涂油机说明书

OPERATING INSTRUCTIONSPRAY CHAMBEREOS III – PC – 4100SATG - FORD - CAF05-00105-001Accompanying documents:Declaration of conformityInstructionIssue RegisterContents 00 0 General notes 00 1 General safety instructions 00 2 Technical data and 00 3 technical descriptionPackaging, transport and 00 4 storageSetting up and installation 00 5 Commissioning and operation, 00 6 taking out of serviceMaintenance and repair 00 7 Spare parts and parts lists 00 8 Drawings and plans 00 9 Purchased parts 00 1005-001EU Manufacturer´s Declarationaccording to Appendix II A of the EU Machinery Directive (98/37/EG)The manufacturer:E ckardt Umformtechnik GmbHWestliche Gewerbestrasse 2D-75015 Brettenherewith declares that the machine describedbelow:Spray chamber EOS 3 - 4100 PCaccording to drawing No.: 109745-3is a machine ready for use within the meaning of the EU Machinery Directive and corresponds to the requirements of this directive. Commissioning the plant is not allowed until it is determined that the total plant in which it is integrated corresponds to the EU Machinery Directive! Applied EU directives:0 98 / 37 / EWG1 73 / 23 / EWG 0 Machinery Directive1 Low Voltage DirectiveApplied harmonized standards:2 DIN EN 602043 DIN VDE 0470 – 14 DIN EN 4145 DIN EN 10502 Safety of machines, electrical equipment4 Types of protection by housing5 Safety of machines, possible hazard6 Safety of machines, causes of hazardDesign changes which have effects on the technical data stated in this product description and the use as intended, there fore essential changes, make this declaration of conformity invalid!Bretten, 14. April 2005Jochen Eckardt, Managing Director05-001Instruction No.:I here with confirm by my signature that I was instructed before starting work on the spray chamber.I have read and understood the operating instructions and especially the safety instructions.Remarks SignatureDate Name Department Plannedwork05-0011. General notesThese operating instructionsare directed without exception to all persons who have to do with the transport, setting up, the installation, the operation, the maintenance, the repair or storage of the spray chamber andshould simplify for them all work in connection with the spray chamber andmake them familiar with the principles and mode of operation of the spray chamber.It contains important technical information about the spray chamber andimportant notes in order to operate the spray chamber safely, correctly and as intended.These operating instructions comprise only the operation of the spray chamber, but not the installation and operation of the total plant or fault rectification of the purchased parts. Please refer to the original descriptions of the manufacturers in Chapter 10 …Purchased parts and conveyor systems“ and the operating instructions of the total plant for the corresponding information.These operating instructions with all enclosed illustrations, plans and drawings are protected by copyright and must not be neither duplicated nor made accessible to third parties in the original or as copy without our approval.Before commissioningRead the operating instructions completely before installation or commissioning.Confirm on the enclosed form that you have read and understood the operating instructions and especially the safety instructions!Keep this operating instructions carefully.Liabilities of any type can not be accepted by the manufacturer if these operating instructions were not read or observed!File the operating instructions for the spray chamber together with the associated technicaldocuments at an easily accessible place!Inform the operating and maintenance personnel concerning the obligation to read theinstructions as well as where the instructions are kept!You can reach us at:Eckardt Umformtechnik GmbHWestliche Gewerbestrasse 2D-75015 BrettenTelephone 0049 72 52 / 94 20 - 0Telefax 0049 72 52 / 94 20 - 18E-Mail j.eckardt@Internet www.eckardt-gmbh.de05-00105-0012. General safety instructions2.1 Warnings and symbols usedThe following symbols are used in these operating instructions:Caution! Directly threatening danger for life and limb!Possibility of the hazard!Dangerous situation! Possibility of personal injury and material damage!Required procedure! Corresponding to the circumstances to prevent injuries.Observe the safety instructions! Confirm on the form that you have read and understood the operatinginstructions and especially the safety instructions!2.2 Protective clothingWear protective clothing. Adapted to the circumstances.Wear protective eye - glasses. Adapted to the circumstances.2.3 ScopeThe general safety instructions (Section 2.5) apply to the same extent for all personnel who have to do with the transport, setting up, installation, operation, maintenance, repair or storage of the spray chamber. In addition further safety instructions must be observed for certain persons or activities. These safety instructions are named in this chapter as well as in the description of the corresponding activity.The purpose of the safety instructions is to keep residual risks for persons and material assets as low as possible!2.4 Use as intendedThe blanks are oiled on both sides in a continuous process with the spray chamber. For this purpose the blanks are loaded and unloaded by belt conveyors.The spray chamber must be used exclusively for oiling blanks with suitable dimensions.(see Chapter 3, …Technical data“).Any use extending beyond this, especially spraying unsuitable materials, is not as intended. The manufacturer is not liable for damage resulting from this.The risk for this is borne solely by the user.Compliance with the operating, maintenance and repair regulations prescribed by the manufacturer also belongs to use as intended.The relevant accident prevention regulations, as well as the other generally recognized safety, labour medical and road traffic rules shall be complied with.Unauthorized changes to the machine exclude liability of the manufacturer for damage resulting from them. 2.5 General safety instructionsSafety is basically a matter of your knowledge and your experience! There are generally valid safety rules which must always be observed! Moreover every situation has its own special features that are not always described in the safety regulations! Always look out for safety risks and problems! Work far sightedly and remove sources of danger on time!Keep this operating instructions at a place that is accessible at any time and together with the associated technical documents! Inform all persons authorized to work on the spray chamber concerning the obligation to read the instructions and the place where the instructions are kept!Read the operating instructions completely before working with the spray chamber! Observe the safety instructions and instructions in these operating instructions when working with the spray chamber! Otherwise you endanger your health and that of other persons!05-00105-001Working with the spray chamber is permitted only for correspondingly qualified and instructed skilled personnel! Make sure that no unauthorized persons stay in the working area of the spray chamber!All persons involved must be healthy and fulfil the physical requirements! It is strictly forbidden to work under the influence of drugs, alcohol, medicaments or other agents changing the consciousness!Caution! No open fire in the area of the plant. Danger of explosion and fire due to cleaning agents, solvents and oil residues. Easily combustible mixtures can form in combination with oxygen.Possibility of danger due to stumbling or slipping during work!Wear suitable working clothes, adapted to the circumstances! Thus you reduce the risk of injury!Inform yourself regular about the position and use of fire extiguishers or other means for fire fighting!Keep order at the workplace! Remove especially residual material and lubricant residues immediately from the floor! Risk of slipping!Proceed carefully with lubricants (oils, greases)! Prevent by suitable measures spilling or swallowing, as well as skin or eye contact! Send lubricant residues for recycling! Prevent lubricants getting into the ground or the sewage system! Danger of environmental contamination!Observe the safety regulations valid at the location of use required by the relevant legislation or professional associations and comparable institutions and add to these operating instructions ifnecessary or issue working instructions.05-001Possibility of danger due to the spray medium / oil type!Observe the manufacturer‘s safety data sheets and handle with the spray media / oil type in the prescribed form. The handling with the spray media / oil type is only on-machine / plant part of the description.2.6 Safety devicesThe safety devices are not part of the scope of supply. The operator of the plant has to ensureprotective fences, light grids and EMERGENCY OFF devices. These must be integrated into the safety concept of the total plant. Without protection an essential aspect of the EU declaration of conformity is infringed and makes this thus ineffective.Existing safety devices:At the control cabinet / control console of the machine / plantCaution! Possibility of injury due to stumbling or slipping with restricted freedom of movement in the working area!Caution! Ensure sufficient ventilation in repair and maintenance work with cleaning agents and solvents! The spray chamber must not be manually loaded and unloaded. Because of the throughput speed severe impact and cutting injuries can arise.Caution! Grabing into the machine in the area of the loading and unloading point of the blanks is not permitted in operation.2.7 Residual riskDue to the design of the spray chamber no protective cages are fitted at the loading and unloading points of the blanks. There fore grabing into the machine is possible in the set-up mode and in maintenance work. This can lead to injuries.Caution! Loading and unloading of blanks permitted only using conveyor belts. No manual loading and unloading.DANGERDANGER3. Technical data and technical description3.1 Technical dataDimensionsSpray chamber overallLength (in transport direction)approx.1045mmWidth approx.7280mmHeight approx.2880mm Control cabinetLength approx.1250mmWidth approx.600mmHeight approx.2200mm Control console integrated in the control console of the plantLength approx600mmWidth approx250mmHeight approx800mm Weight3000kg Spray chamber overall, without control cabinet approx.max.Inlet height ( blank loading )1400mm Adjustment over frame min.+ / - 10 mm ThroughputSpeed approx.180m/min Loaded blanksPassage width approx.4300mm Die plate width approx.4100mm Die plate length approx.2200mm Spray chamberSpray bars ( top / bottom )2Spray nozzles per bar41Lubricant dosing1-5g/m²Spray air pressure ( top / bottom, differently adjustable )0,2-3bar Application of the lubricant , spray field width approx.100x100mm Lubrication patterns ( top / bottom )separately adjustable LubricantsNumber of oiltypes1Oiltype PL 3802-39 Fuchs at 40°mm²/s Supply from casks with double diaphragm pumps05-0013.1 Technical data ( continuation )Filter plant ( 2 pieces )Suction capacity approx.3000m3/h Filter stages5Separating capacity approx.98% Elektrical systemConnection voltage400VAC Nominal current15A Line frequency50Hz Protective class ( spray chamber inside / spray chamber outside )IP 67 / IP65 Pneumatics ( compressed air supply )Air pressure5bar Air quality unoiled ClimateStorage temperature-25 °C to +60 °C Working temperature 1 °C to +38 °C Air humidity96% at 35°C05-0011 23.2 Construction and functionThe spray chamber is used for the section-by-section oiling of blanks passing through a closed chamber. The blanks are loaded and unloaded by belt conveyors (not part of the scope of supply).During the passing through the spray chamber the blanks are fixed and transported by conveyor belts and oiled according to specified set-ting. The lubrication patterns are set and controlled by a PC or the operating unit of the overall plant.Oiling takes place in a chamber closed except for the inlet and outlet opening. Two adjustable spray nozz-le bars (one each top and bottom) with 41 switchable spray nozzles guarantee a uniform and reproducible spraying result. When thick and higly viscous oils are used, the medium can be heated by the heating in the oil supply bar.The oil supply is from casks. By means of a suction lance and an air operated diaphragm pump the mediumis delivered into the storage tub in the spray chamber. Out of there the medium is pumped by an air operated piston pump through pressure tanks to the spray nozzles.Different lubricant pressures and spray air pressures can be applied to the spray nozzles. In this way the appli-cation quantity and degree of atomization can be influenced.The surplus of oil mist is kept back in the spray chamber by an oil mist separator and separated in a filter. Sur-plus of oil from the walls of the spray chamber runs back into a collecting tank.For maintenance and repair purposes the spray chamber can be driven out of the press working line with a pneumatic drive on standstill of the overall plant.The different stations of the plant and their functions are discussed briefly below. The processes are described with commissioning.The transport of the blanks is ensured by conveyorbelts (1) with round belts (2). The conveyor belts areattached in distances of 100 mm (cross to transportdirection).05-0013 455 6The conveyor belts are driven by a gear motor whichactuates a central drive shaft (3). For every belt adriving wheel (4) is seated on the shaftThe lubrication on both sides occurs by the upper andlower spray nozzle bar (5). The distance to the sprayplane is fixed. Each spray nozzle bar has 41 switchablespray nozzles (6).05-00105-001The oil supply of the spray unit happens by an air ope-rated diaphragm pump (7) and a suction lance (8) from casks into the storage tub (9) in the base frame. Filling by machine-control automatically.t.1110The upper and lower spray bar are supplied with oil by pressure tanks (10) and (11). The pressure tanks are filled from the storage tub (9) with an air operated piston pump (12) through the double filter (13).For further information see the pneumatic plan in chap-ter 9.The pressure tanks are admitted with compressed air.The air pressure is controlled by the pressure re-ducer (14) and (15). By changing the pressure the applicated oil quantity is appointed. The pressure can be controled and adjusted manually.05-00133The spray air supply (main air) consists essentially of the electrical starting valve (30), the pressure control valve (31) and the pressure switch (32).The units named above are mounted twice to supply the top and bottom spray nozzle bar.The spray air pressure is controlled by the pressure control valves (33) and (34). The setting is manually (basic setting factory preset).The higher the spray air pressure while spraying, the bigger the deve-lopment of oil mist!! This can result in an emission of oil mist out of the spray unit!An increase of oil mist means that the filters of the oil mist seperatorsclog and have to be changed !!05-001OIL PRESSURETOPOIL PRESSUREBOTTOMSPRAY AIR PRESSUREBOTTOM SPRAY AIR PRESSURETOP The function of the valve group (35) is shown in the pneumatic plan in chapter 9.05-001The pressure controller (40) presets the air pressure for the piston pump (41).The pressure is set by the manufacturer and should not be changed.The pressure controller (42) presets the air pressure for the diaphragm pump (7) for the storage tub filling. The pressure is set by the manufacturer and should not be changed.05-00149The pressure control-ler (44) presets the airpressure for the pneumatic motor (45) of the drive unit. The pressure is set by the manufacturer and must not be changed , because this would also change the driving velocity.Actuating one of the twomanual valves (46) starts the driving movement.The parking position is fixed by a bolt (48). The position of the bolt is monitored by limit switches (49).05-001The oil mist is extracted from the chamber by two filter plants (50) through pipes (51). The air outlet is loca-ted at the top of the filter plant. Filters can be changed through the lateral maintenance doors (53).In maintenance work please observe the enclosed operating instructions in chapter 10.The condition of the filters can be assessed from the differential pressure before and after the multistage filter. Differential pressure meters (55) transmit permanently the contamination level of the two endfil-ter stages to the control system.Corresponding warning messages are indicated at the control display.The spray nozzles can be tested in a hand operated mode. This may happen for a single or for a group of nozzles. This occures with a key switch loated on the chamber. Corresponding to the chosen menu on the cont-rol panel a single or a group of nozzles can be selected.05-00105-001Automatic modeThe automatic mode is activated by the control system of the total plant.The spray process is activated by sensors (85) of the blank detection.Standstill of the spray chamberMaintenance, cleaning and repair work:Special care must be taken here that the electrical off switch on the control cabinet of the total plant is switched off and secured by a lock against unauthorized switching on.( See section 2.5, Safety devices )3.3 Operating modes05-0014. Packaging, transport and storageSafety instructionsObserve the general safety instructions (see Section 2.5)!Use exclusively means of transport and handling that are suitable for the transport task! Observe specially:The weight of the spray chamber must not exceed neither the permissible load of the means of transport nor of the means of slinging (see Section 3 …Technicaldata“)!Use only tested and technically perfect hoists, means of transport and slinging!Wear protective helmet, safety boots and working gloves in all work with hoists! Thus you reduce the risk of injury!Secure the spray chamber before transporting or changing position! Remove loose parts!Ensure that the means of slinging are fastened safely!Observe the maximum permitted spreading angle for chains and ropes!Always suspend the load horizontally and so that the centre of gravity is located vertically below the crane hook!Prevent the ropes slipping!DANGERNever walk or grip under raised or suspended loads! Danger to life!Lock the storage place and prevent access of unauthorized persons!The spray chamber is normally transported in completely assembled condition and if possiblestanding on timbers non-slipping,covered with weather-resistant foil (for transport in the open), if necessarypacked weatherproof in wooden crates (for overseas or long-distance transport).Always store the spray chambercleaned and conserved,protected against weather influences (humidity, large temperature fluctuations, extreme temperatures),so that dropping down, dropping over or tilting is excluded,if possible in buildings or containers kept closed to exclude the access of unauthorized persons.05-00105-001C r a n e g e a r - S t a t e m e n tn o c h a i n s5. Setting up and installationSafety instructionsObserve the general safety instructions (see Section 2.5)!DANGERSetting up and installation work may be performed only by trained skilled personnel!Prevent inadvertent start-up of the spray chamber during setting up and installation work! Always switch off the electrical safety switch on the spray chamber and lock this with a lock! Risk of accident!Before all work on the electrical system separate the spray chamber from the power supply (switch the main fuse off)! Never perform work on the electrical system of the spray chamber without previously checking for freedom from voltage! Risk of electric shock!Make the spray chamber pressureless before all work on the pneumatics! Risk of accident!Wear suitable working clothing, adapted to the circumstances! Thus you reduce the risk of injury!Release the spray chamber for operation only if all subassemblies are in correct condition and all safety devices and covers are installed and functioning!Subject the spray chamber annually to a detailed check! Record the test results in writing!05-00105-0015.1 Setting upThe spray chamber must be placed on a level and sufficiently loadbearing concrete floor in the rails provided on site. When choosing the installation location consider:the total mass of the spray chamber in the operationally ready condition,the position of the machines linked upstream and downstream, the position of the power and compressed air supply,the space requirement (including space requirement for operators and service work),leaving escape routes free.Proceed in installation as described below:Measure and mark out the installation location of the spray unit on the concrete floor!Set the completely installed spray chamber down on the marked place by means of hoist (see chapter 4, …Packaging, transport and storage“)!Align the spray unit by means of spirit level and levelling device using the wheel blocks and the adjusting elements exactly vertical and at the specified height.Fix the adjustment.After setting up and alignment you must connect the spray unit to the power supply, to the compressed air supply, to the oil supply and to the control unit.Further installation work is not required since the spray unit is delivered in completely assembled condition.5.2 Installation05-001341(The hose-connections differ in their form from those shown in the picture.)1Main air supply 12Main air supply 23Oil supply from the barrel4Air connection diaphragma pump from oil-supplyWork on the electrical system may be performed only by a trained electrician!Never perform work on the electrical system of the spray chamber without previously testing for free-dom from voltage!Close the control cabinet doors again after completion of the work! Risk of electric shock!Connect the feed cable in the control cabinet corresponding to the data of the electrical documentation! Electrical connectionThe connection is made with the enclosed ca-bles to the control cabinet of the total plant.Connect the control cables in the control cabinetcorresponding to the data in the electrical docu-mentation!Signal cable connectionWork on the control unit may be performed only by authorized and trained personnel!Further installation work is not required. The settings are made on commissioning!DANGERDANGER05-00105-0016. Commissioning and operating, taking out of serviceSafety instructionsObserve the general safety instructions (see section 2.5) and the residual risks (see section 2.6)!Inform yourself about the position of the OFF switch in the control cabinet and the EMERGENCY OFF switch on the control panel. Immediately take the spray chamber out of operation with the EMERGENCY OFF switch in hazardous situations!Never grab between moving parts! Risk of injury!Caution! Possibility of injury due to stumbling or slipping with restricted freedom of movement in the working area!Operate the spray chamber only if it is in a technically perfect condition! The spray chamber must have been released by the installation personnel before the first commissioning! Take the spray chamber out of operation immediately in case of damage and operating faults and inform the service personnel! Attach a sign …Caution, spray chamber defective“ to the control console, switch the electric safety switch off and lock the switch with a lock!When operating the spray chamber all safety devices and covers must be installed and functioning! It isstrictly forbidden to bridge over safety devices or restrict them in their protective effect in another way! Risk of accident!Wear suitable working clothing, adapted to the circumstances! Thus you reduce the risk of injury.Wear closely fitting clothing and no open long hair!Draw the attention of all persons who come into the vicinity of the machine !Use the spray chamber only within the sense of its use as intended! (see section 2.4).DANGER6.1 Operational control of the spray unitThe operation of the spray unit occures by the PC in the control panel and the settings of the oil- and spray-air pressures at the pneumatic- and oil-supply board.1Main switch Plant …ON“12key-operated switch PRESELECTION3Illuminated push button EINRICHTEN4Illuminated push button operational mode…AUTOMATIC“5Push button Nozzle test6Illuminated push button Disturbence RESETThe control keyboard is located on the control panel.05-00105-0016.2 Pressure setting6.2.1 Oil pressure = Oil quantityAdjust the oil pressure according to the requirement.For the top and bottom spray bar different pressures (oil quantities) can be adjusted.Oil pressure minimum = (0,3 bar)Oil pressure maximum = (6,0 bar)A rising oil pressure increases the application quantity !For the upper side and the lower side of the blank can be set different oil quantities.The oil quantity for the blanks upper side is controled by the pressure reducer (81.1) which changes the air pressure in the pressure tank (10).The oil quantity for the blanks lower side is controled by the pressure reducer (81.2) which changes the air pressure in the pressure tank (11).05-001Adjust the air pressure according to the requirement.The air pressure for the upper and lower spray bar can be adjusted separately.Air pressure minimum = (0,2 bar)Air pressure maximum = (3,0 bar)A rising air pressure makes the oil mist finer.The higher the spray air pressure while spraying, the bigger the deve-lopment of oil mist!! This can result in an emission of oil mist out of the spray unit!An increase of oil mist means that the filters of the oil mist seperatorsclog and have to be changed !!The air pressure and sowith the drop size (Fineness and distribution of the oil mist) are set manually at the pressure reducers at the right side of the pneumatic console.3Pressure reducer Spray air Setting drop sizes by changing the pressure Spray nozzles above 3.1Manometer Spray air Set pressure - drop sizeSpray nozzles above 4Pressure reducer Spray air Setting drop sizes by changing the pressure Spray nozzles below 4.1ManometerSpray airSet pressure - drop sizeSpray nozzles below6.2.2 Spray air pressure = Drop size = Degree of atomization6.10 Information on operationIn Operation the spray plant is controlled fully automatical by the control system. The operator has to fulfil the following tasks:Monitoring the quality of the performed spraying ( adjust as required )Monitoring the loading and unloading of the blanksMonitoring the supply media and the oil supplyRectification of faults6.11 Taking out of service6.11.1 Taking out of service due to dangerIn a hazard situation immediately operate the EMERGENCY OFF switch! Put the spray chamber back into operation only if the source of danger has been completely removed!The EMERGENCY OFF switches are located on the control panel of the total plant. The plant must be reseted and started up new.6.11.2 Switching off the spray chamberIn normal operation the spray chamber is controlled by the control system of the total plant. If you nevertheless have to switch the spray chamber off (e.g. for maintenance work), then proceed as followed:1. Switch off the total plant2. Switch off the main switch of the total plant3. Interrupt the compressed air supply6.11.3 Taking out of service for a longer timeShould the spray chamber not be used for a longer period, then proceed as followed:1. Switch the spray chamber off as described under section 6.3.2 …Switching off the spray chamber“2. Close or empty the oil circuit3. Separate the spray chamber from the compressed air supply ( close main valve )!4. Separate the spray chamber from the power supply ( switch off fuse )!4. Clean the spray chamber from dirt deposits and material residues!5. Cover the spray chamber if possible with a foil!05-001。