alpha700 manual

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ALPHA 700

Particle classifier


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Contents

ALPHA 700

Contents

Safety warnings .........................................................1Icons used and danger warnings ...................................................... 1

Suitable use of the particle classifier ................................................. 2General safety warnings ................................................................. 2Safety in handling and storage ......................................................... 3Technical specifications of the classifier ............................................ 4Description of the particle classifier .........................6Operating principle of the particle classifier ....................................... 9Vibrations ..................................................................................... 11Classifier options ........................................................................... 13Classifiers with cooling system ........................................................ 14Transport and assembly .............................................16Transport ...................................................................................... 16Work prior to assembly ................................................................... 18

Tools necessary for assembly, disassembly and maintenance .............. 18Assembly ...................................................................................... 19Work after assembly ...................................................................... 22Start-up ......................................................................23Commissioning .............................................................................. 23Ignition period ............................................................................... 23Operation ...................................................................25Commissioning a plant .................................................................... 25Settings during operation ................................................................ 26Maintenance ..............................................................27Standard maintenance .................................................................... 27Special maintenance (for ceramic particle classifiers only) ................... 29

Removing the rotor ........................................................................ 30Assembling the rotor ...................................................................... 33Tightening the trapezoidal belts ....................................................... 33Spare parts lists ............................................................................. 34Lubrication .................................................................................... 36Fault search ...............................................................37Appendices ................................................................38Electrical appendix ......................................................................... 38

Contact details

Contact persons : Sergio Alegre and Javier PeaManufacturer / Technical Service : ECUTEC Barcelona SLAddress: Gran Va de les Corts Catalanes 701, 3er 1 APostcode: 08013 Barcelona SPAINTel. (+34) 932 477 700

rev.02.2011


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Safety warnings

ALPHA 700

1. Safety warnings

1.1 Icons used and danger warnings

The terms DANGER, ATTENTION, CAUTION and WARNING indicate specificdangers or special information that requires particular attention. The termNOTE refers to information that does not involve danger to persons.

Stickers: Electric risk, mechanical risk, earth

DANGER

Indicates danger of death and personal injury if the necessaryprecautions are not taken.

ATTENTION

Indicates that severe personal injury can occur if the necessaryprecautions are not taken.

CAUTIONIndicates that minor personal injury can occur if the necessaryprecautions are not taken.

WARNING

Indicates that exclusively material damage can occur if the necessaryprecautions are not taken.

NOTE

Notes contain relevant technical information that may not be obvious toa specialist technician. Follow the points indicated exactly to avoid

damage to the machine.

ELECTRICAL RISK

The electrical risk sticker is used to indicate zones and / or elements ofthe machine which present a risk of electrical shock.

MECHANICAL RISK

The mechanical risk sticker is used to indicate zones and/or elements ofthe machine that present risk of physical injury, such as being trapped,hit or cut.

EARTH

The earth sticker is used to indicate a valid and effective earth at onepoint in the machinery.


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Safety warnings

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1.2 Suitable use of the particle classifier

The objective of particle classifier ALPHA 700 is the classification ofpulverised products for the mining, chemistry or pharmaceutical industrieswhere these materials are used, for example, to produce paints or plastics.The classifier can be used to classify fine materials in a range between 7 mand 40 m.The raw material may be either minerals, pigments, foodstuffs or groundchemical materials with a particle size smaller than 2 mm.To guarantee optimum classification, the starting material must be dry witha degree of moisture lower than 0.5%. If the moisture level is higher than0.5% you must set up a device for drying the starting material.During assembly, disassembly, commissioning, operation andmaintenance, the particle classifier must only be handled by qualified staff 1.

1.3 General safety warnings

Changes of any kind to any of the machine's parts are not permitted andmay be grounds for the termination of the machine's warranty.Adherence to occupational health and safety guidelines is especiallyimportant for low and medium voltage systems.The assembly, operation and maintenance, the mechanical and electricalinstallations, the transport, construction and commissioning must beperformed or supervised by qualified staff 1 with the adequate specialistknowledge.

The particle classifier must be only be started up and operated if it has beenthoroughly checked mechanically and if all the doors and inspection holesare closed.Staff should check that the size of the particles in the ground raw material doesnot exceed 2 mm and that its degree of humidity is no greater than 0.5%.

The staff must use personal protection equipment such as hard hats, gloves,ear protection, etc.It is important to avoid operations that jeopardise the health of staff or thesafety of the particle classifier.

1. Qualified staff are those who, based on their training, experience and knowledge of the applicable norms, standards,safety rules and operating conditions, have been authorised by the plant safety officer to do the required work. They mustbe capable of recognising and avoiding potential injury and damage.

ATTENTION

Machine in operation. Unforeseeable damage in the event of anemergency.It is recommended that emergency stops are installed in the necessaryplaces, in order to stop the machine in the event of an emergency.

ATTENTION

Working at a height. Falls and blows.The user must take into account the risks of working at a height withrelation to the assembly, use and maintenance of equipment.


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Unauthorised alterations and the reproduction of the particle classifier areprohibited.The instruction manual must always be kept in an easily accessible place forfuture consultation.

The plant safety officer must guarantee that the staff can use this documentregularly.

1.4 Safety in handling and storage

The products supplied are indicated in the packing list. Immediately onreceiving the elements, check that all the products have been delivered.When you manipulate the ECUTEC products, ensure that the lifting andtransport equipment can withstand the loads.

There are different ways of packaging, depending on the dimensions of theclassifier and the method of transport.The symbols marked on the packaging indicate how to proceed. They havethe following meanings:

The classifier must be stored in a dry place, with no vibrations.The different parts cannot be stored one on top of another.If the machinery must be stored outdoors, it must be carefully covered andprotected from moisture.Unless otherwise stated in the contract, the unit must not be exposed to extremeenvironmental factors such as chemical products, high pollution, moisture ortemperatures greater than 0C/ 32 F or 20C/ 68 F.Do not use the eyebolts (DIN 580) of the motor to manipulate the machine.

NOTE

The classifier is delivered pre-assembled and with grease in thebearings.

This wayup

Fragile Keepdry

Keepcool

Centre of gravity

Use nohand hook

Attachhere


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1.5 Technical specifications of the classifier

Serial number 0173

Customer Name Moengo MineralsAddress Paramaribo/SurinamProject 09.008Type of machine ALPHA 700

Design/operation data

Length 2257 mmWidth 1786 mmHeight 4200 mm

Machine weight 3300 kgRotor weight 730 kgRotor speed (maximumworking speed) 1200 rpm

Motor pulley (diameter) 315 mmMachine pulley (diameter) 355 mmRelationship 0.88Transmission belt length 3550 mmUpper bearing type SKF 23024 CC W33 C3Lower bearing type SKF 23024 CC W 33 C3Grease type Klueber ISOFLEX NBU 15

Electric motor data

Rated power 37 kWSpeed (maximum working) 1360 rpmVoltage 4 40 VFrequency (max im. working) 4 6 H zProtection type IP55 FSize 225S IMB3

Protection againstexplosion No

Thermal resistance 1PTCSupplementary coolingsystem Yes

Motor weight 300 kgManufacturer/Type HELMKE DOR 225S-4S-1G-031


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Special design

Ceramic rotor NoCeramic material NoCeramic Linning Al2O3Polyurethane coating NoRust-proof NoHardening process NoMonitoring system No

Process data

Air flo 26.35 0 m3/hFeed rate 7 .2 T/h

Installation

Grip points 4

F. STA. (N) F. DYN: (N)HORZ. VERT.

F1 8250 1250 625F2 8250 1250 625F3 8250 1250 625F4 8250 1250 625

Analogue signals

Speed sensor 10 - 30 V PNPSafety system 48 - 240 V AC/DC

Digital outputs

Sensor PT100 4 - 20 mA 3 wiresMachine vibration sensor NoBearing condition sensor No


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Description of the particle classifier

ALPHA 700

2. Description of the particle classifier

The ALPHA 700 has been designed for the classification of pulverisedproducts and thus can obtain granulometric distribution suitable for the

various markets to which you can direct the final product.The range of products to classify is very broad, such as minerals, pigmentsand foodstuffs.The classifier is comprised of 3 bodies.A first body containing the classifier rotor.

Fig. 1 First body of classifier

A second body with the fines output.

Fig. 2 Second body of classifier A third body with the input of material and output of coarse material.

1 Motor 2 Bearings support

1 Fines output


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Fig. 3 Third body of classifier

The first body contains the support for the bearings, which are only on oneside of the rotor, the upper part of the classifier.The shaft is made of high-quality steel and welded to the rotor, generatinga rigid unit. The shaft rests on a pair of ball bearings that have beendesigned to work uninterrupted for 10,000 hours.

Fig. 4 Special join between axis and rotor

The casing of the bearings has been designed with connections for the periodicgreasing. In addition to containing radial seals that do not let contaminationinto the bearings and, moreover, form a barrier to keep the grease in contactwith the bearings.To seal between the rotor and the stator correctly, an air seal plus a labyrinth ringhave been designed, which impede coarse material getting into the rotor.The power transmission system is performed by the upper part of themachine and by means of trapezoidal belts.All the machines are delivered with temperature probes to control thetemperature of the bearings.

1 Coarse material output 2 Feed

3 Level sensor connection

NOTE

In some special designs, the connection between the shaft and rotor canbe made using a hexagonal bolt.

1 Hexagonal bolt DIN912 M8x20 2 Lock washer


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In addition, the machine may also be supplied with probes for vibrationsand the condition of the bearings.There are different versions of the machine according to the requirements,some examples are:

Ceramic rotor Polyamide rotor Ceramic-coated casing Polyurethane-coated casing Stainless steel System for monitoring the machine's bearings and vibrations

The particle classifier may be supplied as part of the whole plant assemblyor as a single unit.Example of the assembly of a classifier in a plant.

Fig. 5 Example of a plant

1

2

3

4

6

7

8

9

1 Flow regulation valve 2 Feed silo

3 Rotary valve for feed 4 Particle classifier

5 Rotary valve for coarse material output 6 Filter

7 Rotary valve for fines output 8 Butterfly valve

9 Suction fan


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If the particle classifier has been delivered as a single part, the fines outputvalve and the components that make up the plant are not supplied.

2.1 Operating principle of the particle classifier

For optimum classification, the starting material must be ground and drywith a maximum degree of moisture of 0.5%.

Fig. 6 Operating principle

WARNING

Internal damage. Machine breakage.Do not allow a particle size greater than 2 mm.

NOTE

The staff must check the size of the particles before operation. If the moisture content is higher than 0.5% you must set up a device

for drying the starting material.

1

2

3

4

1 Starting material input 2 Separation area

3 Fine material output 4 Coarse material output


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The machine can be fed in two ways, mixed with the suction air or throughthe upper part of the machine.The feed type configuration depends on the quantity to feed and the productto classify (see figure 6).

If it enters through the upper part, the product falls towards the machine due togravity. In the two types of feed it is absolutely necessary to use a rotary valveto be able to regulate the dosage and generate the correct sealing withoutinterference from outside.The Alpha classifier is connected to a fan that causes a suction flow thatpasses through the rotor. Inside the machine, the product is displacedtowards the rotor due to the suction current.Once the product reaches the height of the rotor, it is displaced at high speed ina cyclonic movement and thus the coarser particles are expelled by a filterlocated at the end of the circuit.The coarse product is collected by the lower casing and is expelled from the

machine by a rotary valve.The general rules to be able to configure the machine are the following: At higher speeds, the cut point is closer and, consequently, you will

achieve a finer product but in less quantity. With a greater air flow, the cut point is not as close and, as such, you will

obtain a coarser product and the production quantity will increase. With a greater feed, the cut point is not as close and, as such, you will

obtain a coarser product and the production quantity will increase.The minimum components to be able to produce with this type ofmachinery are the following:

Rotary valve for feed with a well-sealed circuit and a good dosage. Rotary valve for coarse material output with a well-sealed circuit. Suction fan. Bag filter


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Fig. 7 Segundo cuerpo del clasificador

2.2 Vibrations

Knowledge of vibrations is one of the best methods for determining thecondition of a machine. For this reason it is recommended to use an

ongoing monitoring system. In some machines such as those with theceramic rotor, this element is absolutely necessary. In these cases, due tothe safety of the machinery and the staff, it must not be operated withoutanalysing the vibrations.

1 Upper part feed 2 Lower part feed

WARNING

Internal damage. Machine breakage.The system must be connected to the electric panel so it can cut the powersupply when the alarm values are exceeded.

NOTE

To avoid minimum signal loss, you should not use cables of more than

3 metres long, from the module to the measurement point.


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Fig. 8 Vibration sensor

When you start up the machine for the first time (see section 4) you mustcheck the vibrations to identify the tensions, resonances and faults ofassembly before any major problem occurs.The normal vibration value must be set. The best way to calculate this valuefrom the bearings is in the horizontal direction.

1 Machine vibrations probe 2 Bearings condition probe

NOTE

The vibrations measured out of the frequency range 3 to 1000 Hz mustnot be considered vibrations coming from the machine.

Intensity (mm/s) Condition

11These working conditions must be avoided at alltimes, given that parts of the machine may sufferirreversible damage in minutes, hours or days.

WARNING

Internal damage. Machine breakage.Vibration intensity must not exceed 11 mm/s. Should it do so, shut downthe machine and contact the manufacturer.

NOTE

The testing of the machine must be more thorough if the vibrationintensity in the bearings exceeds 4.5 mm/s.


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A very large increase in vibrations in a very short period may mean it isoff-balance, so we recommend you analyse the condition of the rotor and,if possible, rebalance.

2.3 Classifier options

Rotor and ceramic coatings

Some materials must be processed with ceramic parts due to their highabrasiveness. For these cases, ECUTEC supplies the machines with ceramiccomponents that require more rigorous care than the steel components. Ceramic is brittle so it should never be hit. During the rotor assembly process, you must take extreme care that the

rotor does not come into contact with the other parts. Sharp changes in temperature are not recommendable for the ceramic

parts. The maintenance and revisions must be increased with respect to the

steel parts (see the maintenance list in point 6.3). Vibrations must also be strictly monitored. Please contact ECUTEC staff

regarding any queries you may have.

Due to the abrasive power of these products, the machine must bebalanced more frequently.

In addition, we recommend you have a replacement ceramic rotor due toits fragility, so the interruption of the production process is kept to aminimum.

All the surface coated with ceramic must be checked and repaired withEpoxy cement.

Polyurethane parts

These are used for abrasive materials with low abrasiveness. Thetreatments are the following: Do not clean or use solvents. Do not allow high temperatures.

Motor

In some applications, as they work at a low rpm, it is necessary to connect asupplementary fan to cool the motor. You must take into consideration: This must be switched on at the same time as the motor. The machine may never function if this fan is off. It must remain free of dust and dirt.

WARNING

Internal damage. Machine breakage.Never exceed the maximum rotor speed.


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2.4 Classifiers with cooling system

Introduction

Depending on the product to be treated and the working and environmentalconditions, certain classifiers may be supplied with an air-oil cooling systemfor the bearing casing. The cooling circuit system will be comprised of a 100-litre oil tank, a suction pump, an air cooler and the flexible hoses needed forthe connection to the various elements. All the screwed connections will use1" BSP screws.

Fig. 9 Cooling system

1

2

3

4

5

1 Oil discharge from the bearingcasing

2 Oil injection into the bearingcasing

3 Oil collector 4 Air cooler pump

5 Oil collector/pump suction discharge


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Operation of the cooling system

There are different ways to operate the cooling system, depending on thecomplexity required.Option 1- Circuit always in operation: Cooling of the bearings is forcedregardless of their temperature. During the start-up operation the coolingsystem connects in parallel with the classifier motor.Option 2 - Circuit regulated by the temperature of the bearings: Thetemperature of the bearings is compared to a pre-set setpoint and when thetemperature exceeds the setpoint the cooling system connects. The coolingsystem continues to operate in this way until a minimum disconnectiontemperature value is reached.

Type of oil

ECUTEC recommends the use of KLUBER AIRPRESS 15 oil, which hasobtained the best results in the tests performed on the machinery. This oilhas been designed for most of the industry, but in the event of specialrequirements please contact our staff before performing start-up.


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Transport and assembly

ALPHA 700

3. Transport and assembly

3.1 Transport

Due to the weight of the particle classifier and its respective parts, thetransport and assembly imply significant risks. For this reason, all theindividual parts that cannot be moved manually due to their weight or shapeare provided with fixing elements.

Lifting the motor casing part

ATTENTION

Falling objects. Risk of crushing and blows. Due to the weight, only use suitable lifting machinery that has been

officially checked and approved for transport and assembly. When lifting individual parts, only use the existing fixing points.


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Lifting the fines output part

Lifting the coarse output part


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3.2 Work prior to assembly

All the brackets must be cleaned of the accumulated grease and dirt. The useof an industrial solvent is recommended.Always use fasteners of 8.8 quality or higher.All the bolts must be fixed with Loctite 2701.The tightening torques are indicated in the following table.

3.3 Tools necessary for assembly, disassembly and maintenance

Socket wrenches for hexagon screws between M8 and M24 Double ended spanners between M8 and M24 Set of spanners for bolts DIN 912

Extractor for bearings with outer diameter of 100 mm, inner diameter of50 mm

Grease pump Rubber mallet

MetricQuality of fastener

8.8 10.9Torque Nm

M5 6 8,5M6 10 14M8 25 35

M10 49 69

M12 86 120M14 135 190M16 210 295

M16x10.5 225 315M18x10.5 325 460

M20 410 580M24 710 1000

M24x2 780 1100M30 1450 2000

M30x2 1600 2250M36 2450 3560

M36x3 2650M42 4070 5720M48 6140 8640

M48x3 6213


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3.4 Assembly

The three assemblies of the particle classifier may be pre-assembled on theground or assembled directly at the operation site.

In general, the machine shall be delivered in three parts, which must beassembled before their final positioning.The first step is to place the body containing the fines output on a base thatis stable and capable of resisting the weight of the machine.

Assembly

Add and spread silicon or polyurethane on the flange to seal the inside ofthe machine from the outside. For example Loctite 5910.Orient and place the casing containing the rotor and the bearing support.The orientation depends on the customer's needs and it has differentpositions.

NOTE The transporting of each machine element must only be done by

personnel authorised to handle the corresponding transport devices. The particles classifier must be installed on a horizontal, level surface

that is resistant enough to bear the total weight of the equipment.


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Add and spread silicon or polyurethane on the flange that joins the seal withthe closure of the fines output.

Fig. 10 Assembly 1: Fitting the motor casing

Once the two parts are in the correct position, use the following componentsto fix the two parts:

o Hexagonal bolt M16x50 DIN 933 (16 units)o Spring washer 16 DIN 127 (32 units)o Hexagon nut (24 units)

To do the following step, you must open the door and place the followingelements through the lower part of the sealing flange:

o Hexagonal bolt M16x30 DIN 933 (8 units)o Spring washer 16 DIN 127 (8 units)

1 Area to apply silicon 2 Hexagonal bolt M16x50DIN 933

3 Spring washer 12 DIN 127 4 Hexagon nut

5 Sealing flange


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Assembly 2

Fig. 11 Assembly 2: Fitting the motor casing

Then place the casing containing the coarse material output and, as with theothers, add silicon and the corresponding fasteners:

o Hexagonal bolt M16x45 DIN 933 (28 units)o Spring washer 16 DIN 127 (56 units)o Hexagon nut (28 units)

Once assembled, place the temperature probes if they are not installed andthose of vibrations if they have been supplied (optional).

1 Area to apply silicon 2 Hexagonal bolt M16x45DIN 933

3 Spring washer 16 DIN 127 4 Hexagon nut


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3.5 Work after assembly

Once all the parts are joined and correctly tightened, you must check thetolerance between the moving and fixed parts. To do this, you must open thedoor and verify that the space between the rotor and the seal is 0.5 - 1.2 mm.

Fig. 12 Labyrinth seal

1 Checking the seal


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Start-up

ALPHA 700

4. Start-up

4.1 Commissioning

Before commissioning the classifier for the first time you have to check thefollowing: Check the condition of the rotor (the rotor turns without problems, the

fins are OK). Check the distance between the rotor and the labyrinth seal (the space

between the rotor and labyrinth seal must be between 0.5 and 1.2 mm). Check the belts. Check the lubrication.

4.2 Ignition period

ECUTEC recommends starting the machine by increasing the revolutions in2 or 3 steps up to the maximum number of revolutions. This operationshould take approximately 6 hours.During commissioning or after changing the bearings, you must check thefollowing points: Check the power. Check that it turns gently.

WARNINGInternal and/or external damage. Machine breakage. The commissioning of the machine should be carried out by ECUTEC

personnel. If the client decides to dispense with ECUTEC staff, thecompany can decide to cancel the warranty and all personal harm ormaterial damage shall be the client's responsibility.

NOTE

During the commissioning of the machine, the 2 lubrication points in thebearings must be greased with approximately 15 g of grease (ISOFLEXNBU 15 from KLBER).


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Start-up

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Verify the rotation direction.

Fig. 13 Rotation direction

Verify the vibrations and that the temperatures do not exceed thestandard values (max. 95C)

It is advisable to grease the machine after the first 30 hours of operation.


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Operation

ALPHA 700

5. Operation

5.1 Commissioning a plant

Fig. 14 Commissioning a plant

To commission a plant the following order must be respected:1. Turn on the classifier cooling fan and motor.2. Turn on the valves for coarse and fine output to empty the respective

silos.3. Turn on the suction fan.4. Open the butterfly valve to create a circulation of air between the

classifier and the filter.5. Turn on the rotary valve for feed.6. Adjust the input butterfly valve to regulate the air flow.

1

2

3

4

6

7

8

9

1 Flow regulation valve 2 Feed silo

3 Rotary valve for feed 4 Particle classifier

5 Rotary valve for coarse material output 6 Filter

7 Rotary valve for fines output 8 Butterfly valve9 Suction fan


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Operation

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5.2 Settings during operation

The general rules to be able to configure the machine are the following: At higher speeds, the cut point is closer and, as such, you will obtain a

finer product but with less quantity. With a greater air flow, the cut point is less close and, as such, you will

obtain a coarser product and production will increase. With a greater feed, the cut point is less close and, as such, you will

obtain a coarser product and production will increase.

DANGER

Machine in movement. Serious injury or death. Keep limbs away from rotating elements such as fans or shafts. The maximum speed indicated in the table of characteristics is the

maximum working speed. This speed should not be exceeded underany circumstances due to the high risk of material damage orpersonal injury, including risk of death.

If the client exceeds this working speed, ECUTEC may decide toterminate the warranty of the machine and all personal harm ormaterial damage shall be the client's responsibility.

Before starting up the machine, verify that the frequency adjuster hasbeen limited so the machine cannot exceed the maximum rotationspeed.


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Maintenance

ALPHA 700

6. Maintenance

6.1 Standard maintenance

The following inspections and maintenance work must be performedregularly.

Lubrication

It is advisable to install a central greasing unit, for example Vogel type.ECUTEC tests the machines with Isoflex NBU 15 grease from Klueber so werecommend you use this grease. Alternatively, some equivalents are listedat the end of section 6.7.

Using unsuitable greases or applying grease excessively can cause hightemperatures, which may lead to the shaft dilating excessively and thereforeincreasing the probability of breakage.You must consider the ambient conditions to be able to increase or decreasethe periods between lubrications. An increase in temperature at constantoperating conditions may indicate insufficient grease.

DANGER

Electrocution and/or cuts on limbs. Serious injury or death.

Maintenance tasks may only be carried out on machines which havebeen disconnected from the mains or with the power supplysectioned off.

Do not proceed to make any adjustments or cable connections withthe power supply switched on.

Use lockout devices and the corresponding warnings signs in order toprevent the machine from being started up accidentally.

If there is more than one power source, ensure that they are allswitched off.

Make sure fans and moving parts have come to a full stop beforestarting maintenance procedures.

Regular reviews must be carried out on the status of the earth toensure its integrity. Repair if not in optimum condition.

CAUTION

Blows and cuts on limbs. Minor injuries. If there are sharp, burred or panelled pieces, use protective gloves. If there are blocked elements, use the proper tools and lubricants to

release these.

NOTE

During the commissioning period, it is mandatory to use Isoflex NBU15 grease. If you wish to use another grease, ECUTEC personnel mustconfirm its use.

The warranty may be cancelled in the event of not complying with thisrequirement.


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Maintenance

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Bearings and seals

The bearings must be changed regularly. The service life of the bearingsmay be longer or shorter, depending on the operating conditions (product,humidity, temperature).

The history of measurements from the monitoring system (see section 2.3)must be used as an indicator of the condition of the bearings.Bearings breaking very frequently may indicate bad greasing, insufficientbalancing or defects in some parts.Whenever you replace bearings, you must change them for the types thatECUTEC indicates and, if possible, from one of the following manufacturers:SKF, NSK or FAG.

Belts

Do not over-tension the belts as this may cause excessive tensions in the

shafts of the machines. Excessive temperatures in the bearings may indicateexcessive tension.

Labyrinth seal

The labyrinth seal is the element that allows you to keep the area of materialto classify separate from the area of fine material. Therefore, an increase inparticles in the fine product may indicate this part is excessively worn. Inaddition, this seal must be kept perfectly clean so it can do its job.The replacement period of this element must be adapted to thecharacteristics of material to classify.It is very important to check the distance between the labyrinth seal and therotor. This must be between 0.5 mm and 1.2 mm.

Bolted joints

The bolted joints must be checked every 10,000 h.

Electric motor

See the manual from the supplier.

NOTE

If coarse particles are found in the labyrinth joint, contact themanufacturer.


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Maintenance

ALPHA 700

6.2 Special maintenance (for ceramic particle classifiers only)

Labyrinth seal

In these classifiers, the design of the seal has been modified to lengthen itslifetime. The distance between the rotor must be observed, as with thestandard classifiers at between 0.5 and 1.2 mm.In this case you must check it by placing a material that can be distortedbetween the rotor and seal. To do so, follow these steps: Lift the rotor. Place a material that can be deformed (chewing gum, plasticine, etc.). Lower the rotor and bolt it. Unscrew and lift the rotor. Finally remove the distorted object and measure its thickness after

being distorted.

Condition of the ceramic

At intervals of a certain number of hours, check the condition of the ceramic.If some of the parts that cover the casing have come off, they must replacedwith new parts, always using Epoxy adhesives.The verification must centre, above all, on the points where the most wearoccurs, such as union elbows, points where the material hits directly, etc.We recommend the disassembly of the different bodies for this verification.


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Maintenance

ALPHA 700

6.3 Removing the rotor

Step 1 Start the process of dismantling the rotor by removing the beltprotector. Once this has been removed, you must loosen the beltsand remove them.

Fig. 15 Loosening the belts

Step 2 The remove the tightening bolts of the pulley and move it towardsthe lower part of the machine using a rubber mallet.

Step 3 Once the pulleys are out, remove the M12x25 bolts and use theelevation screws to lift the rotor.

Step 4 You can use the holes made in the ribs of the bearing support to liftthe rotor.

1 Tensing system 2 Belt protector


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Maintenance

ALPHA 700

Fig. 16 Extracting the pulleys To perform the maintenance of the bearings, follow these steps:Step 1 Remove the screw and washer from the block (pos. 12, pos. 13).Step 2 Remove the inner hexagonal bolts and lock washers

(pos.14 and 15)Step 3 Remove the cover that protects the bearings (pos. 38.01.10) and

the radial seal (pos. 17).Step 4 Remove the inner hexagonal bolts and washers from the block

(pos. 21 and 20)Step 5 Remove the bearings casing (pos. 38.01.01) using a large extractor.

Along with the casing, also remove the upper bearing (pos. 16).Step 6 Remove the spacer between bearings (pos. 38.01.09) and the lower

bearing (pos. 16) using a bearing extractor.

1 Tightening bolts 2 Elevation screws

3 M12x25 bolts


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Maintenance

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Step 7 Finally remove the radial seal (pos. 24) and lower protective cover(pos. 38.01.04).

Fig. 17 Extracting the bearings

Table of classifier maintenance for non-abrasive materials:

Table of classifier maintenance for abrasive materials:

Parts to check Change (hours) Revision (hours)Bearings 10000Radial seals 10000

Balancing 15000Tensioning 6000Labyrinth seal 6000Distance between rotor and seal 6000Greasing 10000 500-1000

Parts to check Change (hours) Revision (hours)Bearings 10000Radial seals 10000

Balancing 6000Tensioning 6000Labyrinth seal 6000 2500Distance between rotor and seal 2500Greasing 10000 500-1000Ceramic lining 500Rotor 6000 500

38

38

38

38

38

38

38

NOTE

Once it is assembled, retighten the belt.


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Maintenance

ALPHA 700

6.4 Assembling the rotor

To assemble the motor, follow the same steps in reverse order as forremoving it.

6.5 Tightening the trapezoidal belts

Once you have assembled the rotor, you must tension the trapezoidal belts usingthe tensioning system incorporated next to the motor.Check the tension of the belts in the following way:

Fig. 18 Tensioning the belts

The tensioning depth is calculated using the formula:

t = a x 0.016The tensioning force authorised is selected according to the followingtable depending on the type of section and the diameter of the smallesttransmission pulley.

Type ofprofile

Effective of thesmall pulley (mm)

Tensioningforce (N)

SPZ67 - 95 10 - 15

100 - 140 15 - 20

SPA100 - 132 20 - 27140 - 200 28 - 35

SPB160 - 224 35 - 50236 - 315 50 - 65

SPC224 - 355 60 - 90375 - 560 90 - 120

a Distance between shafts F Tensioning force

t Tensioning depth


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Maintenance

ALPHA 700

Example of tightening:In the machine, you have to measure the distance between shafts of 1,050mm, and an effective diameter of the small transmission pulley of 250 mm.The name of the belt is SPB.

Using the distance between shafts, calculate the tensioning depth.t= 1,050 mm x 0.016 = 16.8 mm P 17 mmAccording to the table, the tensioning force must be between 50 and 65 N.The tension of the belt is optimum when, with a tensioning depth of 17 mm,it has a tensioning force of between 50 and 65 N.

6.6 Spare parts lists

Spare parts list 1

Fig. 19 Spare parts list 1

Pos. Name38.01.00 Bearings casing38.01.01 Rotor38.01.07 Lower protector38.01.09 Spacer38.01.10 Upper protector38.01.11 Upper ring

12 Lock washer13 Lock washer14 Inner hexagonal bolt DIN 912 M8x20

38

38

38

38

38

38

38


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Maintenance

ALPHA 700

Tab. 1 List of spare parts table 1

Spare parts list 2 l

Fig. 20 Spare parts list 2

Tab. 2 List of spare parts table 2

38.01.08 Lower ring15 Lock washer A8 DIN 12716 Bearing 23024 CC/W33 C317 Radial seal CR135x160x15 CRSA120 Inner hexagonal bolt DIN 912 M10x2521 Lock washer A12 DIN 12723 PT 100 M8x25 (no image)24 Balance weight (no image)26 Grease Isoflex NBU 15 (no image)

38.01.02 CD Ceramic rotor (ceramic version only)

Pos. Name38.00.01 Seal

12 Motor 225M13 Pulley SPB 17/B d=35014 Belts DIN 2215 B/17 Lw=355015 Pulley SPB 17/B d=31546 RPM sensor (no image)59 Ceramic coating ( ceramic version only), (no image )

38.00.01 CD Ceramic seal (ceramic version only)60 Vibration sensor ( version with vibration analysis only )

38


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Maintenance

ALPHA 700

6.7 Lubrication

The machine has two lubrication points. These are in the upper part of themachine. The system is designed to be greased by a manual pump or anautomatic greasing system.

If possible, use the grease suggested by KLBER. ECUTEC recommends theISOFLEX NBU-15.The machine has some holes for releasing the excess grease.

Fig. 21 Location of lubrication holes

.

Tab. 3 Table of recommended greases

1 Lubrication holes 2 Release of grease

NOTE

ECUTEC recommends regreasing the bearings every 500-1000 hours forlocations with environmental temperatures between 20 C and 35 C, inhotter countries the regreasing period must be shorter.

The machine is delivered with lubricant but it is advisable to regreaseafter the first 30 hours of running.

During the commissioning period, it is mandatory to use Isoflex NBU15 grease. If you wish to use another grease, ECUTEC personnel mustconfirm its use.

The warranty may be cancelled in the event of not complying with thisrequirement.

When you change the bearings, ECUTEC advises that you check thegrease holes and look for possible obstructions.

Product Type

Isoflex NBU-15

Beacon 325

Mobilgrease 28

Berulub FR 16


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Fault search

ALPHA 700

7. Fault search

Fault Cause Solution

Rotor clogged particles too large check the size of the feed transmission shaft

dilated monitor the bearings

Fine material doesnot correspond tothe setting

rotor diameter is notcorrect

change the rotor

input butterfly valvechanged

adjust the input butterflyvalve

length of sealbetween the rotorand the stator toolong

change the labyrinthseal

Length of sealbetween the rotorand the stator toolong

wear or deformity change the labyrinthseal

Bearings noisy bearings broken change the bearingsThe rotor shaftcannot be moved

bearings broken change the bearings

Excessivetemperature in thebearings

excessivetensioning

loosen

bearings damaged bearing change

insufficient grease greaseHigh vibrations bearings damaged bearing change

rotor out-of-balance rebalance


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Appendices

ALPHA 700

8. Appendices

8.1 Electrical appendix

Components necessary for the functioning of themachine

The machine is configured by modifying the speed, for which the use ofa frequency converter is required.

The machine has 3-wire temperature probes to monitor the temperatureso it is necessary to install displays for two probes.

ECUTEC supplies a speed sensor and a display that must be installed inthe control panel. The sensor is PNP type.

The protection systems of the motors must be installed and, dependingon the motor, they are delivered with PTC or PT-100.

During machine maintenance, it must be impossible to operate the

machine. Therefore, an emergency stop switch or disconnector switchmust be installed at a distance of less than 2 metres from the machine.

Requirements of the control panel

The classifier must have a frequency converter that allows you tomonitor the speed.

It must have a general ammeter and voltmeter and ones for theclassifier and main fan.

ECUTEC recommends the use of a PLC to check the components. There must be outputs and inputs for PT-100 temperature probes. There must be outputs and inputs for vibration probes. Below some examples are shown. These do not reflect the real powers,

but do reflect the way of operation.


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Appendices

ALPHA 700

Examples of circuit diagrams

Fig. 22 General electric circuit

L 1 L 2 L 3

+ ( 2 4 V D C )

1 8 ( 2 3 0 V )

1 9 ( 2 3 0 ) P

E

L 1 P E

L 2 U

x K W

- x A

( P O S

. x ) L 3 V 3 7

K W W

P E

8 0 8 1 A

M M E T E R

A

P A

B R E A K I N G

R E S I S T O R P B

R E A D Y

E 0 0 0 0

C O M

8 3 L O A D

I N D I C A T O R

A O 1

8 4

P E

+ 1 0

B R O W N 8 5

A I 1

G R E E N 8 6

P O T E N T I O M E T E R

F O R V E L O C I T Y

W H I T E 8 7

P E

S T A R T +

2 4 V L I

1

8 8 8 9

8 3

A 1

T H E R M I S T O R

P R O T E C T I O N

R E L A Y

A 2

T 1

T 2

T H E R M I S T O R

L 1 L 2 L 3 + ( 2 4 V D C )

1 8 ( 2 3 0 V )

1 9 ( 2 3 0 V )

P E

W H I T E

B R O W

N

M 3 ~

U C F x

F T x

4 . 1

7 . 1

4 . 3

/ 3 . 1

/ 3 . 1

/ 3 . 1

/ 4 . 1

/ 4 . 1

/ 4 . 1

/ 3 . 1

Q S x

N S x x x A

2

4

6

1

3

5

x / 5 A

x / 5 A

R 1 B

R 1 C

R 1 A

9 5 9 6

9 7 9 8

1 3 1 4

1 0 K O h

1 0 R o u n d s

V W 3 - A 6 6 7 0 4

R 2 A

R 2 C

P A x

R 1 C R 1 B

R 1 A

R 2 C

R 2 A

R R x

X x

U x

V x

W x

M x

P C x

Q P x

T I x

K M x

P E

R R x

9 0

9 1

X x

9 0 M

A L P H A 7 0 0


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Appendices

ALPHA 700

Fig. 23 Analogue inputs circuit 1

S L O T x

U A x

- ( 0 V ) P

E

+ ( 2 4 V D C )

2 4 V D C

1 1 1 2

1 5

5 B R O W N

E A 0 0 0 4

x ( I + )

I W x

S E N S O R S P E E D

4 - 2 0 m A

( P O S . x )

7

P U L S E I N P U T

F R E Q U E N C Y V O L T A G E

C U R R E N T C O N V E R T E R

P & F K F U 8 - F S S P - 1 . 0

A N A L O G I C O U T P U T

4 - 2 0 m

A 1 4

1 3 4 - x ( M - )

B R O W N

E A 0 0 0 5 x

( M + )

W H I T E

E A 0 0 2 5 x

( S - )

I W x

P T 1 0 0

B E A R I N G U P

T E M P E R A T U R E

( P O S

. x )

G R E E N

E A 0 0 3 5 x

( M - )

B R O W N

E A 0 0 0 6 x

( M + )

W H I T E

E A 0 0 2 6 x

( S - )

I W x

P T 1 0 0

B E A R I N G D O W N

T E M P E R A T U R E

( P O S

. x )

G R E E N

E A 0 0 3 6 x

( M - )

x ( I + )

I W x

x ( M - )

T E R M I N A L N

B I T R A C K x /

S L O T x

I W x . . .

x

A N A

L O G I C S I N P U T S

2 0 2

2 0 1

2 0 0

X

E A 0 0 0 6 M

E A 0 0 3 6

E A 0 0 2 6

E A 0 0 2 6

E A 0 0 0 5 M

E A 0 0 3 5

E A 0 0 2 5

E A 0 0 2 5

X X

B D x

s +

-

B T x

B T x

8 . 8 /

7 . 8 /


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Appendices

ALPHA 700

Fig. 24 Analogue inputs circuit 2 S L O T x

6 . 8

/

/ 5 . 8

/ 5 . 8

/ 5 . 8

/ 6 . 8

/ 6 . 8

/ 6 . 8

/ 6 . 8

/ 6 . 8

/ 6 . 8

/ 9 . 1

P E

E A 0 0 0 0 B R O W N

E A 0 0 0 0

x ( I + )

I W x

C O N T R O L

V I B R A T I O N

W A R N I N G

4 - 2 0 m

A

( P O S

. x )

E A 0 0 2 0 W H I T E

E A 0 0 2 0 x

( M - )

E A 0 0 0 0 M

E A 0 0 0 1 B R O W N

E A 0 0 0 1 x

( I + )

I W x

C O N T R O L V I B R A T I O N

B E A R I N G U P

W A R N I N G

4 - 2 0 m

A

( P O S

. x )

E A 0 0 2 1 W H I T E

E A 0 0 2 1 x (

M - )

E A 0 0 0 1 M

E A 0 0 0 2 B R O W N

E A 0 0 0 2

x ( I + )

I W x



W A R N I N G

4 - 2 0 m

A

( P O S

. x )

E A 0 0 2 2 W H I T E

E A 0 0 2 2 x

( M - )

E A 0 0 0 2 M

x ( I + )

I W x

x ( M - )

P E

T E R M I N A L N

B I T

R A C K x /

S L O T x

I W x . . . x

A N A L O G I C S I N P U T S


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Appendices

ALPHA 700

Fig. 25 Digital inputs circuit 1

S L O T x

3 . 8 /

2 . 8

/

2 . 8

/

2 . 8

/

2 . 4

2 . 7

3 . 3

/ 5 . 1

/ 5 . 1

/ 5 . 1

/ 5 . 1

P E

1 8 ( 2 3 0 V )

1 9 ( 2 3 0 V )

+ ( 2 4 V D C )

E 0 0 0 0

E 0 0 0 0

x . 0

R E A D Y

A L P H A 7 0 0

( P O S

. x )

E 0 0 0 1

x . 1

T H E R M I S T O R R E L A Y

F A U L T

A L P H A 7 0 0

( P O S

. x )

B N x

E 0 0 0 2

x . 2

S E N S O R

M A X

. L E V E L

A L P H A 7 0 0

( P O S

. x )

L

2 3 0 V N

P E

E 0 0 0 3

x . 3

T H E R M I C

C O O L E R

( P O S

. x )

P E 1 8 ( 2 3 0 V )

1 9 ( 2 3 0 V )

+ ( 2 4 V D C )

B I T

T E R M

I N A L N

R A C K x /

S L O T x

x . 0 . . . 3

D I G I T A L S I N P U T S

F T x

X x

E 0 0 0 0

+

1 8

1 9

P E

Q G x

3 1 3 2

9 7 9 8


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Appendices

ALPHA 700


S L O T x

5 . 8 /

5 . 8 /

5 . 8 /

5 . 8 /

/ 8 . 3

/ 8 . 4 / 8

. 4

/ 8 . 5

/ 8 . 5 / 8

. 6

/ 8 . 1

/ 7 . 1

P E

1 8 ( 2 3 0 V )

1 9 ( 2 3 0 V )

+ ( 2 4 V D C ) B

M x x

E 0 0 0 8

x . 8

C O N T R O L

V I B R A T I O N

B E A R I N G U P

W A R N I N G

( P O S

. x )

W A R N I N G

+

4 - 2 0 m

A

O U T 1

+ A L A R M

E 0 0 0 9

x . 9


B E A R I N G U P

A L A R M

( P O S

. x )

L

2 3 0 V N

P E

4 - 2 0 m

A

O U T 2

E 0 0 1 0 x

. 1 0



W A R N I N G

( P O S

. x )

W A R N I N G

+ B L A N C O

M A R R O N

B L A N C O

M A R R O N

+

E 0 0 1 1 x

. 1 1



A L A R M

( P O S

. x ) A L

A R M

E A 0 0 0 1

E A 0 0 2 1

E A 0 0 0 1 M

E A 0 0 0 2

E A 0 0 2 2

E A 0 0 0 2 M

P E

+ ( 2 4 V D C )

B I T

T E R M I N A L N

R A

C K x /

S L O T x

x . 8 .

. . 1 1


E A 0 0 0 1

E A 0 0 2 1

E A 0 0 2 1 M

E A 0 0 0 2

E A 0 0 2 2

E A 0 0 0 2 M

E 0 0 0 9

X x

1 8

1 9

P E

E 0 0 1 0

E 0 0 1 1

X x

E 0 0 0 8

+


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Appendices

ALPHA 700


S L O T x

4 . 8 /

4 . 8 /

4 . 8 /

4 . 8 /

/ 8 . 1

/ 8 . 2 / 8

. 2

/ 6 . 1

/ 6 . 1

/ 6 . 1

/ 6 . 1

P E

1 8 ( 2 3 0 V )

1 9 ( 2 3 0 V )

+ ( 2 4 V D C )

x . 4

x . 5

B M x E

0 0 0 6

x . 6

C O N T R O L

V I B R A T I O N

W A R K I N G

( P O S

. x )

W A R N I N G

+

4 - 2 0 m

A

+ A L A R M

E 0 0 0 7

x . 7

C O N T R O L

V I B R A T I O N

A L A R M

( P O S

. x )

L

2 3 0 V N

W H I T E

B R O W N

P E

E A 0 0 0 0

E A 0 0 2 0

E A 0 0 0 0 M

P E 1 8 ( 2 3 0 V )

1 9 ( 2 3 0 V )

+ ( 2 4 V D C )

B I T

T E R M I N A L N

R A C K

x / S L O T x

x . 4 .

. . 7


E A 0 0 0 0 M

E A 0 0 2 0

E A 0 0 0 0

E 0 0 0 7

X x

X x

E 0 0 0 6

+

1 8

1 9

P E


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Appendices

ALPHA 700

Fig. 29 Motor cooling circuit

2 . 8 /

2 . 8 /

2 . 8 / 2 .

8 /

7 . 1

7 . 1

4 . 7

/ 4 . 1

L 1 L 2 L 3 P E

x K W - x

A

C O O L E R

( P O S

. x )

P E

M x

X x

U x

V x

W x

P E

1

3

5 6

4

2

K M

x x A

Q G x

x - x A

1

3

5

2

4

6

4 4 4 3

3 1 3 2

M 3 ~


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Appendices

ALPHA 700

Configuration of the process operationsTo achieve the quality and quantity established by ECUTEC in addition to theprotection of the components and staff, you must follow the instructionsbelow:

The first element to be connected is the classifier, thus it protectsagainst coarse product getting into the area of fine product.(30 s. approx.)

If the motor has a cooling fan, this must be connected at the same timeas the motor.

The following element is the connection of the system for cleaning the

filter. (10 s. approx.) Once all the systems that ensure the accumulated product output in thedifferent elements are connected, then connect the fan. (60 s. approx.)

When the classifier and the fan are in full operation, this is the momentto open the butterfly valve that is between the filter and the fan and thatcloses the circuit. (15 s. approx.)

Finally, start the feed.

Rules for stopping the machineThe following rules must be followed to protect people, the machine orquality. Whenever an alarm is triggered in any of the elements, you must stop

all the elements that are behind this, for example if the classifier stops,the valve, fan and filter must be stopped.

The temperature probes of the machines must be configured with analarm at 85 C and a machine shutdown at 95 C.

The vibration systems must have an alarm configured at 7 mm/s and amachine shut down at 11 mm/s.

Any PTC or thermal signal must stop the components for their safety. If the cooling fan is not connected, you cannot continue with the

sequence.

ATTENTIONRotating element. Cuts and personal injuries.First connect all the output rotary valves (filter and classifier).Never connect the feed rotary valve first (10 s. approx.).

alpha700 manual

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