50 C) at a distance

of at least 50 cmfrom the filter so that the pressure of the jet does not irremediably ruin the filter.

A

B

Completely remove the cover D from the shell block (below).

At this stage, the filter E can be easily accessed and removed from its housing for inspection.Wash both sides of the filter under running water.


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Allow the filter to dry at an ambient temperature of approx. 20 25 C (below).

The filter should be completely replaced after a maximum of 4-5 washes.

It needs replacing after repeated washings and dryings due to the fact that the special material

of which it is made starts to lose its filtering properties.


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Part. 1Part. 2

FAN

Before proceeding to wash the blower, separate the Electric motor from it and store it in a dry,

segregated place.

Then re-assemble the parts and connect the terminal board to the blower only when it is perfectly

dry.

The same type of checking and cleaning procedures must also be run periodically on the impeller

of the blower fan.

Check the conditions of the impeller with the same frequency as that applied to the air filters.

In order to avoid irreparable damage to the power supply system of each drive unit installed on

the fans, the wiring from the terminal board to each of the motors requiring disassembling must

be disconnected.

After identifying the terminal board of the motor in question (Det. 1 below), loosen and remove

the fastening screws from the cover (Det. 2 below).


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Part. 1

Part. 2

A

Using the special wrench provided, loosen and completely remove the contact fastening nuts.

Then slide all the eyelets of the contacts out of their seats (Det. 1 below).

Still using the wrench provided, loosen the pressure clamp A (identifiable by its grey colour)

holding the wiring cable in place, so that the latter can be removed from the connector block,

together with the cables and fastening eyelets (Det. 2 below).

In order to avoid damaging the contacts, great caution should be exercised when performing

these operations.


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Part.1

- exercising great caution, remove the

flange and motor from the fastening stud bolts;

- rest the motor on a bench, making it as

stable as possible and, using a suitable socket

wrench(Det. 1 alongside), completely remove

the screw from the electric motor output head

and remove the impeller from the pin.

Proceed to clean the impeller using the same

method as that used for cleaning the air filters

(this operation is described in par. Air filter).

Once the check has been run and the fan cleaned, wherever necessary, reassemble the parts on

the body of the blower, by following the above steps in reverse order.

Part. 1

Once the electric power cables have been disconnected, isolate the latter so as to avoid placing

them next to heat sources or in damp areas (keeping them off the ground).

Now the electric motor can be disassembled,

following the procedures described below:

- us ing a sui table wrench, loosen the

fastening nuts of the larger outer flange (Det. 1

alongside).

When this operation is being carried out, it mightbe necessary to support the electric motor

manually in order to prevent it from

unexpectedly sliding out of its stud bolts (these

always remain attached to the shell of the fan);


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2.2 Combiner

GREASING

This operation has to be carried out when the machine is locked.

Where should the machinery be lubricated?

The Combiner section point which requires a periodic lubrication is the gear that allows the

Combiner rotation (below).

When should the machinery be lubricated?

For a continuous and correct functioning the graesing operations have to be carried out at

regular time intervals, indicated in working hours.

Greasing frequence: 24 h.

Regular, periodical greasing of these parts so crucial to the Combiner unit will guarantee machineefficiency and extended production life.


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How should the machinery be lubricated ?

Attraverso lutilizzo di un pennello distribuire il grasso nel punto di incastro tra ingranaggio ecremagliera in modo che al ripristino del ciclo di produzione il movimento del devio - riunitore

distribuisca ulteriormente il grasso su tutto il meccanismo.

What is necessary to lubricate ?

For a better production we advise to use some SYNTHETIC greases with a termic large interval

of use.

Hereby you will find the two recommended sinthetical greases:

- ESSO Unirex S2;

- Mobil Mobiltemp SHC


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3 Absolute filter

3.1 Three steps filtration check

As three steps filtration we mean the series connection of three filters:

a) Cloth STD.

b) Pre-filter with efficiency 85% D.O.P. (Inserted in the first Canister INOX)

c) Absolute filter with efficiency 99.99% D.O.P. (Inserted in the second Canister INOX)

a b c

WARNING! THE DEEPING OF THIS PARAGRAPH HAS TO BE CARRIED OUT

ONLY IF ON THE SUPPLY SOME ABSOLUTE FILTERS HAVE BEENINSTALLED


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MEASURING INSTRUMENT DESCRIPTION

These values are surveyed through a particular manometer described in the picture below:

This particular kind of manometer is composed by:

1

2

3 4

1) A FIL cap for the input or filling up of Red Gauge Oil ; (inserted in the packing);

2) A graduated scale from - 0.1 to + 8.0 ;

3) A ZERO SET knob fot the calibration to the Environmental Atmospheric Pressure (1013

mb);

4) A level to permit the correct collocation of the instrument on the Canister group you have

to check.

The packing box is equipped with the following accessories:

1) a sealed packing of RED GAUGE OIL, complete with the special injection neck;

2) two 1/8 rubber tube hoses, supplied with the related fixing bolts and washers, that have

to be fixed on the Canister group (for this kind of operation, at least three 1/8 rubber tube

hoses are necessary);

3) a double tube (separable) in rubber with a length of 2,5 mt.


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Instrument assembling and calibration

The diagnostic manometer on the Air filters efficiency can be installed directly on every Canistergroup. You have to check that it is used as portable instrument to apply temporarly on the single

Canister group to be diagnosed.

WE ADVISE ALWAYS THE INSTRUMENT DEFINITIVE FIXING ON THE

CANNISTER GROUP TO BE DIAGNOSED

In order to prepare the instrument, after the packing opening, carry on as follows:

- in the upper part of the Manometer there is a FILL cap; unscrew it and keep it out from

the manometer body;

- screw, after having kept off the provisional closing cap, on the RED GAUGE OIL bottle

the special injection neck and pour the whole contents inside the hole.

Once closed the cap we can go on with the instrument calibration in order to carry on the air

filters check inserted in the Canister groups.


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DEFINITIVE INSTRUMENT INSTALLATION

This operation can be carried on both during the production and when the installation is off

Manometer fixing and levelling:

For the instrument, we advise to get a fixing support on the structure of every Canister Group

on which you want to install the instrument.

The picture below shows how to carry on the instrument fixing:

A

- if you decide to use the portable instrument, we advise to buy the special optional A-612

shown in the manual supplied with the packing.

- before fixing definitly the instrument to the support, in order to obtain a more precise

reading, it is necessary to put it horizontal.

To obtain this aim, it is necessary to use the special bubble integrated with the instrument and

indicated by the arrow in the picture on side.


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Manometer gauging

TO CANNISTER UNIT

TO MANOMETER

GAUGE

Fig. A Fig. B

BOTH YOU USE AN UNIC PORTABLE MANOMETRE FOR THE CONTROL

OF SEVERAL CANISTER GROUPS, AND SEVERAL MANOMENTERS HAVE

BEEN FIXED ON THE INSTALLATION, THE GAUGING OF THE

INSTRUMENTS HAS TO BE CARRIED ON BEFORE EVERING MEASURING

It is necessary to withdraw the double rubber tube, contained in the packing, and separate it in

two single tubes as required for the application (below).

One of the two tubes is marked, in all its length, by a RED line.

The function of this line is to allow the necessary distinction to the correct instrument connection

to the Canister Group.

Through the ZERO SET marked knob (Fig. A) regulate the manometer indicator on 0 (Fig.

B).


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Tubes connection to the manometer

Insert the two tubes extremities into the two rubber tube hoses, obtained in the upper part of theinstrument.

In the bulb on the right side of the instrument you can read the indication LOW (Low Pressure)

while on the left you can read HIGH (High Pressure).

HIGH

LOW

a b c

In the picture below you have the scheme of a Canister Group installed on an air conveyor.

The arrow indicates the air flow directional way.


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Differential pressure measuring

In order to measure the Differential Pressure DP on the Prefilter b it is necessary to operateas follows:

- insert the free extremity of the tube correspondent to the High Pressure (HIGH) in the tube

rubber hose recalled by the particular 1 below.

- insert the free extremity of the tube correspondent to the Low Pressure (LOW) in the tube

rubber hose recalled by the particular 1 below.

a b c

Part. 1

a b c

Part. 1


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In order to measure the Differential pressure DP on the absolute filter c operate as follows:

Lettin unchanged the disposition of the other two extremities already inserted into the readingmanometer, insert the free extremity of the tube correspondent to the high pressure (HIGH) in

the rubber tube hose shown in the part. 1 below.

The extremity of the rubber tube, previously unthreated fron the rubber tube hose shown in the

part. 1 behind, has to be inserted in the rubber tube hole shown in the part. 1 below.

a b c

Part. 1

a b c

Part. 1


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The following reading and interpretation of the values pointed out by the manometer has to

be expounded in this way:

1) When the filter is clean the differential pressure DP will have to be:

Prefilter : D P = 13 mm H2O

Absolute Filter : D Pmax

= 25 mm H2

O


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2) Maximum DP acceptable conditions on the single filters (besides these limits it is

necessary the cleaning/replacement of the air filters):

Prefilter : DPmax

= 30 mm H2

O

Absolute Filtero : DPmax

= 60 mm H2O

All the pointed out values have to be expounded considering the following points:

1) The DP values measured with the differential manometer are not influenced neither

by the fan capacity, nor by the upstream and downstream single filters conditions.

2) The total DP measuring (between the fan delivery point and the chambe input) is not

significant as far as the single filters condition evaluation is concerned.


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SUMMARY

1) As three steps filtration we mean the series connection of three filters:

a) Cloth STD.

b) Pre-filter with efficiency 85% D.O.P. (Inserted in the first Canister INOX)

c) Absolute filter with efficiency 99.99% D.O.P. (Inserted in the second Canister INOX)

2) Maximum DP acceptable conditions on the single filters (besides these limits it is

necessary the cleaning/replacement of the air filters)

Lack of differential pressure D P max. acceptable , on all filters in clean conditions:

a) Prefilter : DP = 13 mm H2

O

b) Absolute filter : DP = 25 mm H2

O

3) Lack of differential pressure DP max. acceptable , on all filters in dirty conditions:

a) Prefilter : DP max = 30 mm H2O

b) Absolute filter : DPmax

= 60 mm H2O

4) The values D P ,given by the differential manometer,are not inflluenced neither from

the fan size nor from the up and down stream conditions of singular filters, since , in the first

case it is about static pressure values, and in the second case about absolute values..

5) The total D P measure ( between fan mouth and room entrance) it is not relevant as far

as the condition of each filter is concernedi.

6) Minimum approximative pressure values P referred to to the atmospheric pressure and

necessary to guarantee the line feed of containers :

a) Near the unscrambler , with stop, bent or gradient conditions:

D P = 120 130 mm H2

O

b) Along the flat conveyor, with containers moving regularly:

D P = 70 80 mm H2

O


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MAINTENANCE

FILTROTECNICA ITALIANA S.r.l. modular units have been installed on this supply.

Please find below to proceedings to reach the filters:

- unscrew the fastening hand grip on the side of the hollow, where there is the filter (below);

Fig. BFig. A

Fig. A Fig. B Fig. C

- unclamp (Fig. A) and disassemble (Fig. B) the door from its place in order to reach the

filter;

- unclamp first the superior (Fig. A below) and inferior ones (Fig. B below) and extract the

filter from its place (Fig. C below).

To guarantee better performance during the production cycle and to simplify maintenance

procedures, the Maintenance Manual has been attached, with the manufacturers permission,

for your reference


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1

AIR CONVEYOR - Pneumatic

Par. Title Pag.

Pneumatic

1 Maintenance safety rules 2

2 Bosch 3

2.1 Adjusting 4AIR WORKING PRESSURE 4

2.2 Maintenance 5FILTER CONDENSATION DRAINAGE 5

REPLACING THE AIR FILTER 6

2.3 Pneumatic diagrams 8BOTTLE RELEASE TO THE UNSCRAMBLER 8

INTERMEDIATE BOTTLE RELEASE 9

BRAKE 10

COMBINER 11

PNEUMATIC SIDE GUIDES 12

3 Festo 13

3.1 Adjusting 14AIR WORKING PRESSURE 14

AIR EXIT PRESSURE 15

3.2 Inspection of the presence of air in the circuit 16

3.3 Maintenance 18FILTER CONDENSATION DRAINAGE 18

REPLACING THE AIR FILTER 19

3.4 Pneumatic diagrams 21BOTTLE RELEASE TO THE UNSCRAMBLER 21

INTERMEDIATE BOTTLE RELEASE 22

BRAKE 23

COMBINER 24

PNEUMATIC SIDE GUIDES 25


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Pneumatic - AIR CONVEYOR

THE WHOLE CHAPITER IS EXCLUSIVELY DEDICATED TO THE QUALIFIEDSTAFF

IN THIS CHAPTER WE DEAL WITH ALL THE PNEUMATIC SYSTEM (BOSCH

or FESTO) WHICH CAN BE INSTALLED ON THE SUPPLY

BEFORE READING THIS CHAPTER, THE OPERATOR HAS TO VERIFY WHICH

KIND OF SYSTEM IS ACTUALLY INSTALLED ON THE SUPPLY

AIR DELIVERY

1 Maintenance safety rules

MADATORY TO CLOSE THE AIR DELIVERY UPSTREAM THE EQUIPEMENT

BEFORE EFFECTUATING ANY KIND OF INTERVENTATION (below)

Always observe the intervals of frequency laid down for the performing of maintenance operations:

CHECK

EVERY 600 HOURS OF OPERATION

AIR DELIVERY

FESTO BOSCH


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SINGLE EXIT MORE THAN AN EXIT

2 Bosch

To run this check, access must be gained to the Filter-Reducer unit.

This is located on the outer side of the base that supports the unscrambler unit (below).


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Part. 1

A

B

2.2 Maintenance

FILTER CONDENSATION DRAINAGE

Although the pneumatic system has been designed to operate with dry air, some residual humidity

may build up as it passes through the filter.

This humidity tends to condense and deposit on the bottom of the lower casing "A" (below)

enclosing the filter.

When the water deposits due to the condensation build up, this can jeopardize the performance

of the air filtering system, so that it becomes necessary to drain the water deposited at thebottom of the transparent casing.

To do so, access the black cap "B" (below) underneath the casing (det.1 below) and unscrew it

in order to drain off the water.

Only reclose the cap after all the liquid deposited has been thoroughly drained out of the casing.


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Part. 1

A

B

REPLACING THE AIR FILTER

In the lower part of the Filter-Reducer Unit, located underneath the central block of the gauge,

there is a component A which is cylindrically shapedand made of plastic material (det. 1

below):

- unscrew the knob manually by turning it in a clockwise direction (det. 1 below);

- separate it completely from the main unit "B".

The gold-coloured filter is easily identifiable (arrow below).


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AFTER THE MAINTENANCE INTEVENTATION, BE SURE THAT:

ANY KIND OF METAL OBJECTS DONT REMAIN ON THE MACHINE



Still working manually, unscrew the ring nut "C" underneath the filter (below), remove it from

its seat and replace it with a new one.

Now, screw down the ring nut "C" so as to tighten the new filter in its seat and screw the

cylindrical section "A" back into the place on the unit "B" (below).

The replacement filter may be requested from the LANFRANCHI S.r.l. Client Technical Assistance

Service either by phone or fax.

The manufacturer will not be held liable to replace parts under warranty that have been damaged

through improper handling.


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2.3 Pneumatic diagrams

BOTTLE RELEASE TO THE UNSCRAMBLER

Pos. Subject

1 Support base

2 Coil

3 Connector

4 Limit switch

5 Gauge

6 Pressure reducer

7 Solenoid valve

8 Cylinder

2

1

3

8

5

7

6

4

Feeding

UNSCRAMBLER

Filter Reducer Unit


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INTERMEDIATE BOTTLE RELEASE

2

1

3

45

Feeding

UNSCRAMBLER

Filter Reducer Unit

Feeding

COMBINER

Filter Reducer Unit

Feeding

EXISTENT EXTERNAL

NET

Feeding

PNEUMATIC SIDE

GUIDES

Filter Reducer Unit

Pos. Subject

1 Support base

2 Coil

3 Connector

4 Solenoid valve

5 Cylinder


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COMBINER

Pos. Subject

1 Support base

2 Coil

3 Connector

4 Gauge

5 Pressure reducer

6 Tank

7 Valve (coupled with the solenoid valve 5/2)

8 Solenoid valve 5/2

8a Solenoid valve 5/3

9 Flow regulator

10 Cylinder

Feeding

EXISTENT EXTERNAL

NET

8a

9 10

56

87

4

21 3


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PNEUMATIC SIDE GUIDES

Pos. Subject

1 Support base

2 Coil

3 Connector

4 Solenoid valve

5 Cylinder

Feeding

UNSCRAMBLER

Filter Reducer Unit

Feeding

EXISTENT EXTERNAL

NET 32

1

4

55


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SINGLE EXIT MORE THAN AN EXIT

3 Festo

To run this check, access must be gained to the Filter-Reducer unit.

This is located on the outer side of the base that supports the unscrambler unit (below).


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15


M

part. 1

A

AIR EXIT PRESSURE

The air exit pressure can be adjusted with a very simple operation (below)

On the electro-valve you can find a screw for the regulation (det. 1 below).

Adjust the exit pressure following your requirements, using a screw driver (Fig. A).

Turning the screw towards left the exit pressure increases, turning it towards right the pressure

reduces (Fig. A); carry out this operation checking always the value directly on the special

manometer "M" (Fig. A).


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part. 1

3.2 Inspection of the presence

of air in the circuit

An important operation for the good working of the pneumatic circuit is the inspection of the

presence of air in the machine circuit.

You can carry out this working with a very simple operation (below).

On the electro-valve you can find a pushbutton for the manual working of the presence of air in

the circuit (det. 1 below).


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part. 1

POS1

POS0

POS0 POS0

part. 2

part. 3

Unclamp the pushbutton (det. 1 below), turning it from "POS. 0" to "POS. 1" (det. 2 below) and

press (det. 3 below).

Once carried out the working turn the pushbutton to "POS. 0"


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18


A

part. 1

part. 2

3.3 Maintenance

FILTER CONDENSATION DRAINAGE

Although the pneumatic system has been designed to operate with dry air, some residual humidity

may build up as it passes through the filter.

This humidity tends to condense and deposit on the bottom of the lower casing "A" enclosing

the filter.

When this condensation reaches a certain level a tap drains off the excess liquid, conveying it to

the exterior of the cup shaped casing (det. 1 below).

We recommend, nonetheless, that you connect a flexible rubber hose to the trap outlet, so as to

convey the condensation to a drain (det. 2 below).


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19


part. 1

1

REPLACING THE AIR FILTER

In the lower part of the Filter-Reducer Unit, located underneath the central block of the gauge,

there is a component A which is cylindrically shapedand made of plastic material (det. 1

below):

- unscrew the knob manually by turning it in a clockwise direction (det. 1 below);

- separate it completely from the main unit "B".

The gold-coloured filter is easily identifiable (arrow 1 below).


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20


Still working manually, unscrew the ring nut "C" underneath the filter (below), remove it from

its seat and replace it with a new one.

Now, screw down the ring nut "C" so as to tighten the new filter in its seat and screw the

cylindrical section "A" back into the place on the unit "B" (below).

The replacement filter may be requested from the LANFRANCHI S.r.l. Client Technical Assistance

Service either by phone or fax.

The manufacturer will not be held liable to replace parts under warranty that have been damagedthrough improper handling.

AFTER THE MAINTENANCE INTEVENTATION, BE SURE THAT:

ANY KIND OF METAL OBJECTS DONT REMAIN ON THE MACHINE




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21


3.4 Pneumatic diagrams

BOTTLE RELEASE TO THE UNSCRAMBLER

Pos. Subject

1 Support base

2 Coil

3 Connector

4 Limit switch

5 Gauge

6 Pressure reducer

7 Solenoid valve

8 Cylinder

2

1

3

8

5

7

6

4

Feeding

UNSCRAMBLER

Filter Reducer Unit


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INTERMEDIATE BOTTLE RELEASE

Pos. Subject

1 Support base

2 Coil

3 Connector

4 Solenoid valve

5 Cylinder

2

1

3

45

Feeding

UNSCRAMBLER

Filter Reducer Unit

Feeding

COMBINER

Filter Reducer Unit

Feeding

EXISTENT EXTERNAL

NET

Feeding

PNEUMATIC SIDE

GUIDES

Filter Reducer Unit


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23


BRAKE

Pos. Subject

1 Support base

2 Coil

3 Connector

4 Solenoid valve

5 Cylinder

2

1

3

45

Feeding

UNSCRAMBLER

Filter Reducer Unit

Feeding

COMBINER

Filter Reducer Unit

Feeding

EXISTENT EXTERNAL

NET

Feeding

PNEUMATIC SIDE

GUIDES

Filter Reducer Unit


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AIR CONVEYOR - Size change

Par. Title Pag.

Size change

1 Size change 2


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Size change - AIR CONVEYOR

1 Size change

In addition to the size change operations involving the unscrambler equipment described in Ch.

Size change, another important adjustment must be made to facilitate the smooth passage of

the bottles along the bottling line , i.e. the adjusting of the air conveyor side guides.

This adjustment takes place:

- MANUALLY as described to the Ch. Trasportation and installation, in par. Side guides;

- AUTOMATICALLY when the air conveyors are equipped with pneumatically regulated

guides , i.e. guides regulated by means of air pistons that vary the distance of the guides each

time that the bottle size to be processed is changed from the keypad of the main control panel.

Automatic regulating operations must always be carried out when the machine and the conveyors

are not in operation.


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AIR CONVEYOR - Spare parts

Tab. Title Pag.

Spare parts

SPARE PARTS DEMAND 3

SPARE PARTS REQUEST FROM 4

Tab.1 Bottle release to the unscrambler 5

Tab. 1.1 Pressure reducer 7

Tab. 1.2 Solenoid valve 8

Tab. 1.3 Flow regulator 9Tab. 2 Intermediate bottles release 10

Tab. 2.1 Pressure reducer 11

Tab. 2.2 Solenoid valve 12

Tab. 2.3 Flow regulator 13

Tab. 3 Feet 14

Tab. 4 Side guide 15

Tab. 4.1 Fixed/Manually adjustable 15

Tab. 4.2 Pneumatic side guide 17 TAB. 4.2.1 COMMAND SIDE GUIDE 17

TAB. 4.2.2 SIDE GUIDE 18

Tab. 4.2.2.1 Semi pneumatic 18

Tab. 4.2.2.2 Pneumatic side guide 20

Tab. 5 Combiner 22

Tab. 5.1 Asymmetrical 22

Tab. 5.2 Symmetric 24

Tab. 6 Bilanciatore 25

Tab. 7 Brake 27

Tab. 8 Blower 28

Tab. 9 Blower with absolute filter 30

Tab. 9.1 Double cannister 30

Tab. 9.2 Single cannister 32TAB. 9.2.1 WITH FEET 32

TAB. 9.2.2 WITHOUT FEET 34


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Spare parts - AIR CONVEYOR


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AIR CONVEYOR - Spare parts

SPARE PARTS DEMAND

We remember to our Customers that for a better service from our After Sales Department, as far

as the spare parts supply is concerned, it is necessary to draw up the whole table in the following

page and send a copy to our offices only per fax to the following number:

Fax (0039 - 0521) 802.149

In order to allow an easier spare parts research, you can attach a copy of the pages where the

required parts tables are described

THE NON-DRAWING-UP OF THE TABLE OR OF ONE OF ITS PARTS WILL

INVALIDATE THE REQUEST


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Spare parts - AIR CONVEYOR

N Code SUBJECT Pc.

1___________________________________________________________________________

2___________________________________________________________________________

3___________________________________________________________________________

4___________________________________________________________________________

5___________________________________________________________________________

6__________________________________________________________________________

7___________________________________________________________________________

8___________________________________________________________________________

9___________________________________________________________________________

10___________________________________________________________________________

11___________________________________________________________________________

12___________________________________________________________________________

13_____

air conveyor manual

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