Professional Documents
Culture Documents
T E C N I C A
USER’S MANUAL
138.11.A01_00
PISTON PUMPS FOR CERAMIC SLIP
TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇAO TÉCNICA
LISH
ENG
138.11.A01 Revision 00 Date 04.10.1999
TABLE
INDICE OF CONTENTS
0-2
Revision 00 Date 04.10.1999 138.11.A01
TABLE OF CONTENTS
USER’S MANUAL
MANUFACTURER
SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
SERIAL NUMBER
YEAR OF MANUFACTURE
PUBLISHED ON
November 9, 1999
REVISION
00
VERSIONS
0-3
138.11.A01 Revision 00 Date 04.10.1999
TABLE
INDICE OF CONTENTS
0-4
Revision 00 Date 04.10.1999 138.11.A01
TABLE OF CONTENTS
Page
1 GENERAL INFORMATION ........................................................................................................................1 - 1
1.1 INTRODUCTION ......................................................................................................................... 1 - 1
1.2 HOW TO KEEP THE MANUAL ....................................................................................................1 - 1
1.3 HOW TO USE THE MANUAL ......................................................................................................1 - 1
1.4 USERS OF THE MANUAL .......................................................................................................... 1 - 1
1.5 WARRANTY ................................................................................................................................ 1 - 2
1.6 SUPPLEMENTS ...........................................................................................................................1 - 2
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN
THE MANUAL ............................................................................................................................. 1 - 2
1.8 MACHINE IDENTIFICATION PLATE .......................................................................................... 1 - 3
4 INSTALLATION ........................................................................................................................................ 4 - 1
4.1 LIFTING AND HANDLING .......................................................................................................... 4 - 1
4.2 POSITIONING AND CONNECTING THE PUMP ........................................................................4 - 3
5 START UP ..................................................................................................................................................5 - 1
5.1 GENERAL INFORMATION ......................................................................................................... 5 - 1
5.2 PRELIMINARY CHECKS .............................................................................................................5 - 1
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TABLE
INDICE OF CONTENTS
7 ADJUSTMENTS ........................................................................................................................................ 7 - 1
7.1 MACHINE ADJUSTMENTS DURING OPERATION ...................................................................7 - 1
9 DECOMMISSIONING ................................................................................................................................ 9 - 1
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Revision 00 Date 04.10.1999 138.11.A01
GENERAL INFORMATION 1
1 GENERAL INFORMATION
1.1 INTRODUCTION
WARNING!
E0004P
Carefully read the entire User’s Manual before working on the machine and/or the packaging of the various parts.
This manual contains important information for safeguarding the operators, the maintenance staff as well as the
machine itself.
Sacmi reserves the right to make changes to the machine and in the manual without giving prior notice.
Copyright. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI.
The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,
reproduced, disclosed or transferred.
Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.
WARNING!
E0004P
This manual is supplied with the machine and must be kept along with it even if it is resold. Always keep the manual
near the machine where it can be easily consulted. The manual must always be close at hand so that the operator and
maintenance staff are able to consult it rapidly at any time.
The lay-out of this manual allows it to be easily consulted as all the information and instructions provided are grouped
together and divided into chapters and paragraphs. The user has to simply refer to the table of contents.
The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to the
operator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and
are written in italics, as shown below.
WARNING!
E0004P
Chapter 3, SAFETY EQUIPMENT AND PRECAUTIONS, must be carefully read in its entirety as it contains
important information and warnings regarding safety.
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1 GENERAL INFORMATION
1.5 WARRANTY
SACMI shall be held responsible only for the machine as it was at the time of delivery.
Any modifications to the machine or work cycle must be carried out by SACMI personnel or duly authorized by SACMI’s
Engineering Dept.
SACMI shall not be held responsible for damage deriving from the use of non-original spare parts.
WARNING!
E0004P
The operators or maintenance staff should not carry out any operations, special maintenance or repairs when the
machine is under warranty. These procedures are to be performed only by the manufacturer’s specially trained
personnel. For this reason, these types of operations are not dealt with in this manual.
1.6 SUPPLEMENTS
- None
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE
MANUAL
DANGER SYMBOLS
General hazard
E0004P
ALERT SYMBOLS
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Revision 00 Date 04.10.1999 138.11.A01
GENERAL INFORMATION 1
TIPO
TYPE
MATRICOLA No.
SE R I A L N U M B E R
ANNO
YE A R
E0020
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1 GENERAL INFORMATION
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MAIN FEATURES 2
2 MAIN FEATURES
2.1 DESCRIPTION OF THE EQUIPMENT
The piston pump is engineered and constructed to deliver ceramic slip to spray dryers. It basically consists of two parts:
a piston pump assembly and hydraulic power unit. The function of the pump assembly is to create a flow of liquid and
maintain it at the preset delivery rate and pressure required for the system in which the pump is installed.
The hydraulic power unit delivers oil at a constant pressure. Thanks to the hoses used, the oil is sent alternately to
the cylinders of the piston pump.
1 Pump assembly
2 Hydraulic power unit
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2 MAIN FEATURES
2.1.1 MAIN ASSEMBLIES
Alumina, which is particularly wear resistant, was opted for as dense fluids (especially ceramic slip) are highly abrasive
on the moving parts. In order to reduce wear, clean water should be put in the top of the pump casing near the ring
nut (9). Creating a flow over the seals, the water “lubricates” them, thereby reducing friction while at the same time
washing the piston and eliminating any abrasive liquid which may have leaked out.
Guards (12) are provided for protection against the moving parts, thus safeguarding the operating personnel. The
reverse sensors (14) and timing sensors (15) are found on the guard mounts (13). The sensors are protected by the
removable covers (16).
This particular set up allows the position of the sensors to be changed without having to take off the guards (12). In
this way, the operator can safely adjust the piston stroke while the machine is running.
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MAIN FEATURES 2
1 Alumina pistons
2 Hydraulic cylinders
3 Pump casing
4 Intake valve (plate-type)
5 Delivery valve (plate-type)
6 Manifold
7 Accumulator
8 Seals
9 STD tie-rod system
10 Hydraulic lines (upstroke and timing)
11 Piston slide
12 Guards
13 Mounts
14 Reverse sensors
15 Timing sensors
16 Removable covers
7
10
11 2
15 13
12
14 9
3
4
16
15
6
5
1
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2 MAIN FEATURES
2.1.1.2 Hydraulic power unit
(references given in figure 2.1.1.2)
The hydraulic power unit comes with a sheet metal reservoir (1). Along with the oil required for proper system operation,
a tube-bundle heat exchanger (2) is found inside the reservoir. The exchanger is connected to the water supply
system. The motor-and-pump unit (3), oil thermostat (4), filler (5), suction filter (6), drain filter (8) and a hydraulic
assembly (7) for controlling the pressure and cylinder reverse motion are found on the reservoir.
1 Reservoir
2 Heat exchanger
3 Motor-and-pump unit
4 Oil thermostat
5 Filler
6 Suction filter
7 Hydraulic control assembly
8 Drain filter
3
7 5
4
8
1
6 C1637
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Revision 00 Date 04.10.1999 138.11.A01
MAIN FEATURES 2
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE
E0004P
WARNING!
The pump is part of a spray drying plant and is therefore operated remotely from the spray dryer’s control panel.
It cycles together with the spray dryer.
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2 MAIN FEATURES
577
207
950 659 659
1840 1363
750
700
= =
560
= =
600
1050
1000
= =
= =
520
= =
585 C1638
= =
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Revision 00 Date 04.10.1999 138.11.A01
MAIN FEATURES 2
2.3.1 SPECIFICATIONS
PPB308 PPB313
3
Maximum head with material having a specific weight of 1.7 kg/dm m 3.5 3.5
Maximum flow rate of fluid to be transferred l/h 8000 13000
Maximum pressure of fluid to be transferred bar 30 30
Operating pressure range bar 5 - 30 5 - 30
Power requirements (at 50 Hz) kW 15 22
Cooling water at 20° C flow rate l/1' 20 20
Oil in hydraulic power unit l 150 150
Hydraulic unit reservoir (capacity) l 160 160
Hydraulic unit pump (delivery rate) l/min 75 85
(maximum pressure) bar 80 115
(operating pressure) bar 75 110
Weight hydraulic power unit (no oil) kg 350 350
pump kg 1000 1000
Oil accumulator inflating pressure bar 50 70
Slip accumulator inflating pressure (pre-charge)* bar 13 - 15 13 - 15
Minimum pressure for cooling water atm 2 2
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2 MAIN FEATURES
2.3.2 NOISE LEVELS
Test conditions
- Operating conditions (refer to ISO/DIS 11202 standard, point 9.5)
- Type of operation:
- fluid pumping
- Work cycle:
- pumping (refer to ISO/DIS 11202 standard, point 3.11)
- Test conditions:
- hydraulic unit pressure (bar) 100
- operating pressure (bar) 30
- flow rate 11 m3/h
- Test environment in a factory
Instruments employed
Class 1 instruments (IEC 804)
Measurements
LbA Background noise level (dB A) P1 41.3
LpA Acoustic radiation pressure emitted, corrected, weighed A, average over time (dB A) P1 81
LwA Noise emission level in dB, weighed A (dBA) 92
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MAIN FEATURES 2
2.3.3 LUBRICANT SPECIFICATIONS
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2 MAIN FEATURES
2.4 DIAGRAMS
1 Suction line
2 Pump
3 Delivery line
4 Slip filters
5 Spray dryer supply line
6 Nozzle holder
7 Drying unit
8 Hydraulic unit pump
6
3
8 5
7
2
4
1
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MAIN FEATURES 2
2.4.2 HYDRAULIC SCHEMATIC
23
YV1
A B
YV2
22 22
A B
24 SQ1 SQ4 P T
7 6 7
8 5
A B
3
YV4 P T YV3
SQ2 SQ3
1
P
12 13 14 9
21
10 11
20
15
19 16 17
H2O
18
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2 MAIN FEATURES
2.4.3 POINTS OF USE (INSTALLATION DIAGRAM)
3 B A
5
HD31 HD31
HD30
6 C1640
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MAIN FEATURES 2
2.4.4 WIRING BOX 1, HYDRAULIC POWER UNIT
M
ST3
YV4 YV3
SC.2
303
304
305
306
901
2
2
2
303 303
304
ST3 304
R1 N.C
900 - 901 305
101
102
103
104
900
24
24
1
2
YV4
2 - 306 2
YV3 1
2 - 305
C1641
YV1
YV2 2
SQ1 SQ4
SQ2 SQ3
YV1
2 - 303
YV2
2 - 304
101
102
103
104
303
304
24
24
2
2
24 24
SQ1 101 104 SQ4
2 2
24 24
SQ2 102 103 SQ3
2 K21 2
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2 MAIN FEATURES
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SAFETY EQUIPMENT AND PRECAUTIONS 3
The machine is provided with a number of protection and safety devices which safeguard the operator and the
machine.
Shutdown devices
These devices (oil thermostat in hydraulic power unit) detect malfunctioning and prevent the machine from being
started or stop it if running.
Stoppage
The operator is informed by the spray dryer control system whenever a stoppage occurs.
E0004P
WARNING!
Only the wrenches supplied with the machine can be pushed through the slots in the fixed guards. Keep your hands
or any objects away from the slots.
SENSOR COVERS
The removable covers (3) are installed on the sides of the machine. These covers protect the reverse and timing
sensors from being banged or accidentally moved.
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138.11.A01 Revision 00 Date 04.10.1999
1 Pump guard
2 Valve cover
3 Sensor cover
4 Pressure relief valve
5 Oil thermostat
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SAFETY EQUIPMENT AND PRECAUTIONS 3
E0004P
WARNING!
INSTALLATION
Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations
in force in your country.
It is extremely important that the machine is properly connected to adequate earth electrodes. SACMI shall not be held
responsible for any damage to the machine or injury to personnel resulting from improper installation.
QUALIFIED PERSONNEL
The assembling, disassembling and servicing of the machine must be performed by qualified personnel. When
carrying out these operations, always use adequate equipment and follow the instructions provided.
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138.11.A01 Revision 00 Date 04.10.1999
E0004P
WARNING!
HANDLING
The load should always be lifted and handled with the aid of sticks, levers and grapples. Never use your hands!
The person in charge of handling and lifting must always:
- Know where the machine is to be carried.
- Instruct the crane operator from a visible position.
- Stop the operations if hazardous situations occur.
- Keep bystanders away from overhead loads.
INSTALLATION
If the machine is installed by the customer’s personnel, the instructions provided by the manufacturer and current
safety regulations are to be followed. Always connect the machine to adequate ground electrodes. Improper
installation may result in severe injury to personnel and damage to equipment. The manufacturer declines all
responsibility. The manufacturer shall not be held responsible for unsafe machine operation if some parts are provided
and installed by the customer.
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Revision 00 Date 04.10.1999 138.11.A01
SAFETY EQUIPMENT AND PRECAUTIONS 3
E0004P
WARNING!
The maintenance staff should be employed on the basis of the same criteria.
In addition, they must be qualified in specific technical fields (mechanical, electric, and pneumatic) so that they can
safely carry out the operations they are responsible for (as specified in the manual).
Tasks the operator and maintenance staff are and are not responsible for
The jobs the personnel are responsible for are dealt with in various parts of this manual (i.e. machine operation, routine
maintenance, special maintenance, etc...).
It is fundamental that the personnel only carry out the tasks they are specifically responsible for (mechanical, electric,
and pneumatic).
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138.11.A01 Revision 00 Date 04.10.1999
The aim of this chapter is to inform the operators and maintenance staff:
- about some potentially hazardous and/or dangerous situations that may be encountered while operating or
performing maintenance on the machine
- about the safety measures and devices employed and how to use them correctly
- about any additional risks
- on the measures to be taken (general and specific precautions to eliminate potentially harmful situations).
Detailed information is given in this chapter. Your attention is called to the instructions in this manual, at the points
where the situations are encountered.
E0004P
WARNING!
For added clarity, some illustrations in the manual show the machine or parts of it without guards or with the guards
removed.
Do not operate the machine if the safety guards and devices have been removed or inactivated.
In addition to satisfying the requirements stated above the operator and maintenance staff must attend a training
course and receive on-the-job instructions before working on the machine. Along with receiving information on
machine operation and maintenance under normal conditions, they should know:
- the safety precautions and how to use the various devices,
- how to identify, control and face dangerous situations described in this manual and in particular in this chapter.
When operating this machine, the potential hazards more likely to be encountered are in the mechanical, hydraulic
and electrical systems. Where possible, hazardous situations have been eliminated:
- directly, during the design stage
- indirectly, by using barriers, guards and safety devices.
E0004P
WARNING!
Do not operate the machine if the barriers, safety guards and devices have been removed or altered in any way.
Before performing any type of operation on the machine, always consult the manual for information on how to
correctly carry out the procedures. In addition, the manual contains important information concerning safety. If any
doubts arise, contact SACMI’s After-Sales Service Department.
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Revision 00 Date 04.10.1999 138.11.A01
SAFETY EQUIPMENT AND PRECAUTIONS 3
3.5.1 HAZARDS DERIVING FROM MECHANICAL PARTS
LIGHTING
It is fundamental that the areas surrounding the machine and in particular the work zone are always well lit. Replace
any defective elements without delay. Minimum value 300 lux.
E0004P
WARNING!
Whenever a component either inside or outside the switchboard has to be replaced, the maintenance man must
shut off the system with the main switch and padlock it in its open position to prevent it from being started up
accidentally.
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138.11.A01 Revision 00 Date 04.10.1999
The safety measures to be observed while performing maintenance are given in this paragraph. The procedures and
any additional safety precautions are given in chapter 8, MAINTENANCE OPERATIONS for each individual job.
Make sure the machine is in a safe condition before carrying out any maintenance operations. Once the operations
have been completed make sure the machine is able to work safely. In particular make sure all the safety devices and
guard interlocks operate properly.
E0004P
WARNING!
Failure to observe these precautions may cause severe personal injury.
E0004P
WARNING!
Do not carry out any repairs or maintenance while the machine is running.
Signs must be put up to inform the operators.
Before carrying out any operations, disconnect the machine from the power supply by using the main switch. The main
switch can also be padlocked in the “power off” position to prevent the machine from being started up accidentally.
To ensure top machine performance and proper operation closely follow the instructions provided by the manufacturer
and carry out maintenance at the stated intervals. Periodically check all the safety devices for proper operation and
the insulation of the power cables. Replace them if damaged.
Once maintenance has been completed, check the machine for proper functioning. Most of all make sure all the safety
devices are efficient and the guards are in place.
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Revision 00 Date 04.10.1999 138.11.A01
SAFETY EQUIPMENT AND PRECAUTIONS 3
When the machine is no longer to be used, it should be made inoperative by following the instructions given below:
- Shut off the electrical power to the machine by using the main switch
- Unplug the power cable attached to the terminal block in the electrical cabinet
- Unplug the cables between the electrical cabinet and the machine
- Disconnect the cooling system from the water supply and factory drain system
- Thoroughly clean the entire machine, especially the moving parts, lubricate the parts to protect them
- Close the doors of the electrical cabinet and the machine guards to prevent damage, build-ups of dust, etc...
- Use any safety devices provided.
For information on how to dismantle the machine see chapter 9 DECOMMISSIONING.
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138.11.A01 Revision 00 Date 04.10.1999
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Revision 00 Date 04.10.1999 138.11.A01
INSTALLATION 4
4 INSTALLATION
4.1 LIFTING AND HANDLING
LIFTING EQUIPMENT
The points for lifting and transporting the parts are shown in figure 4.1.
To lift the packed parts, use suitable equipment and observe all safety precautions.
Use maximum care when handling the crates both indoors and outdoors. Always use equipment adequate for the
weight of the crate.
On arrival, it is fundamental that the all the parts are precisely weighed.
E0004P
WARNING!
The manufacturer shall not be held responsible for injury to persons or damage to equipment that are caused by
failure to observe current safety precautions regarding lifting and handling material inside the factory.
E0004P
WARNING!
The machine can be lifted and handled only by qualified and authorised personnel.
It is extremely important that no one is near the load and/or within the range of action of the overhead traveling
crane while the machine is being lifted and moved.
- closely follow the instructions given in the SAFETY EQUIPMENT AND PRECAUTIONS chapter.
- While being handled the load must always be kept perfectly horizontal regardless or the type of equipment used.
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4 INSTALLATION
1 Pump casing
2 Hydraulic power unit
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Revision 00 Date 04.10.1999 138.11.A01
INSTALLATION 4
When installing the equipment, which is to be done according to the plant requirements, keep in mind the pumps
cannot take in a fluid that has the indicated specific weight from a depth greater than that indicated in paragraph
2.3.1 - SPECIFICATIONS, even when working at their max. capacity.
E0004P
WARNING!
The equipment is to be connected to the ground electrodes provided.
The points of connection on the equipment are marked with the international ground symbol:
E0006
Failure to ground the equipment may cause serious personal injury and property damage.
E0004P
WARNING!
The equipment is to be connected by qualified personnel as indicated by SACMI.
E0004P
WARNING!
The RST cable is not supplied with the machine. Its characteristics and dimensions are given in paragraph 2.3.1
SPECIFICATIONS.
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138.11.A01 Revision 00 Date 04.10.1999
4 INSTALLATION
3 B A
5
HD31 HD31
HD30
6 C1640
4-4
Revision 00 Date 04.10.1999 138.11.A01
INSTALLATION 4
(See figure 4.2/B)
Ball valves should be fitted to both the delivery (13) and suction lines (12) of the machine so that the latter can be shut
off without affecting the rest of the system, thereby allowing maintenance to be carried out without stopping the spray
drying plant.
2
11
10
4
7
6
8
5
14 13
12
1 15
C1642
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4 INSTALLATION
E0006
C1633
E0006
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Revision 00 Date 04.10.1999 138.11.A01
START UP 5
5 START UP
5.1 GENERAL INFORMATION
E0004P
WARNING!
These operations are to be carried out only by the manufacturer’s personnel who are responsible for starting up
the equipment as specified in chapter 1 GENERAL INFORMATION. Hazardous situations may be created causing
serious injury to persons and/or damage to equipment if these operations are performed by anyone other than the
manufacturer’s staff.
For information regarding the control keys, see chapter 6 OPERATING INSTRUCTIONS.
First time start up requires specialized mechanics and electricians. The customer’s operator and maintenance staff
only have to see how the machine is started up (as it is useful to understand the operating principle of the machine,
how to adjust the auxiliary equipment and accessories as well as the safety guards and devices employed) and the
trials run to see if the parts have been properly set.
CONDITIONS
The machine has already been tested when delivered therefore the machine only needs to be checked for any damage
that might have occurred during shipment or installation.
- Make sure the max. pressure in the relief valve 115 bar for the PPB 313 or 80 bar for the PPB 308.
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138.11.A01 Revision 00 Date 04.10.1999
5 START UP
PREPARATION
(for the references see figure 5.2)
- Circulate the cooling water for the hydraulic power unit as well as the water for flushing the porcelain pistons.
E0004P
WARNING!
Never start the pumps without water for washing the pistons as the seals will be prematurely worn and irreparably
damaged.
4
7
6
8
5
14 13
12
1 15
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Revision 00 Date 04.10.1999 138.11.A01
OPERATING INSTRUCTIONS 6
6 OPERATING INSTRUCTIONS
E0004P
WARNING!
The directions given in this manual must be closely followed and all safety precautions fully observed.
Before starting the machine make sure all the safety devices (which may have been removed during maintenance)
are correctly installed.
Check the inflating pressure in the slip accumulator ( the values are indicated in paragraph 2.3.1 SPECIFICATIONS)
and make sure the pressure control valve is completely open.
Make sure the reverse and timing sensors are placed in such a way as to fully exploit the stroke of the pistons (the
reversals are reduced and therefore system performance is improved).
When the equipment is started up for the first time or after maintenance has been performed on the hydraulic pump,
fill the suction hose of the pump with oil before starting the electric motor. Once the motor has been started up, bleed
any air from the delivery hose of the pump.
The electric motor can now be started. The entire flow is delivered by the hydraulic pump but the cylinders do not
operate as there is hardly any pressure in the circuit. Gradually adjust the control valve. In fact, as a result of slight
increases in the oil pressure the alumina pistons accelerate significantly as the duct that joins the pump to the point
of use is still empty. Once the line is full, the pressure of the fluid will start to increase and the pump will slow down.
The pressure can now be gradually increased until the required value is reached.
In versions equipped with a proportional pressure control the start-up ramp and operating pressure control are
controlled from the ATM’s electrical cabinet.
The operating pressure of the hydraulic circuit is strictly related to the pressure of the slip circuit. For this reason, if the
pressure in the hydraulic circuit does not rise neither will the pressure in the slip circuit.
The pressure ratio in the PPB 313 is 3.5:1. For example, in order to obtain a pressure of 30 bar in the slip lines,
the oil pressure must be about 105 bar. The pressure ratio in the PPB 308 is 2.5:1. or example, in order to obtain
a pressure of 30 bar in the slip lines, the oil pressure must be about 75 bar. This ratio is however approximate as
it is strictly related to the friction created by the working parts of the machine, in particular between the seals and
alumina pistons.
Reverse motion should be optimised during this stage. To do this, adjust the relative throttles (7) (see figure 6.3).
Increasing braking will extend the stroke of the pump pistons, therefore timing sensors SQ1 and SQ2 need to be reset.
In addition, be careful not to full extend or retract the hydraulic cylinders.
At this point, the machine will run at normal speed. Check the pressures in the two lines. The pressure gauge (3) should
be shut off by using the cock (2).
This prevents malfunctioning due to changes in pressure during operation. If the speed of the equipment varies
notably due to increased ATM output or one of the pumps has stopped, etc., repeat the adjustments described above
in order to suit the new conditions.
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6 OPERATING INSTRUCTIONS
6.2.2 STOPPING THE MACHINE
First of all, gradually relieve the pressure until the equipment stops by using the control valve. Once this has been done,
shut off the electric motor with the main controls.
At this point, check the pressure gauge located on the slip accumulator to see whether the pressure has dropped. This
will ensure that the lines located after the pump are no longer under pressure, thus preventing problems from arising
during flushing.
The water for flushing the alumina pistons should be shut off after approximately ten minutes. This will ensure that any
slip residues are flushed from the washing chambers.
The same should be done with the hydraulic unit cooling water. In addition, it is good practice to flush the delivery
and intake valves of the pump. To do this, use the valves located on the inlet and outlet fittings of the machine. If good
results are not obtained, take off the protective frame and covers of the valves and wash by spraying water.
6.3 OPERATION
(references given in figure 6.3)
The gear pump (14), which is driven by the electric motor (12), provides a constant flow of oil which passes through
the hydraulic control assembly and is alternately delivered to the upper chambers of the hydraulic cylinders (22). As
a result, the cylinders move down.
One of the cylinders will move up while one of the pistons goes down, as the two lower chamber are connected to each
other.
The operating pressure is obtained by setting the control valve (10), which gives the element (9) the pressure at which
it has to drain the excess oil. A second pressure level, which is slightly higher than the first one, is obtained through
the pressure relief valve (11). The latter comes into operation if the control valve (10) fails to work.
The order of operation of the cylinders is defined by the reversing valve (6). The latter is operated by the solenoid valve
(8) which receives the pulses for reversing from sensors SQ3 and SQ4. The position of the sensors determines the
extent of the stroke.
The speed at which the spool of valve (6) reverses motion can be varied by adjusting the throttles (7). As a result, any
pressure variations created during this stage will be kept to a minimum.
The accumulator (5) can also reduce pressure peaks. The oil pressure is controlled by the pressure gauge (3), which
is turned on by opening the cock (2).
The check valve (1) is installed in the hydraulic control assembly which protects the pump (14) from abrupt changes
in pressure.
The equipment also includes a tube bundle heat exchanger (19), suction and drain filters (16 & 17) and a thermometer
with switch (21) which reads the oil temperature. When the temperature is too high the electric motor stops running.
Note that a level indicator (20) is located outside the reservoir (18).
6-2
Revision 00 Date 04.10.1999 138.11.A01
OPERATING INSTRUCTIONS 6
23
YV1
A B
YV2
22 22
A B
24 SQ1 SQ4 P T
7 6 7
8 5
A B
3
YV4 P T YV3
SQ2 SQ3
1
P
12 13 14 9
21
10 11
20
15
19 16 17
H2O
18
C0867
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138.11.A01 Revision 00 Date 04.10.1999
6 OPERATING INSTRUCTIONS
6.4 TIMING
(references given in figure 6.4)
During machine operation oil leaks are present in the upper chamber of the cylinders (22) (at high pressure) which tend
to increase the volume of oil in the lower chambers (at low pressure).
These leaks would cause the machine to stop running as the left-hand cylinder (22) would reach its upper most position
before the right-hand one reaches sensor SQ3. As a result the valve (6) would not receive the pulse for reversal. To
solve this problem, the timing valve (23) is installed between the reservoir and the upstroke circuit. This valve is piloted
by sensor SQ1 which drains the oil from the lower chambers while the left-hand piston keeps SQ1 activated. During
this stage the left-hand piston stays in its upper most position while the right-hand one continues to move down until
the relative piston activates sensor SQ3 and reversal starts.
Under normal operating conditions, the right-hand piston has to reach SQ3 before the left-hand one activates SQ1 so
that the latter comes into action only if oil leaks are really present and not during each reversal.
6-4
Revision 00 Date 04.10.1999 138.11.A01
OPERATING INSTRUCTIONS 6
23
YV1
A B
YV2
22 22 A B
24 SQ1 SQ4 P T
7 6 7
8 5
A B
3
YV4 P T YV3
SQ2 SQ3
1
P
12 13 14 9
21
10 11
20
15
19 16 17
H2O
18
C1011
6-5
138.11.A01 Revision 00 Date 04.10.1999
6 OPERATING INSTRUCTIONS
When the machine is started up for the first time, i.e. when the lower chambers of the cylinders (22) are either empty
or almost empty (see figure 6.5), a problem opposite to that described in paragraph 6.4 will arise. The left-hand piston
moves fully down before the right-hand slide reaches SQ4 and therefore the valve (6) does not reverse the flow of fluid.
The problem can be solved through the use of the charge valve (24). In fact the latter, which is piloted by sensor SQ2,
provides a link between the upper chamber of the left-hand cylinder (under pressure during this stage) and the lower
chambers. At this point, the left-hand piston remains fully down as both chambers are under pressure while the right-
hand one moves up until SQ4 is activated causing reverse motion.
The valve (24) must not come into action and SQ4 should be activated slightly before SQ2. In addition, keep in mind
that the delay time for timing sensors SQ1 and SQ2 in relation to the reversing sensors SQ3 and SQ4 varies depending
on the speed of the machine and on how the reversing throttles (7) are set .
6-6
Revision 00 Date 04.10.1999 138.11.A01
OPERATING INSTRUCTIONS 6
23
YV1
A B
YV2
22 22 A B
24 SQ1 SQ4 P T
7 6 7
8 5
A B
3
YV4 P T YV3
SQ2 SQ3
1
P
12 13 14 9
21
10 11
20
15
19 16 17
H2O
18
C1012
6-7
138.11.A01 Revision 00 Date 04.10.1999
6 OPERATING INSTRUCTIONS
6-8
Revision 00 Date 04.10.1999 138.11.A01
ADJUSTMENTS 7
7 ADJUSTMENTS
E0004P
WARNING!
The operations are to be carried out with the machine off and following all the safety precautions dealt with at the
beginning of the manual.
Always shut off the electrical power to the machine before accessing the electrical cabinet, electrical boxes and
wherever “danger-of-electrocution” signs are located.
The adjustments described below are to be carried out when necessary in the presence of malfunctioning or after
maintenance has been performed, parts replaced, etc.. Carefully observe all the safety precautions when carrying out
these operations.
Figure 7.1/A
7.1 MACHINE ADJUSTMENTS
1
DURING OPERATION
C1635
Figure 7.1/B
C1643
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7 ADJUSTMENTS
7-2
Revision 00 Date 04.10.1999 138.11.A01
MAINTENANCE OPERATIONS 8
8 MAINTENANCE OPERATIONS
GENERAL INFORMATION AND SAFETY PRECAUTIONS
E0004P
WARNING!
Only expert personnel who know how the machine and plant operate should carry out maintenance, as indicated
in chapter 3 - “SAFETY EQUIPMENT AND PRECAUTIONS”.
Take all the precautions required in order to prevent accidental machine start-up.
- turn the main switch on the board to OFF
- remove the safety key
- post a “maintenance in progress” sign on the electrical cabinet.
- press the emergency stop buttons
Always keep in mind that risks may arise and follow the safety rules given in chapter 3 - “SAFETY EQUIPMENT
AND PRECAUTIONS”.
All the maintenance operations must be carried out with the machine stopped and cooled down. Maintenance
operations must be carried out at the stated intervals. The operations are divided as follows:
- SCHEDULED OPERATIONS;
- SPECIAL MAINTENANCE.
8-1
138.11.A01 Revision 00 Date 04.10.1999
8 MAINTENANCE OPERATIONS
E0004P
WARNING!
Only the pin wrenches provided with the machine can be put through the slots in the boards. Never put your hands
through them. This is of vital importance.
8-2
Revision 00 Date 04.10.1999 138.11.A01
MAINTENANCE OPERATIONS 8
1
2
1
2
4 4
5
5
C
7
6 B A
6 A
1 Ring nut
2 Ring
3 Seal pack C1013
4 Piston
5 Pump casing
6 Spacer
7 Seal
8 Device for installing seals
8-3
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8 MAINTENANCE OPERATIONS
1
2
9
1
2
4 4
5
5
C
7
Figure 8.1/A2 - INSTALLING THE SEALS AND PUMP
CASING 6 B A
7
1 Pressure plate
2 Stay bolt
6 A
3 Seal pack
4 Piston
5 Pump casing
6 Ring spacer B
7 Seal
8 Device for installing seals
9 Nut
C1341
The hydraulic power unit can be cleaned by blowing compressed air and using rags. This should be done to ensure
that the electric motor cools down well and to prevent matter from building up on the cover of the unit, which if parts
are removed, may get inside the reservoir and dirty the oil. Running water can be used for the pump to remove any
dust or slip build ups that tend to block the ring nut and reduce the sensitivity of the reversal and timing sensors.
8-4
Revision 00 Date 04.10.1999 138.11.A01
MAINTENANCE OPERATIONS 8
3 Washing the valves and piping
(references given in figure 8.1/B)
This operation is normally carried out at the end of each work shift or when the material being handled is changed.
Shut the pump off from the rest of the system by using the main ball valves located before and after the machine. This
should be done after the machine has been stopped and any remaining pressure has been eliminated (check there
is no pressure by observing the relevant gauge). Once this has been done, open the ball valves on the delivery and
suction lines so that water can flow through the pump, thereby flushing the casing and the plate-type valves.
From time to time, thoroughly clean the entire system in the following way. Take off the protective frame, covers and
plates of the valves and wash the valve seats and the inside of the pump with jets of water coming from the delivery
valve. As a result, the fluid flows through the pumping chamber and out of the intake valve.
After checking the seals and seats for condition, wash the bodies of the valve, prime the pump and put everything back
in place.
4
7
6
8
5
14 13
12
1 15
C1642
8-5
138.11.A01 Revision 00 Date 04.10.1999
8 MAINTENANCE OPERATIONS
4 Checking the slip accumulator pressure (OPT)
At the end of each work shift, make sure the pre-charge pressure has not decreased (the value is indicated in paragraph
2.3.1 - SPECIFICATIONS). If the pressure has dropped, find out what is causing the nitrogen to leak.
A certain amount of fresh grease (see paragraph 2.3.3, LUBRICANT SPECIFICATIONS) should be injected through
the fittings on the guide columns to remove the fine abrasive powders captured by the grease during operation. Take
off the front protective board to carry out this operation.
1 Reservoir
2 Heat exchanger
3 Motor-pump unit
4 Oil thermostat
5 Reservoir filler
6 Suction filter
7 Hydraulic control assembly
8 Drain filter 7 5
4
8 1
C1637
6
8-6
Revision 00 Date 04.10.1999 138.11.A01
MAINTENANCE OPERATIONS 8
7 Cleaning the heat exchanger
Install the inflator- tester to check the nitrogen pressure. It should be about 60-70% of the flow pressure. If the value
read is lower, inflate the bag with a full nitrogen cylinder.
8-7
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8 MAINTENANCE OPERATIONS
The special maintenance operations that usually regard only the machine in question are described below.
IMPORTANT!
When the ring nut or plate (1) is almost all the way down the whole seal pack (3) has to be replaced. The alumina
piston will wear down much more quickly if overworn seals are used. For this reason, the ring nut should be replaced
when the piston only completes 2/3 of its total stroke.
IMPORTANT!
The seals (7), when supplied, have the correct length and adequate contact surfaces.
The spacers (6) have to be cut in slices. Insertion is made easier if the clamp (8) provided with the machine is used.
Do not overlap points (A) of the seals over those of the clamp (B) to avoid oil leaks.
- Put a spacer (6) (cut so that it fits around the piston 4) in the seat of the cylinder (5). Push it all the way down.
- Put a seal (7) around the piston (4), being very careful to accurately join the ends together and fit it into the seat of
the cylinder (5).
- Fit the clamp (8) over the piston (4) and push it downwards to lower the seal. Make sure that the seal is in place
before pushing the clamp down. Also ensure the joints of the clamp do not match those of the seals.
- Remove the clamp (8) and take it apart.
- Put on another cut ring spacer (6).
- Install another seal (7) by performing the procedure described above and continue until the entire pack (3) has been
installed.
RING-NUT ADJUSTMENT
- Hold the ring (2) in place by slightly tightening the respective screws.
- Tighten the ring nut (1) until it rests on the seal pack
- Secure the ring (2).
STAY-BOLT ADJUSTMENT
- Turn the nuts (9) of the stay bolts (2) to bring the plate (1) into contact with the seal pack.
- Slightly pre-load with the nuts (approx. half a turn).
WARNING!
To further preload the seal pack (3), turn the ring nut (1, figure 8.1/A1) or the stay bolts of the plate (1, figure 8.1/A2).
This operation is to be performed with the pump running only if required.
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Revision 00 Date 04.10.1999 138.11.A01
MAINTENANCE OPERATIONS 8
8.2.2 OVERHAULING THE DELIVERY AND INTAKE VALVES
(references given in figure 8.1/B)
The disk (6) and valve seat (8) get worn when slip under pressure flows in the intake valves. These parts therefore
need to be replaced.
- Take off the protective frames (11)
- Replace the parts (6 and 8)
- Put the parts back in their correct position and tighten the clamp (3)
- Put the protective frames (11) back on.
8-9
138.11.A01 Revision 00 Date 04.10.1999
8 MAINTENANCE OPERATIONS
NOTE: Class 12.9 screws must be tightened with a torque wrench as if they were class 10.9.
Example: a 12 mm diameter screw, 1.75 thread, 12.9 must be tightened to 12.28 Kg instead of 14.74 Kg.
DIAMETER mm. 4 5 6 8 10 12 14 16 18 20 22 24 27 30 36
PITCH mm 0.70 0.80 1.00 1.25 1.50 1.75 2.00 2.00 2.50 2.50 2.50 3 3 3,5 4
Sr mm2 8.78 14,2 20,1 36,6 58 84,3 115 157 192 245 303 353 459 561 817
5.8 M (Nm) 1,9 3,8 6,5 15,4 31,3 53 84,3 128 177 250 332 432 631 857 1500
P (N) 2500 4000 5600 10250 16200 23600 32200 44000 53800 68600 84800 98800 129000 157000 228800
8.8 M (Nm) 3,1 6 10,4 24,6 50,1 84,8 135 205 283 400 532 691 1010 1370 2398
P (N) 3930 6360 9000 16400 26000 37800 51500 70300 86000 110000 136000 158000 20600 251000 366000
CLASS
10.9 M (Nm) 4,3 8,5 14,6 34,7 70,5 119 190 288 398 562 748 971 1420 1930 3372
P (N) 5530 8950 12700 23100 36500 53000 72500 98900 121000 154000 191000 222000 289000 353000 514700
12.9 M (Nm) 5,2 10,1 17,5 41,6 84,6 143 228 346 478 674 897 1170 1700 2310 4046
P (N) 6640 10700 15200 27740 43900 63700 86900 119000 145000 185000 229000 267000 347000 424000 617600
DIAMETER mm 8 10 12 14 16 18 20 22 24 27 30 36
S.R. mm2 39,2 61,2 92,1 125 167 216 272 333 384 496 621 865
5.8 M (Nm) 16,3 32,7 56,6 89,6 134 193 270 357 457 667 923 1587
P (N) 11000 17100 25800 35000 46800 60500 76200 93200 108000 139000 174000 242200
8.8 M (Nm) 26 52,4 90,6 143 214 308 431 571 731 1070 1480 2539
P (N) 17600 27400 41300 56000 74800 96800 122000 149000 172000 222000 278000 387500
CLASS
10.9 M (Nm) 36,6 73,6 127 202 302 434 607 803 1030 1500 2028 3570
P (N) 24700 38500 58000 78800 105000 136000 171000 210000 242000 312000 391000 544900
12.9 M (Nm) 43,9 88,4 153 242 362 520 728 964 1230 1800 2490 4284
P (N) 29600 46300 69600 94500 126000 163000 206000 252000 290000 375000 469000 653900
8 - 10
Revision 00 Date 04.10.1999 138.11.A01
DECOMMISSIONING 9
9 DECOMMISSIONING
Proceed as follows to dismantle the machine:
- disconnect the machine from the electricity supply.
- disassemble the various parts observing all safety precautions and following the instructions given in chapter 4 -
INSTALLATION.
9-1
138.11.A01 Revision 00 Date 04.10.1999
9 DECOMMISSIONING
9-2