Multi-Function Separator SP-MF: Operating and Service Manual
Multi-Function Separator SP-MF: Operating and Service Manual
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Constructional layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Subassemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Position within a plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fan BR-FD500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Addition of waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Heavy part separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Air separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Metal Separator SP-EM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Filling level control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Further information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Warning messages and faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Other indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Keyboard and display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Key-operated switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Malfunctions and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Display brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Control systematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Preparation for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
First start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Daily preparations for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Setting exhaust air output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Purging air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Heavy part separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Overview of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
00 Working Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
35 Set door locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
39 Lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
40 Enter limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
41 Reset counter EM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
49 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
50 Display control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
51 Display scheduled value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
60 Autoleveller to be calibrated? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
61 Change control parameters? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
78 Display ejections EM? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
79 Extraction flap EM service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
80 Selection of language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
87 Network address TKN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
89 Display program numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
98 Set system clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Volumetric flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Functional description of integral action controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Balancing operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Dealing with malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Malfunction indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Basic procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Fault messages –
causes and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fire in wheeled waste container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Replacing wheeled waste containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Replacing CO2 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Spark detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Waste compartment door opened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
LED indicators in switch cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Frequency converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cleaning fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Cleaning filter sieves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Cleaning light barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Cleaning comb profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Cleaning air ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Cleaning extraction flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Filter pressure controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cleaning volumetric nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Cleaning waste compartments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Machine panelling, frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Functional testing of display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Functional testing of aggregates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Further service operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Replacing CO2 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Replacing fluorescent lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Material feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Material suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Dust extraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Metal detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Machine dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fire extinguishing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Gas cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Gas cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Introduction
In this chapter you will find important safety pre-
cautions as well as explanations on the structure
of this operating and service manual and on the
symbols and conventions employed.
Intended use
The Multi-Function Separator SP-MF is intended
exclusively to be used in spinning mills. The ma-
chine serves for separating heavy parts and
metal from unprocessed cotton and synthetic
fibres. In addition, the machine separates burn-
ing or smouldering parts from the material and
automatically extinguishes any fire inside the ma-
chine. Use in any other way does not constitute
an intended use and is expressly forbidden.
The intended use also entails reading the operat-
ing and service manual and adhering to the in-
spection and maintenance intervals.
Type plate
You will find the type plate allowing precise
identification of the machine on the side on
which the material leaves the machine. There the Tr ützschler GmbH & Co. KG
Safety measures
Organisational measures Safety of persons
This machine has been built to the state of the The personnel employed for operation and main-
art and the recognised safety regulations. If used tenance must be qualified for their work or must
in an improper manner, however, the machine have been instructed by qualified persons.
may pose a danger to the life and limb of the op-
Qualified persons have sufficient knowledge of
erator or of other persons, or machine functions
the machine as a result of their technical training
may be impaired.
and experience. These persons are sufficiently
The personnel employed to work on or with the familiar with the relevant local and national work
machine must have read and understood this safety and accident prevention regulations that
operating and service manual before starting they are able to assess the safe working condi-
work. This applies in particular to personnel who tion of the machine.
are only required to work on the machine oc-
– Observe the working instructions for your
casionally, e.g. for maintenance work.
place of work.
The owner of the machine is obliged to ensure
– Observe the relevant accident prevention
that the machine operates safely and does not
regulations.
present a hazard. He can achieve this through
the following measures: – Observe the safety precautions contained in
this operating and service manual.
– Ensuring that the operating and service
manual is available on the machine at all
times Avoid machine damage
– Carrying out regular training courses As owner of the machine, you are responsible for
– Monitoring the safety and hazard-conscious the following points:
working of the personnel at regular intervals – Use the machine only for applications de-
Warning plates and signs on the machine must scribed as an intended use.
always be easy to read and intact and must not – Observe the operating conditions and
be removed. materials for the machine described in this
operating and service manual.
– Observe the prescribed service intervals.
– Use only original spare parts and process
media recommended by Trützschler.
Safety instructions
Read the following safety instructions carefully Maintenance work, servicing and repairs
and observe them. They are given for your own
safety, for the safety of your colleagues and in As owner of the machine, ensure that only quali-
order to avoid any damage to the machine and fied personnel are employed to carry out main-
the attached components. tenance or repair work on the machine.
Also observe the instructions and directions for
Before switching on the machine maintenance work contained in the manufac-
turers’ documentation in the annex to this operat-
As owner of the machine, ensure that only quali- ing and service manual.
fied personnel are employed to operate the ma-
Install and/or activate all protection and safety
chine.
devices correctly after all maintenance work.
Also ensure that the machine is inspected by
Work on the machine going beyond the oper-
qualified personnel for a safe and hazard-free
ations described in the chapter Maintenance may
condition before it is switched on for the first
only be carried out by Trützschler after-sales ser-
time, after maintenance work and after any
vice personnel or by persons authorised by
technical modifications.
Trützschler.
In particular, make sure that the fire extinguishing
Start all set-up and maintenance operations only
system (spark detector, fire sensor and CO2 cyl-
when the machine has been disconnected from
inder) is properly installed and ready to be trig-
the power supply and has come to a standstill.
gered every time before switching on the ma-
Secure the master switch in the OFF position by
chine. Ensure that the CO2 cylinder is completely
means of a padlock and a warning sign or by
filled.
other suitable means to prevent unauthorised
As operator of the machine, ensure that you switching on. This applies in particular for ma-
request all persons in the danger area of the chine combinations and machines that cannot
machine to leave the area. be monitored in all areas at the same time due to
their size.
Electrical installation and control cabinet Carry out modifications to the machine or its
components only after consultation with
Ensure that the doors of the control cabinet are Trützschler’s after-sales service; otherwise major
kept locked at all times. The key should be kept malfunctions may occur causing serious per-
by a responsible and qualified person, for sonal injury and irreparable machine damage.
example the plant electrician.
Ensure that no liquid can enter the control cabi-
net or other components. Should this neverthe-
less happen, switch off the machine at the
master switch, lock the switch to prevent unau-
thorised switching on and inform the responsible
specialist personnel or the Trützschler after-sales
service.
Safety equipment
Master switch
The red and yellow master switch of the machine
is located on the right side of the machine (see
arrow). It functions as a mains disconnecting de-
vice and serves to shut down the machine in an
emergency.
If necessary, secure the master switch by means
of a padlock, with the machine switched off, to
prevent the machine from being switched on
These dangerous spots are monitored indepen-
again (e.g. during servicing or maintenance
dently of each other to allow work in a secured
operations).
danger area while other parts of the machine
continue to operate, e.g. when one of the
wheeled waste containers has to be emptied.
Service mode
There is a service door on the left-hand side of
the machine. The key-operated switch for the
service mode is located behind this door. The
door is released by the machine control after the
fan has stopped (timing: 3 minutes after switch-
off).
Opening of the service door prevents the quick
closing flap of the metal and spark separator
from being triggered.
When an authorised person has switched on the
service mode with the key-operated switch, all
door locking systems are released and all safety
limit switches overridden.
On a higher level the external emergency stop
circuit has a disabling effect also in the service
mode.
Description
This chapter describes the Multi-Function Separ-
ator SP-MF and provides you with an overview of
the subassemblies and their functions within the
machine.
You will find an overview of the most important
operating elements and an introduction to the
function and operation of the operating unit in
the following chapter Operation from page 21.
Constructional layout
Subassemblies
The Multi-Function Separator SP-MF essentially
consists of the following subassemblies (in ma-
terial flow direction):
– Fan BR-FD500 (1)
– Heavy part separator (2)
– Air separator, optional (3)
– Metal and spark separator (4)
Functional description
Übersicht
Fan BR-FD500
The Transport Fan BR-FD500 (5) is responsible The fan does not have any control system of its
for transporting air and material from the upline own. The machine control or the higher-level in-
machine (e.g. the Bale Opener BO-A) to the SP- stallation control switches the fan on or off and
MF. controls the rotational speed.
At the feeding end (on the right-hand side of the The fan does not have any operating or display
machine) the fan sucks in material through the elements.
suction unit. The material is blown out again
through the exhaust pipe located at the top and
transported to the feeding end of the heavy part
separator. The fan ensures a constant air current.
The suction air volume always remains within the
ideal range, irrespective of the length of the
transport route.
The Metal and Spark Separator SP-EM separates The quick closing flap (11) discharges metal and
metal and burning material from the material burning material without impairing the air current.
flow. The air can escape through a sparkproof sieve in
the waste compartment, preventing sudden over-
pressure or underpressure in the conduit sys-
Fire protection tem.
Two spark sensors in the air duct (6) downline of When opening and closing, the quick closing
the heavy part separator and upline of the air flap is actively moved by pressure cylinders.
separator detect sparks and burning or smoul- Therefore it operates very quickly and reliably.
dering material.
Sufficient underpressure in the metal separator
The Metal and Spark Separator SP-EM dis- ensures trouble-free functioning of the quick
charges the burning or smouldering material into closing flap. A pressure gauge in the switch cabi-
the fireproof wheeled waste container (13) via the net door on the right-hand side of the machine
quick closing flap (11). If the material continues shows the underpressure in the metal separator,
to burn there, a heat sensor (14) on the wheeled thereby allowing you to check it.
waste container will detect the fire and automati-
cally cause it to be extinguished with CO2 (12). The metal separator does not have any control
system of its own. The quick closing flap is auto-
matically controlled and triggered by the spark
Separation of metal sensor in the air duct (6) or by the metal sensor
(9).
A metal sensor (9) surrounds the duct in the
Metal Separator SP-EM. The sensor detects any The waste compartment of the metal separator
kind of metal in the material flow. When the sen- can be opened upon manual request, allowing
sor detects metal, the quick closing flap (11) is the wheeled waste container to be replaced or
opened, and the metal is discharged into the emptied even during ongoing operation.
wheeled waste container (13).
In the event of a fire in the wheeled waste con-
tainer the machine is automatically switched off
and the door to the waste compartment locked.
The fire extinguisher is fully automatically con-
trolled by the fire warning centre.
Switch cabinet
The switch cabinet of the SP-MF is located in the
middle module on the right-hand side of the ma-
chine. The red and yellow master switch of the
machine is installed in the door of the switch
cabinet. The red warning siren is located above
the master switch.
A housing fan and a housing filter may be in-
stalled in the switch cabinet door, if necessary.
Components
Housed in the switch cabinet are:
– Electrical main supply line
– Electrical connections
– Main fuse and other fuses
– Transformer with rectifier
– Matching transformer if necessary
– Motor protection switch
– Fixed-time relay for door locking systems
– Installation control interface
– TKN-2 interface
– Supply voltage socket-outlet for service
Further information
For further information on the switch cabinet and
the electrical installation, please refer to the
documentation for the electrical installation.
Note
A copy of this documentation can be
found in the tray on the inside of the
switch cabinet door.
Operation
This chapter gives you an overview of the most
important operating elements and an introduc-
tion to the function and operation of the operat-
ing unit.
This chapter describes how to switch the ma-
chine on and off as well as all activities during
normal operation, e.g. checking the operating
status and replacing or emptying the wheeled
waste containers.
Servicing and maintenance operations are
described in the chapter Service from page 61
onwards.
The chapter Malfunctions from page 45 onwards
describes how to detect and remedy faults.
Operating elements
To be entrusted with the operation of the ma-
chine, you need to be familiar with and know
how to operate the following operating elements:
– Operating unit (1)
– Push-button for opening the two
waste compartment doors (2)
– Slide gate for adjusting the exhaust air out-
put of the air separator (3)
– Master switch (6)
The section Operating unit from page 22
onwards describes how to handle the operating
unit.
The other operating elements are described in
connection with the corresponding activities
(e.g. switching on the machine or emptying the
wheeled waste container).
Other indicators
A pressure gauge (4) located above the switch
cabinet door on the right-hand side of the ma-
chine shows the underpressure in the metal sep-
arator area. The indicated value provides in-
formation as to whether the transport fan, in
conjunction with the exhaust air slide gate and
the next machine downstream of the SP-MF, is
correctly adjusted.
Operating unit
Description
The operating unit of the Multi-Function Separ-
ator SP-MF is located in the door to the metal
and spark separator on the right-hand side of the
machine.
The operating unit consists of:
– Membrane keyboard with keys and LEDs
– Two-line display
– Key-operated switch
With the keys of the operating unit you can
switch the machine on and off, trigger functions,
set parameters and acknowledge malfunctions.
On the display you see warnings and essential
information as well as text messages concerning
operating statuses, data and measured values.
The key-operated switch serves for switching
over between the different operating modes.
further action. CE NO 4 5 6
R 0 1 2 3
Caution
Do not exert excessive pressure on
the keys, and do not bang on the key-
board or the display to avoid damag-
ing the keys and the display or im-
pairing their functions.
General survey
F1 F2 F3 F4
P N S H YES 7 8 9
CE NO 4 5 6
R 0 1 2 3
– correct inputs When you see the basic display in the display
Some of the individual keys have different func- section, you can open the menu and then navi-
tions, depending on the text messages on the gate in the menu . When the machine has been
display: switched on, the basic display shows the most
important production data:
Digits 0 ... 9
0 9 for inputting numerical values
Opens menu,
H closes menu or function
First start-up
The first start-up of the machine and the con-
figuration of all operating parameters are per-
formed by Trützschler’s after-sales service follow-
ing the erection.
The chapter Settings from page 35 of this operat-
ing and service manual describes how to set and
change the operating parameters.
DANGER
Ensure that all in-plant safety equip-
ment works properly.
Make sure that all safety and accident
prevention regulations are complied
with.
DANGER
In order to prevent unintentional Monitoring production data
switching on of the machine, lock the
The most important production data of the ma-
master switch, e.g. with a padlock.
chine are shown on the display of the operating
unit. The basic display shows the following in-
formation:
V1 Volumetric flow rate upline of the fan
V2 Volumetric flow rate in the metal separator
n Fan speed
z Number of times the quick closing flap in
the metal separator opened during the
past 60 minutes
Note
If the door has been open too long, a
fault message is output (see chapter
Malfunctions from page 45).
Further tasks
The chapter Service from page 61 of this operat-
ing and service manual describes further inspec-
tion, maintenance and service activities. There
you will also find a clearly arranged maintenance
and service schedule.
Settings
This chapter describes all the settings you can
make on the machine.
This concerns manual settings on mechanical
components on the one hand and machine con-
trol settings you can make on the operating unit
on the other hand.
Caution
Perform only the work described
below. Any further changes to the
machine configuration may cause
damage to the machine or material
defects. In any case of doubt please
consult Trützschler’s after-sales
service.
Note
The chapter Operating unit from page
22 of this operating and service man-
ual describes the operating unit as
well as basics on working with the
menu structure.
Machine control
Machine control parameters can only be set 00 Working Memory
when the key-operated switch of the operator’s
panel is in position P. BR-FD
All functions can be directly selected by inputting <25-100%>= 70
their function number.
With this function you can adjust the setpoints
for volumetric flow control. The first parameter
Overview of functions of the function indicates the basic speed of
the fan. Fine adjustment can be made using
The following functions can be selected via the the function 60 Autoleveller to be calibrated?
operating unit of the multi-function separator:
(see page 41).
00 Working Memory 1. Input the new value with the numeric keys.
35 Set door locking system 2. Press key R to display the next parameter.
39 Lamp test
Volumetric flow
40 Enter limits <4500-8000>=6500m3/h
41 Reset counter EM
The second parameter shows the setpoint for the
49 Configuration volumetric flow rate upline of the fan. The value is
50 Display control determined by the technical specification of the
plant and of the machine.
51 Display scheduled value
1. Input the new value with the numeric keys.
60 Autoleveller to be calibrated?
2. Press key R to exit the function.
61 Change control parameters?
78 Display ejections EM?
35 Set door locking system
79 Extraction flap EM service?
Adjust door locking
80 Selection of language
EM <Y/N>=N
87 Network address TKN
89 Display program numbers This function can only be used while the ma-
chine is at a standstill. The function serves for
98 Set system clock testing the safety circuit of the door locking sys-
In the following the functions are described in tems. You can check the locking devices of the
the order of numbering. The first figure always two waste compartment doors and of the main-
shows the display after the respective function tenance flap of the fan one after the other.
has been selected.
Adjust door locking This parameter indicates how long (in minutes)
SP-H <Y/N>=N the waste compartment door of the metal and
spark separator is allowed to be open. When this
3. Press key R to display the next parameter. time has passed, the control system automati-
cally triggers a fault.
The third parameter concerns the maintenance
flap of the fan. 3. Input the new value with the numeric keys.
Adjust door locking 4. Press key R to display the next parameter.
BR-FD <Y/N>=N
EM carriage change
Extractions <0-5>=1
39 Lamp test The filling level of the wheeled waste container in
the metal and spark separator is monitored by
light barriers. When the maximum filling level has
been reached, the display shows a warning, and
the corresponding carriage must be emptied.
With this function you can check the display
elements of the display screen and the LEDs
over the keys of the operating unit.
1. Press key R. All elements of the display
must light up. All LEDs over the keys of the
operating unit must light up.
2. Press key R again to exit the function.
With this parameter you define how many ejec- With this parameter you define how long (in min-
tions are still possible after the monitored maxi- utes) ejections are still possible after the moni-
mum filling level has been reached. When this tored maximum filling level has been reached.
value is reached, the control system automati- When this value is reached, the control system
cally triggers a fault. automatically triggers a fault.
5. Input the new value with the numeric keys. 11. Input the new value with the numeric keys.
6. Press key R to display the next parameter. 12. Press key R to display the next parameter.
With this parameter you can set the opening With this parameter you set the time interval at
period (in seconds) of the quick closing flap of which the extraction flap in the heavy part separ-
the metal and spark separator. ator is to open. The time period depends on how
dirty the material is. It must be chosen so as to
The flap will open immediately when the metal
avoid too much waste collecting in the waste
sensor has detected any metal and close auto-
container over the flap and possibly being blown
matically after the time set here has passed.
into the clean material flow again.
The time interval must be set such that the de-
13. Input the new value with the numeric keys.
tected metal will definitely be discharged.
14. Press key R to exit the function.
7. Input the new value with the numeric keys.
8. Press key R to display the next parameter.
41 Reset counter EM
SP-H monitoring time
Doors <1-10min>=2 Reset counter EM?
<Y/N>=N
This parameter indicates how long (in minutes)
the waste compartment door of the heavy part With this function you can reset the value z in
separator is allowed to be open. When this time the basic display to 0. The value z indicates the
has passed, the control system automatically number of ejections in the metal and spark sep-
triggers a fault. arator within the past 60 minutes (cf. page 30).
9. Input the new value with the numeric keys.
10. Press key R to display the next parameter.
This function serves for selecting the machine This function displays the current volumetric flow
components at the initial start-up. You can acti- rates upline of the fan and downline of the air
vate (key YES) or deactivate (key NO) a compo- separator (discharged air volume). This display is
nent with every parameter. only provided for your information; you cannot
change anything here.
The first parameter concerns the fan BR-FD.
1. Press key R to display the next parameter.
60 Autoleveller to be calibrated?
With SP-H?
<Y/N>=Y V1:6500m3/h + 0.2%
n<25-100>=75%
The second parameter concerns the heavy part
separator. With this function you can configure closed-loop
control of the volumetric flow rate (fan). The dis-
2. Press key R to display the next parameter. play shows the setpoint for the volumetric flow
With BR-ASU? rate upline of the fan, the volumetric flow devi-
<Y/N>=Y ation in per cent and the basic speed of the fan
in per cent.
The third parameter concerns the air separator. You will find a description of the closed-loop con-
trol system and the balancing operation from
3. Press key R to display the next parameter.
page 44 of this operating and service manual.
Configuration to be
set? <Y/N>=N 61 Change control parameters?
With the last prompt you can confirm and import Amplification factor
(key YES) or reject (key NO) the configuration <0.1-1.0>=0.5
you have just set.
With this function you can change the control
parameter and adapt it to your requirements.
50 Display control The parameter concerns the amplification factor.
1. Input the new value with the numeric keys.
nom.6500m3/h n=75.0%
act.6514m3/h n=74.3% 2. Press key R to exit the function.
This function displays the total number of ejec- With this function you can select the language in
tions by the metal and spark separator since which text messages are to be displayed. The
the initial start-up of the machine. This display is available languages are shown one after the
only provided for your information; you cannot other.
change anything here. This counter cannot be
1. Press key YES to select the indicated lan-
reset.
guage.
2. Press key NO for the next language to be
79 Extraction flap EM service displayed.
Service interval EM
100,000 / 123456z 87 Network address TKN
With this parameter you can reset the count of Here you can set the network address of the ma-
ejections by the metal and spark separator to 0 chine. The address is predefined by the higher-
after completing maintenance. level installation control.
ATC 2
495-08.800.001
Balancing operation
Caution
Only qualified persons are permitted
to balance the closed-loop control sys-
tem.
Wrong settings may cause damage to
the multi-function separator, to other
machines and to the material.
Malfunctions
Dealing with malfunctions
Malfunction indication
If a condition necessitating an interruption of
operation occurs while the machine is running,
this is considered to be a malfunction. The ma-
chine or installation control automatically reacts
to a malfunction, switching off the machine and,
if necessary, other machines of the plant.
Malfunctions are always indicated on the operat-
ing unit: F1 F2 F3 F4
CE NO 4 5 6
Note
The chapter Operating unit from
page 22 of this operating and service
manual describes how to handle the
operating unit.
Basic procedure
When a fault has occurred, you can basically
proceed as follows:
1. Read the fault text on the display of the
operating unit. The text gives you initial
information about the cause of the fault.
2. Try to eliminate the cause of the fault
(close an open waste compartment door,
for instance). F1 F2 F3 F4
Fault messages –
causes and remedies
The following table gives you an overview of every fault message has a number, which is
possible fault messages of the Multi-Function shown on the display of the operating unit to-
Separator SP-MF. The possible cause of each gether with the fault message.
fault message is briefly described, and you are
given instructions for the recommended pro- Note
cedure. Below the table individual pro-
cedures, e.g. how to react to a fire in
To allow unambiguous identification (e.g. for a wheeled waste container, are de-
questions for Trützschler’s after-sales service), scribed in greater detail.
150 Fault existed in operating No power supply; connecting Check power supply and
unit cable defective or operating unit connecting cable; replace
defective. operating unit if necessary.
163 Fault TKN network TKN network cable defective. Check TKN network cable.
200 Safety circuit emergency Emergency stop circuit in in- Reset and/or acknowledge
stop stallation control interrupted. emergency switch or other
comparable device in installation
control.
202 Safety circuit fault in Emergency stop circuit in in- Reset and/or acknowledge
installation stallation control interrupted. emergency switch or other
comparable device in installation
control.
207 Motor protection switch has Motor protection switch of fan Check reactor (-L100) and fre-
tripped has tripped. quency converter 2 (-A100).
Check current setting on motor
protection switch -Q100 and
switch motor protection switch
on again.
210 Fault compressed air Not enough compressed air Check compressed-air supply
available in main supply system to machine. Check setting
of machine. (6 bar) of pressure control
switch -S756.
211 Fault in I/O-modules I/O module is not recognised by Check connecting cable
main module. between main module and I/O
module. Replace controller.
221 Frequency converter Frequency converter of fan is Check power supply to fan.
not ready for operation.
655 Door middle left Door on left-hand side of ma- Close door; check door locking
chine (middle frame) is not system -A201 if necessary.
closed.
661 Safety loop SP-H Doors of heavy part separator Close doors; check door locking
could not be locked. systems -A720 and -A721 if
necessary.
670 Left-hand door SP-H Door on left-hand side of heavy Close door; check door locking
part separator is not closed. system -A721 if necessary.
671 Door SP-H waste Door to waste compartment of Close door; check door locking
compartment heavy part separator is not system -A720 if necessary.
closed.
672 Door EM waste Door to waste compartment of Close door; check door locking
compartment metal and spark separator is not system -A751 if necessary.
closed.
673 Extraction SP-H Extraction flap in heavy part sep- Check extraction flap.
arator has not reached the re-
quired positions.
690 SP-H wheeled waste Wheeled waste container of Empty wheeled waste container;
container full heavy part separator is full. clean light barriers -A724 and
-V724 if necessary.
691 EM wheeled waste Wheeled waste container of Empty wheeled waste container;
container full metal and spark separator is full. clean light barriers -A754 and
-V754 if necessary.
692 Metal detector Metal detector detects metal Check and clean material duct
over an extended period of time. of metal detector.
694 Safety installation EM Safety system of metal and Have safety system checked by
spark separator has been qualified personnel.
interrupted.
695 Metal initialization Metal detector is not ready for Check metal detector -A740.
operation. Check automatic circuit breaker
-F030.
696 Compressed air Preventing Preventing pressure control Check compressed-air supply to
switch does not switch. machine; possibly check setting
(1 bar) of pressure control
switch -S755.
697 Safety loop EM Safety circuit of metal and spark Have safety circuit checked by
separator has been interrupted. qualified personnel.
699 Extraction flap EM Extraction flap in metal and Check extraction flap.
spark separator has not reached
the required positions.
700 Extraction flap EM The extraction flap in the metal Service extraction flap.
Maintenance and spark separator must be
serviced within the next few
days.
701 Extraction flap EM Output Output of extraction flap in metal Have output checked by
and spark separator has oc- qualified personnel.
curred too late or not at all.
714 Pushbutton SP-H waste Illuminated push-button key next Acknowledge fault; check
compartment to door to waste compartment of push-button.
heavy part separator has been
pressed too long (20 seconds).
715 Fire protection Fire warning centre is not ready Check power supply to fire
for operation. warning centre; acknowledge
fault on fire warning centre.
716 Fire detected Heat detectors in waste Wait until fire has been extin-
compartment or spark detector guished, then empty wheeled
signal fire. waste container of metal and
spark separator and acknowl-
edge fault (also see sections
Fire in wheeled waste container
and Spark detection from
page 50).
717 Maintenance flap BR-FD Maintenance flap of fan is not Close maintenance flap;
closed. check closing mechanism -A103
if necessary.
718 Safety loop BR-FD Maintenance flap of fan could Close maintenance flap;
not be locked. check closing mechanism -A103
if necessary.
When the heat sensors detect a fire in the waste 3. When the lamp in the push-button is lit con-
compartment of the metal and spark separator, tinuously, the door is no longer locked. Now
the fire warning centre triggers a fault. The fault open the door with a suitable key.
is also indicated on the display of the operating
4. Open the door fully and pull the wheeled
unit, and the warning siren sounds.
waste container out straight.
The machine is switched off immediately. The fire
5. Push the empty wheeled waste container
warning centre usually transmits the fire alarm to
straight into the waste compartment until it
the higher-level installation control, which then
noticeably touches the back wall of the
also switches off all the other machines of the
waste compartment. A magnet on the back
line.
wall holds the wheeled waste container in
The extinguishing operation starts immediately place.
and automatically. The contents of the CO2 cylin-
6. Close the door and lock it with the key. The
der are completely emptied into the wheeled
door safety lock is automatically reactivated.
waste container in the process. The CO2 extin-
guishes the fire, and the contents of the wheeled
waste container cool down rapidly to the point of Replacing CO2 cylinder
freezing.
All doors of the multi-function separator are kept DANGER OF FIRE
closed by the control system for about 5 minutes Never operate the multi-function sep-
arator without a filled CO2 cylinder.
to prevent any injuries in connection with the ex-
tinguishing operation. Afterwards you can open If the CO2 cylinder has been emptied,
the waste compartment door of the metal and replace it immediately with a new,
spark separator, empty the wheeled waste con- completely filled cylinder.
tainer and replace it with an empty wheeled
waste container. If the extinguishing operation has been triggered
by the fire warning centre, the CO2 cylinder will
have been completely emptied in the process. In
Replacing wheeled waste containers this case remove the empty cylinder and replace
The machine can only be switched on again after it immediately with a new, filled cylinder.
the wheeled waste container has been replaced. The chapter Repairs from page 74 of this operat-
ing and service manual describes in detail how
FROSTBITE HAZARD to replace the CO2 cylinder.
The extinguishing operation causes
the waste compartment, the wheeled
waste container and its contents to
cool down enormously. Extended con-
tact may lead to frostbites. Wear pro-
tective clothing (heavy gloves) as an
insulation.
Spark detection
When the spark sensors detect a spark or a 1. Press the fault key on the operating unit to
smouldering fire in the air duct, the fire warning acknowledge the fault. The fire warning
centre triggers a fault. The fault is also indicated centre is reset after approx. three minutes.
on the display of the operating unit.
2. Briefly press the illuminated blue push-but-
The machine is switched off immediately. The fire ton key on the left of the door to the waste
warning centre usually relays the detection of a compartment of the metal and spark separ-
spark to the higher-level installation control, ator. The lamp in the push-button starts to
which then also switches off all the other ma- flash.
chines of the line.
3. When the lamp in the push-button is lit con-
The quick closing flap of the metal and spark tinuously, the door is no longer locked. Now
separator opens immediately whenever a spark open the door with a suitable key.
has been detected. The flap remains open;
4. Open the door fully and pull the wheeled
therefore the door to the waste compartment is
waste container out straight.
kept closed by the control system to prevent any
injuries in connection with the quick closing flap. 5. Push the empty wheeled waste container
The door is only released again after the fire straight into the waste compartment until it
warning centre has been reset. That reset is trig- noticeably touches the back wall of the
gered by acknowledgement of the fault on the waste compartment. A magnet on the back
operating unit of the machine. A reset is possible wall holds the wheeled waste container in
after approx. three minutes. place.
After resetting the fire warning centre open the 6. Close the door and lock it with the key. The
waste compartment door of the metal and spark door safety lock is automatically reactivated.
separator, empty the wheeled waste container
and replace it with an empty wheeled waste con-
tainer.
DANGER OF FIRE
Waste compartment door
Empty the wheeled waste container opened
whenever a spark has been detected
to avoid any fire developing later in the The doors to to the waste compartments are
wheeled waste container. usually opened to remove one of the wheeled
waste containers and to replace it with an empty
After the detection of a spark empty
wheeled waste container. The door then has to
the wheeled waste container in such a
be closed again immediately. If no more than
way that any danger of fire is ruled
3 minutes pass between the opening and the
out. Ensure that the material contains
closing of a waste compartment door, operation
no source of fire.
will not be interrupted, and/or the fan will start
again automatically.
If one of the doors remains open longer, the ma-
chine control will trigger a fault, and the machine
must be switched on by hand after closing of the
respective door and acknowledgement of the
fault.
Warning messages
The following table gives you an overview of
possible warning messages of the Multi-Function
Separator SP-MF. The possible cause of each
warning message is briefly described, and you
are given instructions for the recommended pro-
cedure.
Change wheeled waste Wheeled waste container of Empty wheeled waste container
container SP-H heavy part separator is full and immediately and replace it with
must be emptied. an empty wheeled waste
container.
If the wheeled waste container is
not emptied within the preset
time, the machine control will
automatically trigger a fault,
thus stopping the machine
(see function 40, page 39).
Change wheeled waste Wheeled waste container of Empty wheeled waste container
container EM metal and spark separator is full immediately and replace it with
and must be emptied. an empty wheeled waste con-
tainer. If the wheeled waste con-
tainer is not emptied within the
preset time, the machine control
will automatically trigger a fault,
thus stopping the machine
(see function 40, page 39).
Metal recognized Having detected metal, the Metal and fibres are automati-
metal sensor automatically cally discharged into the
triggers the quick closing flap of wheeled waste container.
the metal and spark separator. Operation is not interrupted.
The flap is opened and closed The operator need not inter-
again. vene.
Notes
The following table gives you an overview of
possible instruction texts of the Multi-Function
Separator SP-MF.
Those texts give you information about the status
of the machine or about individual components
or functions (e.g. open doors). Intervention by
the operator is usually not necessary. Neverthe-
less, pay attention to the displayed texts to in-
form yourself about the condition of the machine.
TKN network not active TKN network not switched on Switch on TKN network if
(P87). necessary (P87).
Drives on installation switched Drives of higher-level installation Stop switching off drives of
off switched off. higher-level installation if
applicable.
Drives are slowing down --- The drives have not yet stopped;
the doors cannot be opened. It
takes the fan approx. 3 minutes
to come to a stop; then the
doors can be opened, if desired.
Drives slowing down Service has been switched on, Error in the safety system. The
SERVICE on but the machine has not yet service switch is located behind
come to a standstill. a closed door and can only be
operated after the machine has
stopped.
SERVICE OFF The service mode has been Wait until the drives are
Please wait terminated; the drives have not stationary.
yet come to a standstill.
Enable door SP-H of waste Door locking system for waste The door can now be opened.
compartment compartment of heavy part sep-
arator has been deactivated.
Waste compartment --- Release of the door has been re- Wait until the material flow is
door EM please wait quested by pressing the illumi- interrupted and the door locking
nated blue push-button key next system is deactivated.
to the door to the metal and
spark separator.
Enable door EM of waste Door locking system for waste The door can now be opened.
compartment compartment of metal and spark
separator has been deactivated.
Activation metal detector The metal detector is being Wait until the instruction text dis-
checked for its proper oper- appears. If the metal detector is
ational condition. not ready for operation, a fault
message will be displayed.
Metal detection deactivated! The metal detector has been Any metal in the material will be
deactivated by connecting neither detected nor discharged.
24 V DC (L+1) to input Z10
(-A031:X10/3).
Fire Warning Centre The fire warning centre has No sparks will be detected; any
deactivated! been deactivated by connecting fire in the waste compartment of
24 V DC (L+1) to input Z11 the metal and spark separator
(-A031:X10/4). can be neither detected nor ex-
tinguished.
Maintenance flap BR-FD Maintenance flap of fan is open. Close maintenance flap.
The LEDs of the electronic modules in the switch Generally speaking, red lamps indicate a fault.
cabinet can provide additional indications of Green lamps indicate normal operation of a com-
faults or malfunctions to aid in trouble shooting. ponent.
1 Frequency converter
2 Miniature control system/central processing
unit KSZ4
3 I/O module DEA1
Frequency converter
The frequency converter serves to control the fan
motor. It has six LEDs (1), which are arranged
one below the other and can assume different
states. The respective combination of illuminated
and flashing LEDs provides Trützschler’s after-
sales service with important information on oper-
ating states or possibly even malfunctions.
Z1 ---
Z2 ---
Z3 ---
Z4 ---
Z5 “Machine OFF” from EGS
Z6 “Machine ON” from EGS
Z7 “Material transport active” from EGS
Z8 Metal detector ready for operation
Z9 Metal detector: no metal
Z10 Metal detector not available
Z11 Fire warning centre not available
Z12 Fire warning centre ready for operation
Z13 Fire warning centre: no fire
Z14 Fire warning centre: no sparks
The I/O module DEA1 is located on the central E5.0 Safety system OK
processing unit KSZ4 and switches the inputs
E5.1 Normal operation
and outputs of the Multi-Function Separator SP-
MF. E5.2 Left-hand middle door open
E5.3 “Ready for operation” from EGS
E5.4 Door of EM waste compartment closed
E5.5 EM safety system OK
E5.6 EM discharging sparks or metal
E5.7 EM quick closing flap closed
Maintenance
This chapter describes measures intended to
maintain or restore the nominal condition of the
machine. Maintenance includes inspections,
servicing and repairs.
Service
Service mode All the required inspection and service measures
must be performed in accordance with the
There is a service door on the left-hand side of national regulations applying to the installation
the machine. The key-operated switch for the site.
service mode is located behind this door.
Through the service door you get into the interior
of the machine, where further flaps for cleaning Maintenance schedule
the air ducts above the quick closing flap and in
The maintenance schedules on the following
the heavy part separator are located and from
pages provide you with a quick overview of the
where the metal detector and the quick closing
maintenance and cleaning operations to be per-
flap of the metal and spark separator can be re-
formed regularly on the machine.
ached.
The purpose of this work is to preserve the safety
Opening of the service door prevents the quick
and optimum operating state of the machine.
closing flap of the metal and spark separator
Therefore be sure to perform these operations
from being triggered.
with utmost care.
When an authorised person has switched on the
service mode with the key-operated switch, all Note
door locking systems are released and all safety Below the maintenance schedule indi-
limit switches overridden. vidual operations are again described
in detail.
On a higher level the external emergency stop
circuit has a disabling effect also in the service
mode.
General instructions
The Multi-Function Separator SP-MF must reg-
ularly be serviced by competent personnel so
that it will permanently and cost-efficiently func-
tion as intended under the conditions that can be
expected on the basis of the intended mode of
operation.
The operating company has to lay down the re-
quired service and inspection measures in the
form of working instructions, depending on oper-
ating conditions and experiences.
Every 6 months
Every months
Every week
Every week
Driving motor (1) Clean motor ventilation cowl
Filter sieves (2) Remove fibre accumulations
Light barriers of wheeled waste containers (3) Clean lenses and acrylic glass with soft cloth
Comb profile (4) Clean
Every month
Frame wall, interior (5) Clean
Flap seal of heavy part separator (6) Clean
Waste compartment area (7) Clean and inspect visually
Outer machine panelling Clean
Every 6 months
Spark detector, heat detector,
fire extinguishing system (8) (See annex: manufacturers’ documentation)
Filter screen cartridge (9) Wash
Extraction flap (10) Clean
Driving motor, gearing (11) (See annex: manufacturers’ documentation)
Every 6 months
Every months
Every week
Every week
Switch cabinet (12) Clean (qualified personnel)
Filter pressure controller (13) Drain condensate
Light barriers of wheeled waste containers (14) Clean lenses and acrylic glass with soft cloth
Every month
Frame wall, interior (15) Clean
Outer machine panelling Clean
Every 6 months
Spark detector, heat detector,
fire extinguishing system (16) (See annex: manufacturers’ documentation)
Metal detector (17) (See annex: manufacturer’s documentation)
Cleaning fan
Chips or metal particles may be deposited in the
fan casing. The drive shaft may also become
dirty. The fan has a maintenance flap secured by
one knurled screw. In addition, the maintenance
flap is protected against opening during oper-
ation (running fan) by a safety locking device.
After switching off the machine you can open the
maintenance flap as soon as the fan has come to
a standstill.
1. Loosen the knurled screw by hand.
The screw is secured to prevent it from
falling out.
2. Open the flap and fold it over to the side.
3. Clean the fan interior and the fan wheel and
check them for damage.
4. Remove any dirt from the drive shaft.
5. Clean the flap seal.
6. Close the flap and tighten the knurled screw
by hand.
Removing fibres
The filter sieves in the metal and spark separator
are visible and freely accessible after the door to
the waste compartment has been opened.
The filter sieves on either side of the air separator
are accessible from the outside through mainten-
ance flaps. Usually there are inspection windows
in the flaps through which you can see the filters
and judge the degree of clogging.
Caution
The filter screen cartridges may only
be removed and installed with the
machine switched off.
Be sure to always put down and se-
cure the heavy side walls and the filter
sieves in such a way that they cannot
fall over or fall off the machine.
Caution
Only use a soft cloth for cleaning the
lenses and the windows. Take care
not to scratch the lenses and the win-
dows.
Note
The flap seal can only be cleaned
with the flap open. Opening of the
flaps in the service mode is described
in the section Functional testing of
aggregates, page 71.
On the operating unit you can now successively Extraction flap of heavy part separator
select the two extraction flaps and the fan for en-
ergisation. To this end, you have to press key- 1. The message Check extraction flap SP-H?
YES each time. If you press key NO, the next is shown on the display of the operating unit.
service step will be displayed for selection. 2. Press key YES. The display shows the text
To change to normal operation you have to Extraction flap SP-H. The red LED over
switch off the service mode with the key-oper- key 0 lights up; the yellow LED over key I
ated switch. Only after that all automatic safety flashes.
functions will be active again. You can then 3. Press key I: The extraction flap is opened
switch the machine on again. and remains open. The red LED over key 0
1. Set the key-operated switch to position 0 to flashes; the yellow LED over key I lights up.
terminate the service mode. 4. Press key 0: The extraction flap is closed
2. Remove the key and close the service door. again. The red LED over key 0 lights up; the
yellow LED over key I flashes.
Extraction flap of metal and spark separator 5. Press key R to switch to the next service
step. Or press key CE to switch to the previ-
1. The message Check extraction flap EM? is ous step.
shown on the display of the operating unit.
2. Press key YES. The display shows the text Fan
Extraction flap EM. The red LED over key 0
lights up; the yellow LED over key I flashes. 1. The message Check BR-FD? is shown on
the display of the operating unit.
3. Press key I: The extraction flap is opened
and remains open. The red LED over key 0 2. Press key YES. The display shows the text
flashes; the yellow LED over key I lights up. BR-FD 0%. The yellow LED over key I
flashes.
4. Press key 0: The extraction flap is closed
again. The red LED over key 0 lights up; 3. Press key I and hold depressed (inching
the yellow LED over key I flashes. mode): The power supply for the frequency
converter is switched on. The yellow LED
5. Press key R to switch to the next service over key I lights up.
step.
After a ready-to-operate message from the fre-
quency converter the fan is enabled and the fan
setpoint activated. The readout on the display
switches from 0% to 100%.
4. Let go of key I: The setpoint for the fan is
cancelled. The yellow LED over key I
flashes.
5. Press key R to switch back to the first ser-
vice step. Or press key CE to switch to the
previous step.
Repairs
General instructions
Any defective element of the machine must no
longer be used and must be replaced with an
equivalent one.
For example, this applies to:
– worn, cracked or bent screws and locks,
– damaged nuts or threads,
– bent clamps or bows,
– damaged seals,
– damaged danger signs and instructions.
All the required repair measures must be per-
formed in accordance with the national regula-
tions applying to the installation site.
DANGER
Any repair work not described in this
operating and service manual may
only be carried out by Trützschler’s
after-sales service.
Improper repair work may cause haz-
ards to people and serious damage
to the machine.
Note
Always keep an operational, filled CO2
cylinder on stock to avoid prolonged
downtimes of the machine.
EXPLOSION HAZARD
Protect the steel cylinder from direct
solar radiation!
Note
Read the section Preparing new cylin-
der on page 77 on how to prepare a
new cylinder for filling without an as-
cending pipe having been fitted.
DANGER OF INJURY
Use only CO2 cylinders conforming to
the technical specifications (see from
page 81 of this operating and service
manual). The use of non-conforming
cylinders may cause serious injuries
and damage to the machine.
7. Remove the clamping tool and put it back Replacing fluorescent lamp
in the mount in the housing wall of the ma-
chine, behind the cylinder. A damp-proof luminaire lighting the material fly-
ing through the air duct of the heavy part separ-
8. Put the tripping device on the ascending ator is installed inside the heavy part separator
pipe valve and secure it with a screw, on the left-hand side of the machine.
a washer, a snap ring and a lock nut.
9. Finally pull out the safety pin (5). ELECTRIC SHOCK HAZARD
Do not perform any work on electric
DANGER OF FIRE lines or electrical connections. Work
The safety pin prevents the valve from on electric lines may only be per-
opening. The fire extinguisher will only formed by trained specialist person-
work if the safety pin has been pulled nel complying with all regulations.
out.
Access to the luminaire is through the service
door on the left-hand side of the machine. This
door is locked and can only be opened while the
machine is at a standstill.
Preparing new cylinder
1. Open and remove the cover of the luminaire.
DANGER OF INJURY
2. Take out the defective lamp and replace it
Use only CO2 cylinders conforming to
with a new lamp.
the technical specifications (see from
page 81 of this operating and service 3. Carefully put the cover back on the luminaire
manual). The use of non-conforming again, making sure that the cover does not
cylinders may cause serious injuries become canted and that the seal is not dam-
and damage to the machine. aged.
4. Lock all closing devices of the cover again.
If you want to use a new CO2 cylinder, you will
first have to install the ascending pipe included in
the scope of supply of the machine.
The ascending pipe is located in the position of
the CO2 cylinder when the machine is delivered.
Use a suitable sealing tape when installing it.
After installing the ascending pipe, have the cyl-
inder filled in accordance with the technical spec-
ifications (see from page 81 of this operating and
service manual).
Annex
Technical data
General notes
Dimensions see drawing in section Machine dimensions
Inner frame width 1,000 mm
Total weight 3,800 kg
Specific floor load 6,314 N/m2
Surface pressure per pedestal max. 158 N/cm2
Compressed air requirements 74 Nl/h
Material quantity in permanent
production max. 1,500 kg/h
Fan
Model BR-FD 500
Type three-phase A.C. motor
Drive direct drive with frequency control
Operating voltage 400 V, 82 Hz
Rating 9.0 kW
Continuous power consumption max. 6.5 kW
Speed range 800–2,240 min --- 1
Torque 36 Nm
Output capacity (air volume) max. 7,500 m3/h
Output capacity (material) max. 1,500 kg/h
Material feed
Material quantity max. 1,800 kg/h
Air intake rate 5,500 m3/h – 7,300 m3/h
Material suction
Material quantity max. 1,800 kg/h
Air intake rate 4,000 m3/h – 6,500 m3/h
Dust extraction
Exhaust air output 1,500 m3/h – 3,300 m3/h
Dust throughput max. 0.3 kg/h
Metal detector
Detector coil Mesutronic Metron 05 PowerLine
Electronic evaluation system Mesutronic AMD 05
Machine dimensions
Gas cylinder
Medium CO2
Steel cylinder to directive 1999/36/EC,
labelled according to TRG 270, No. 8
(German Code of Practice for Compressed Gas Cylinders)
Surface RAL 7011 or RAL 7037
Cylinder valve type K85-20.0-S9
Collar, base DIN 4664
Protective cap DIN EN 962
Valve thread DIN EN 962-1, 25E
Cap thread DIN EN 962, W80
Cylinder filling filled according to German Pressure Vessel Code
Cylinder pressure approx. 60 bar
Test pressure 250 bar
Filling tolerance in accordance with legal provisions
Nominal volume 13.4 l
Filling quantity 10 kg
Weight without filling 17 kg
Weight with filling 29 kg
Dimensions (L × ∅) 1,220 × 140 mm
H Maintenance work, 11
Malfunction indication , 45
Heavy part separator, 15 , 17 Malfunctions, 24 , 45
Housing fan, 20 Master switch, 13
Housing filter, 20 Material flow, 16 , 33
Menu , 25
I Metal separator, 15
I/O module , 59
Injuries, 13 N
Inputs/outputs, 59 Network address TKN (function), 42
Inspection, 31 Number of fault message , 46
Inspection windows, 33
Instruction texts, 53
O
Operating and service manual
K Conventions, 8
Further information, 7
Key---operated switch Purpose, 7
Operating unit, 24 Symbols, 8
Service, 14 , 61
Operating unit, 21 , 22
Keyboard, 22
Operating unit navigation , 25
Keys, 25
Operation , 30
KSZ4, 56 , 58
Overview
Fault messages , 46
Function, 16
L Function numbers, 38
Instruction texts, 53
Lamp, 77
Maintenance and servicing, 62
Lamp test (function), 39 Operating elements, 21
S Testing aggregates, 71
Testing extraction flaps, 71
Safety equipment, 13 TKN address (function), 42
Safety measures , 10 Transport fan, 16
Screen cartridges, 65 Trouble shooting, 56
Selection of language (function), 42 Type plate, 9
Separation of metal, 18
Service, 61
Manufacturers’ instructions , 73 U
Service door, 61 Underpressure, 34
Service interval EM (function), 42 Use, 9
W
Warning messages, 52
Warning plates, 10
Warnings, 24
Waste compartment door , 51
Waste compartment doors , 31
Wheeled waste containers, 19
Work safety regulations, 10
Working memory (function), 38