Operating Manual Small Conveyor Units Series KF and KR
Operating Manual for AViTEQ Small Conveyor Units KF and KR Intended Use The AViTEQ small conveyor units are used to l remove, transport, convey, measure out, and distribute small grain bulk goods and small parts. AViTEQ small conveyor units have a large range of applications and are used in almost all branches of industry, from automation technology to the construction of packaging machines. Please observe the other instructions regarding proper usage in Chapter 1.
Safety Notes You will find three different types of symbols in this operating manual which are intended to point out important information: DANGER! The DANGER warning describes procedures or conditions which could have dangerous or even life-threatening consequences for the person installing or using the equipment. You will find this information associated with procedures in which a danger of damage to equipment exists. This damage could also result in injury to personnel (e.g.
Operating Manual for AViTEQ Small Conveyor Units KF and KR DANGER! Non-sterile small conveyor units in applications in the pharmaceutical industry represent a significant health risk through the spreading of germs For this reason, only small conveyor units in the pharma version, with a surface that can be decontaminated and sterilized, may be used.
© 1999 AViTEQ Vibrationstechnik GmbH COPYRIGHT The AViTEQ small conveyor units of the KF and KR series, the VIBTRONIC controllers, and this operating manual are protected by copyright. Any reengineering of the units will result in criminal prosecution. All rights to this operating manual are reserved, including reproduction via photo mechanical, print, data or any other possible medium, as well as in translation.
Operating Manual for AViTEQ Small Conveyor Units KF and KR Chapter Contents General notices regarding this Operating Manual, our Conditions of Sale, the Warranty and the Intended Use of the small conveyor units 1 Transport, Storage, Extent of Delivery and Disposal 2 Here, you’ll learn all about the mechanical installation of the unit, the installation of working units, and the attachment to the base plate 3 Basics of the controller and its selection.
Contents CONTENTS 1 We are Partners. 1-1 1.1 1.2 1.3 1.4 1.5 1.6 About this operating manual ...............................................................................................1-1 Product liability and warranty..............................................................................................1-3 Field of application and intended use .................................................................................1-5 Installation and operating personnel............................
Operating Manual for AViTEQ Small Conveyor Units KF und KR 1 We are Partners. Chapter outline Although you might want to get started immediately with our small conveyor unit/drive, we would like you to read this chapter first. It provides a summary of the contents of the operating manual and settles our legal relationship as parties to a contract. 1 1.
We are Partners. – About this operating manual Definitions l Small conveyor drive: the compact drive block with the vibration system l Working unit: the actual conveyor unit (pipe, rail, or trough) l Small conveyor unit: working unit attached to the small conveyor (see Figure 1.1). l Controller: the separately shipped controller unit associated with the small conveyor unit that is used for connection to the AC mains. Figure 1.1 Versions of small conveyor units with different working units.
Operating Manual for AViTEQ Small Conveyor Units KF und KR 1.2 Product liability and warranty The small conveyor systems correspond to the current state of technology. Their specified functions have been tested prior to shipping. AViTEQ Vibrationstechnik GmbH carries out product and market research to aid further development and continuous improvement.
We are Partners. – Product liability and warranty for damage other than damage to the product subject to the contract is excluded except in cases of intent, gross negligence or culpable violation of significant contract obligations by AViTEQ Vibrationstechnik GmbH. Also, we do not accept liability for damage to conveyor and automation plants caused by a malfunction of the product or by mistakes in the content of the operating manual.
Operating Manual for AViTEQ Small Conveyor Units KF und KR 1.3 Field of application and intended use Field of application The AViTEQ small conveyor units may be used for removal, transportation, feeding, distribution, and measuring out of small grain bulk materials and small parts. The small conveyor units are not intended to be used for other purposes. Small conveyor units are used as components of conveyor and automation plants.
We are Partners. – Installation and operating personnel Connection to controllers The small conveyor units must only be connected to the AC mains via special VIBTRONIC controllers. A suitable controller exists for every version of the small conveyor drives and units. Other control and connection options are not included. If a small conveyor drive is connected directly to the AC mains or to an unsuitable controller, it may be destroyed.
Operating Manual for AViTEQ Small Conveyor Units KF und KR 1.5 Safety precautions and responsibilities of the operator l This operating manual is part of the small conveyor unit and must be available to qualified personnel at any time. l Qualified personnel must have appropriate tools and test equipment at their disposal. l Qualified personnel must be trained in safe work practices and must be familiar with the safety notes on pages 0-3 and 0-4.
We are Partners.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 2 Extent of Delivery, Packing, Disposal Chapter Outline For storage and transport, certain measures must be observed in order to prevent damage to the units. The contents of the delivery must be checked after unpacking. The packing material should be disposed of properly. What do you do with AViTEQ small conveyor units when you no longer need them? The return guarantee. 2.
Extent of Delivery, Packing, Disposal – Contents of delivery 2.2 Contents of delivery ã After unpacking, check that all parts are undamaged and complete according to the package slip and as stated on the cover sheet of the shipping documents.
Operating Manual for AViTEQ Small Conveyor Units KF and KR Cardboard containers and paper packing tapes can be recycled within the RESY Disposal and Re-utilisation System. Where used, packaging foil, packing tapes, and foam foils are made from polyethylene (PE), the CFC-free cushions are usually made from polystyrene foam (PS). These packaging materials consist of pure carbohydrates and are thus recyclable. In special cases, we use steel packing bands and wooden cases free of chemical treatment. 2.3.
Extent of Delivery, Packing, Disposal – Disposal 2–4
Operating Manual for AViTEQ Small Conveyor Units KF and KR 3 Installation of the Small Conveyor Drive Chapter Outline Unless the small conveyor unit was delivered with a working unit attached, the channel, trough, or rail must first be bolted onto the small conveyor drive. Afterwards, the entire small conveyor unit has to be positioned and bolted firmly onto the base plate or the support. 3.
Installation of the Small Conveyor Drive – Installation of the working unit F For correct alignment of the vibration system, it is best to inform AViTEQ Vibrationstechnik GmbH, Frankfurt, about the actual working weight (not including transported goods) when ordering the small conveyor drive! It is possible to run longer transport systems (channel or rail) with several successive small conveyor drives. Ask AViTEQ about it! NOTE 3.1.
Operating Manual for AViTEQ Small Conveyor Units KF and KR Figure 3.1 Working unit attachment: holes on the side (drive on left) and on top (drive on right) Drive Attachment from above Attachment to face Attachment to side (special version R2) KF 0,3 M4 (4...10 mm) - M4 (4...8 mm) KF 0,5 M5 (4...10 mm) - M5 (4...10 mm) KF 0,7 M6 (5...14 mm) - M6 (5...14 mm) KF 0,9 M8 (6...16 mm) - M6 (5...14 mm) Table 3.
Installation of the Small Conveyor Drive – Installation of the working unit Detuning the eigenfrequency reduces the reliability of the operation! Do not loosen the spring mounting bolts under any circumstances (see the following figure)! ATTENTION! Do not loosen the spring mounting bolts! Figure 3.4 NOTE: unit shown is the standard version 3.1.4 Flow chart - explanations 1 Weigh the channel or rail without transported goods 2 Compare the weight measured with the "Nutzg.
Operating Manual for AViTEQ Small Conveyor Units KF and KR Installation of channel or rail weigh channel or rail attach additional weights to channel, rail, or drive unit weight too low weight without transported goods = "Nutzg.
Installation of the Small Conveyor Drive – Installation of the working unit 5, 6, 7, 8, 9 F Select the attachment type that suits the working unit and select suitable bolts according to Table 3.2 on page 3! Please observe the tightening torques specified in table 3.3! The following figure shows a fully assembled small conveyor unit (shown bolted onto the base plate of a storage container unit). Figure 3.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 3.2 NOTE Mounting the small conveyor unit on the base plate If the small conveyor unit with storage container (optional) was delivered by AViTEQ in a pre-assembled state, the following installation steps refer to the attachment of the structure comprising small conveyor unit, working unit, storage container and possibly a rattler, to the base plate. No additional rubber feet are required. Only the complete small conveyor unit, i.e.
Installation of the Small Conveyor Drive – Mounting the small conveyor unit on the base plate attaching the small conveyor unit to the base plate check rubber feet: damaged, porous, or missing? attach (new) rubber feet to the underside of the small conveyor unit not ok? ok! position small conveyor unit on base plate or support structure mark holes for drilling drill holes via the rubber feet, bolt the small conveyor unit to the base plate or support structure Figure 3.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 3.2.2 1 ATTENTION! Flow chart - explanations Rubber feet are part of the shipment of AViTEQ small conveyor units. They are already screwed to the underside of the small conveyor drive when the unit is shipped. However, the rubber feet may become unusable following plant modification or ageing due to environmental factors. They must be exchanged if there is visible evidence of porosity, lack of elasticity, oily surface or other damage (cf.
Installation of the Small Conveyor Drive – Mounting the small conveyor unit on the base plate Drive Bolt size Spring mount (quality 8.8) Minimum and maximum bolt length inside rubber foot KR-2 M6 8 Nm (M6) 3...5 mm KF 0,3 M4 2.4 Nm (M4) 3...4 mm KF 0,5 M5 5 Nm (M5) 3...5 mm KF 0,7 M6 8 Nm (M6) 3...5 mm KF 0,9 M6 8 Nm (M6) 5...8 mm KF 1 M6 8 Nm (M6) 3...5 mm KF 6 M8 20 Nm (M8) 5...8 mm KF 12 M10 40 Nm (M10) 5...8 mm Table 3.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 4 Selection and Installation of the Controller Chapter outline The drives of the small conveyor units must always be connected to the AC mains using the appropriate controller. A suitable AViTEQ-VIBTRONIC controller is available for each version of the small conveyor units. The chapter gives an overview over the possible combinations, the technical data, and the terminology.
Selection and Installation of the Controller – VIBTRONIC controllers l the simpler controller of type SW... for the smaller conveyor units l the voltage-regulated version of type SC... with soft start and compensation for mains voltage fluctuation influence on the throughput To coordinate conveyor systems in assembly and handling applications, special components are required that control the units.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 4.2.3 Combinations of small conveyor drive / controller Always use Table 4.2 (controllers without voltage regulation) and Table 4.3 (controllers with voltage regulation) to check prior to installation whether your controller is suitable for the existing small conveyor unit! Also check the mains speficiations as stated on the type label! Type Nominal current SU-B50-1 3.0 IP 65 0.6 3,000 KF 0,9/6/12, KR-2 4 ... 20 mA DC SUE-B50-1 3.
Selection and Installation of the Controller – VIBTRONIC controllers 4.2.4 Connection notes for VIBTRONIC controllers A separate operating manual is included with each controller. It includes: l Installation instructions l Commissioning instructions You can find further information on these special applications in the AViTEQ brochures „Sorting and conveying equipment“ and „VIBTRONIC controllers for magnetic and unbalanced drives“.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 4.
Selection and Installation of the Controller – Cabling 4.4 Cabling When you install the cable between the small conveyor drive and the controller, please observe the following: F The cable length must not exceed 40 m. F Only use cable whose insulation suits the special environmental conditions. For pharmaceutical and food processing applications, you must choose sterilizable insulations.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 5 Commissioning and Operation Chapter outline After the installation of working unit, small conveyor unit, and controller you may proceed to commissioning. Commissioning is carried out step by step, following a flow chart. Depending on the transported material’s properties, the working unit and the small conveyor drive may be contaminated. Depending on the application, appropriate cleaning agents will have to be used. 5.
Commissioning and Operation – Commissioning commissioning assembly and installation work is complete switch on unit with smallest vibration width hammering noises? Stopper-to-stopper operation? YES! turn the unit off! troubleshooting see Chapter 6.2 NO! NO! maximum vibration width set? (potentiometer fully clockwise) increase vibration width! YES! check vibrator voltage and current! NO! turn the unit off! measurement values ok according to Table 7.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 3 Listen for hammering noises. These can occur during stopper-to-stopper operation and lead to the destruction of the drive unit. 4 Troubleshooting: see Chapter 6.2 (Troubleshooting)! 5 Increase the vibration width step-by-step by turning the vibration width control (potentiometer at the controller) clockwise.
Commissioning and Operation – Cleaning 5.3 Cleaning Depending on the environmental condition and the properties of the material transported, the components of the small conveyor unit, in particular the working unit, will be subject to varying degrees of contamination. F Check the contamination level on a regular basis. Initially, check on a weekly basis, thereafter check in intervals that you determine based on the requirements.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 6 Maintenance and Troubleshooting Chapter outline Even though the small conveyor units require little maintenance, it pays to check the general state of the units in regular intervals in addition to the regular cleaning of the exterior (see Chapter 5), and carry out maintenance if required. Problems usually crop up during the installation and commissioning procedures.
Maintenance and Troubleshooting – Troubleshooting 6.2 Troubleshooting Two types of problems may occur: DANGER! l Faults during installation and commissioning l Faults during operation Disassembling the small conveyor unit and the controller carries the risk of damage and lethal injury! There are no components inside of the units which could be repaired or serviced by the user.
Operating Manual for AViTEQ Small Conveyor Units KF and KR l Insufficient throughput and low vibration width ã Check whether the working weight is too low! ã Have the spring mounting bolts been loosened? They must be tightened with a specified torque - otherwise the eigenfrequency will shift.
Maintenance and Troubleshooting – Troubleshooting Adjustment: the maximum height at the funnel outlet should be equal to the height of the trough. NOTE l Transported material freezes or sticks ã Condensation may occur on metallic surfaces of working unit and small conveyor unit following abrupt changes in temperature. Depending on the material transported, this may result in the formation of lumps, material sticking to the surface, or even to material freezing to the surface at low temperatures.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 7 Principles of Vibration Conveyor Technology Chapter outline For the interested user, the following contains information about the principle of functionality and the working of the small conveyor units. In this respect, the small conveyor unit and its components are to be regarded as a resonant system that is sensitive to alignment.
Principles of Vibration Conveyor Technology – Alignment of the units l The support plate of the drive unit is firmly bolted to the working unit. Together they form a continuous mass unit within the resonance system (1). l The counterweight is the mass of the housing below. Both masses are connected by leaf springs (3). l Rubber feet (6) support the system with respect to its environment. Smaller drives: each voltage cycle exerts a pulling force on the vibration system.
Operating Manual for AViTEQ Small Conveyor Units KF and KR l Sub-critical operation by increasing the working weight: the vibration width increases (eigenfrequency fe > drive frequency fa). AViTEQ small conveyor units are tuned subcritically such that the vibration behaviour is very stable and insensitive against attenuation. The eigenfrequency is at least 5 Hz above the drive frequency.
Principles of Vibration Conveyor Technology – Tuning data for the KF and KR series Due to the complex tuning process, this work should be undertaken at AViTEQ Vibrationstechnik’s laboratory. If the intended working weight is specified in advance, AViTEQ will be able to tune the drive unit to suit. In an ideal situation, the working unit constructed by the user should accompany the unit for the factory tuning.
Operating Manual for AViTEQ Small Conveyor Units KF and KR 8 INDEX Distance from the resonance frequency 7-2 Drive frequency 7-2 Drive voltage 4-5 Numerisch 24 hour test 5-3 50Hz supply 7-2 E A Eigenfrequency 7-4 Electromagnet 7-1 Environmental temperatures 1-5 EU directive 1-7 Excessive heat-up 6-2 Extent of delivery 2-1 Air gap 7-4 Alignment of the units 7-2 Attachment with bolts 3-2 B Beryllium 2-3 Bolt depth inside attachment plate 3-3 Bolt length inside the rubber feet 3-10 Broken springs 6-3
Index L Leaf springs 6-3 7-2 M Mains voltage fluctuations 4-2 Maintenance 1-6 Material freezes 6-4 Material sticks 6-4 Materials used in the units 2-3 N Nominal current 4-3 O Oil contamination 3-9 Operating permit 1-7 Operating temperature 6-2 Operation without controller 4-1 P Packing 2-1 Packing materials 2-2 Pharmaceutical industry 1-5 Power semiconductor 2-3 Preventative maintenance 6-1 Principle of operation of the small conveyor units 71 Product 1-3 Product liability 1-3 Product temperatures 1-5
Operating Manual for AViTEQ Small Conveyor Units KF and KR V Vibration frequency 4-3 7-4 Vibration width 7-4 Vibrator voltage 7-4 W Warranty 1-3 Warranty conditions 1-3 Warranty exclusions 1-3 Weight 4-3 Working unit 1-2 7-2 Working vibration width 7-2 Working weight 7-4 8 ©1999 AViTEQ Vibrationstechnik GmbH Version 10/1999 iii
Index iv
Operating Manual for AViTEQ Small Conveyor Units KF and KR EU Declaration of Conformity Manufacturer: AViTEQ Vibrationstechnik GmbH Goldsteinstraße 238 60528 Frankfurt/Main, Germany Product description: Small conveyor units Device types: - KF, KR, version „CR“, version „Ex“ The products of the specified type series are in conformance with the following European directives: 89/392/EEC Council Directive for the harmonization of legislation of the member states relating to machinery, under consideration of a
AViTEQ Vibrationstechnik GmbH Im Gotthelf 16 D-65795 Hattersheim-Eddersheim Telefon 06145/503-0 Telefax 06145/503-200 ce VIB 12.
