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PIAB C 1200 Series, Troubleshooting Manual

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PIAB C 1200 Series Troubleshooting Manual Download Page 30

VACUUM CONVEYORS

30

INSIDE COMPONENTS OF COMPRESSED AIR INLET FOR MLL PUMPS

Pos.

Art. No.

Designation

17

31.07.111

Barrel Connector R3/8

17

31.07.194

Barrel Connector M24xM24

25

31.07.031

Hose Connector M5 D=2

26

31.07.030

Hose Connector M5 D=4

27

31.16.055

Shuttle Valve

28

31.07.626

Hose, Nylon 4x2

29

31.07.640

Hose, Nylon 6x4

30

31.07.120

Filter Housing 1/2"

30

31.07.291

Filter Housing 3/4"

3

2

31.07.223

Compressed Air Filter

3

1

31.13.739

O-ring 34.2x3 nitrile

33

31.07.116

Valve Housing

34

31.13.626

O-ring 11.5x3 nitrile

34

31.13.803

O-ring 16x3 nitrile

35

31.07.115

Piston for remote valve

35

31.07.191

Piston for remote valve

36

31.13.627

O-ring 24.2x3

37

31.07.119

Cover for Remote Valve

Summary of Contents for C 1200 Series

Page 1: ...VACUUM CONVEYING C Series Conveyor Troubleshooting Guide www piab com ...

Page 2: ...ypes of equipment or dissimilar units are sometimes connected to perform specific functions you should familiarize yourself with the manuals covering the other equipment before pro ceeding with installation By cross referenc ing the manuals you may save valuable in stallation time and avoid improper operation In the design and manufacture of this equip ment PIAB has exercised the utmost care to en...

Page 3: ...IES PUMP 25 TROUBLESHOOTING CU 1A B 33 PIAB Control Unit CU 1A B CU 2A B CU control function and pneumatic diagrams Pipe emptying TROUBLESHOOTING PPT R 42 PIAB Control Unit PPT R PPT R control function and pneumatic diagram connections Disassembling a PPT R control TROUBLESHOOTING VCC EP 48 PIAB Control Unit VCC EP Mounting and connections Valve Connections for the VCC EP TROUBLESHOOTING WITH A LE...

Page 4: ...irective 94 9 EC Cleaning of filters It is important to check and clean change filters at reg ular intervals so that they are not clogged as this might lead to the fact that the filters will be subjected to overload and that undesired matters or particles leak from the conveyor Emergency stop The system builder shall provide the machine with an emergency stop function As an option to the vacuum co...

Page 5: ...plies the conveyor so that unneces sary pressure drops do not occur The longer the hose the larger the dimension required Also remember that push in connections with built in non return valves may cause pressure drops Also take into consider ation that there may be other devices in the com pressed air network that might consume compressed air Dimensioning of the compressed air pipeline A very impo...

Page 6: ...ations Installation of the conveying pipeline Correct dimensioning and installation is A and O for the system to work in the best possible way Please contact your local PIAB distributor as to dimen sioning of the diameters of the pipes their length number of bends and possible option of injection units or pipe emptying function It is important that the pipe line system is sealed in order to preven...

Page 7: ...VACUUM CONVEYORS 7 CONNECTION EXAMPLES CONTROL UNIT CU 1A B ART NO 01 04 550 ART NO 01 04 552 ...

Page 8: ...VACUUM CONVEYORS 8 CONTROL UNIT CU 1A B WITH FLUIDISATION ART NO 01 04 550 ART NO 01 04 552 ...

Page 9: ...VACUUM CONVEYORS 9 CONTROL UNIT CU 1A B WITH FLUIDISATION AND LEVEL DETECTOR ART NO 01 04 550 ART NO 01 04 552 ...

Page 10: ...VACUUM CONVEYORS 10 CONTROL UNIT CU 1A B USDA ART NO 01 04 550 ART NO 01 04 552 ...

Page 11: ...VACUUM CONVEYORS 11 CONTROL UNIT CU 2A B ART NO 01 04 540 ART NO 01 04 548 ...

Page 12: ...VACUUM CONVEYORS 12 CONTROL UNIT CU 2A B WITH FLUIDISATION AND LEVEL DETECTOR ART NO 01 04 540 ART NO 01 04 548 ...

Page 13: ...VACUUM CONVEYORS 13 CONTROL UNIT CU 2A B WITH FLUIDISATION ART NO 01 04 540 ART NO 01 04 548 ...

Page 14: ...VACUUM CONVEYORS 14 CONNECTION EXAMPLES ...

Page 15: ...VACUUM CONVEYORS 15 VALVE UNIT VCC EP VALVE UNIT VCC EP WITH FLUIDISATION ...

Page 16: ...touching the cage there will be less aspiration and a greater amount of product picked up If the tube is pulled out to be even with the outer tube there will be increased aspiration and a decreased amount of product picked up The tube can be adjusted by unscrewing the top wing nut 2 Feed Adapter The standard feed adapters include two ball valves Both are adjustable which allow in creased aspiratio...

Page 17: ...r to the material being conveyed 4 Fluidization may need to be added to the conveyor If it is already part of the conveyor it may not be functioning properly The material would be stuck in the cone section located at the bottom of the convey or 5 The filter air shock may not be working properly F If the filter air shock does not function properly there wouldn t be a bump to shake the excess materi...

Page 18: ...VACUUM CONVEYORS 18 FILTER REPALCEMENT 1 2 3 4 5 ...

Page 19: ...VACUUM CONVEYORS 19 6 7 8 9 10 11 12 ...

Page 20: ...nts in the filter unit Brush off cleaning procedure 1 Your filter elements have to be dismantled in order to be cleaned 2 Stand the filter elements in a vertical a position as possible e g lean them against a wall see the drawing 3 No dust should be allowed to get into the filter elements during the cleaning operation It is recommended therefore to cover up the inside of the filter e g with adhesi...

Page 21: ...o allow any water to get into the filter elements 7 Leave the filter elements standing at the same acute angle to dry Drying must take place at room temperature minimum 24 hours 8 Reinstall the d dry filter elements in the filter unit Air jet cleaning procedure 1 Your filter elements have to be dismantled in order to be cleaned 2 Stand the filter elements in a vertical a position as possible e g l...

Page 22: ... zone last taking care not to allow any dust to get into the filter elements 7 Reinstall the filter elements in the filter unit Rinse off cleaning procedure 1 Your filter elements have to be dismantled in order to be cleaned 2 Stand the filter elements in a vertical a position as possible e g lean them against a wall see the drawing 3 No dust should be allowed to get into the filter elements durin...

Page 23: ...es Please be careful when cleaning the pump If a nozzle is broken off or rotated the pump will need to be replaced To remove material from the nozzles or chambers PIAB suggests soaking the pump in water or in water with mild detergent such as dishwashing detergent Once the pump has new seals and flap valves and it is clean and put back together it should run just like a brand new pump L100 L200 L4...

Page 24: ... emptying time 9 Control unit Too little carrier air 7 Valves for carrier air Damp powder Clogged conveying pipeline 8 Conveying pipeline The powder sticks to the inside of the conveyor Fluidisation does not work is missing 6 Cone fluidisation Damp powder Too long pump time short emptying time 9 Control unit The filter shock does not work 4 Filter shock The filter shock does not work Hose connecti...

Page 25: ... 87psi cannot be reached on the regulator there is not enough volume of air to feed the pump Make sure compressed air line diameter is the proper size and increase if too small If diameter correct or larger than you need to live with the problem use a smaller size pump requiring less air or shut off other machinery using air so vol ume to pump will increase X Make sure On Off knob is pushed com pl...

Page 26: ...late gasket 2 pcs 3101134 Inlet gasket MLL200 400 1 pc 3101092 V E Spare Kit MLL600 800 consisting of 3101141 Flap valves 300 3 pcs 3101136 Side plate gasket 2 pcs 3101135 Inlet gasket MLL800 1600 1 pc 3101099 V E Spare Kit MLL1200 consisting of 3101380 Flap valves 400 3 pcs 3101136 Side plate gasket 2 pcs 3101135 Inlet gaskets MLL800 1600 1 pcs ...

Page 27: ...01 018 Panel MLL 1200 complete 1 10 31 00 029 Remote valve G1 2 without filter housing 1 1 1 1 11 31 07 170 Barrel nipple KR1 2 KR1 2 1 1 1 1 12 31 07 031 Hose connector M5 D 2 incl washer 4 4 5 5 14 31 07 212 Plug R1 8 2 2 2 2 15 31 13 743 Nylon washer D 14 x 9 8 x 1 2 2 2 2 16 3113752 Screw MFX 4 x 10 A2 22 22 22 22 17 31 07 223 Compressed air filter 1 1 1 1 18 31 07 120 Filter housing 1 2 remot...

Page 28: ...400 1 31 01 368 Panel MLL 600 800 1 31 01 376 Panel MLL 1200 1 2 31 01 602 Vacuum gauge 1 1 1 3 31 07 072 Quick connection JG 6 4 M5 1 1 1 4 31 07 074 Quick connection JG 6 4 M5 1 1 1 5 31 07 010 Actuating valve 1 1 1 6 31 16 055 Shuttle valve 1 1 1 7 31 07 031 Hose connector M5 D 2 with washer 5 6 6 8 31 07 645 Hose 4x2 polyurethane 1 1m 1 2m 1 2m 9 31 01 603 Manometer 1 1 ...

Page 29: ...VACUUM CONVEYORS 29 INSIDE COMPONENTS OF MLL PUMPS ...

Page 30: ... 31 16 055 Shuttle Valve 28 31 07 626 Hose Nylon 4x2 29 31 07 640 Hose Nylon 6x4 30 31 07 120 Filter Housing 1 2 30 31 07 291 Filter Housing 3 4 32 31 07 223 Compressed Air Filter 31 31 13 739 O ring 34 2x3 nitrile 33 31 07 116 Valve Housing 34 31 13 626 O ring 11 5x3 nitrile 34 31 13 803 O ring 16x3 nitrile 35 31 07 115 Piston for remote valve 35 31 07 191 Piston for remote valve 36 31 13 627 O r...

Page 31: ...VACUUM CONVEYORS 31 L100 CLASSIC COMPONENTS ...

Page 32: ...1 32 01 110V Side Plate Gasket 1 32 01 110E Side Plate Gasket 1 10 32 01 126 Compressed Air Filter 1 11 32 01 141 Cover Plate 250 1 12 31 01 304 Flap Valve Nitrile 2 31 01 304S Flap Valve Silicone 2 31 01 304V Flap Valve Viton 2 31 01 304E Flap Valve EDPM 2 13 31 01 305 Non Return Valve Nitrile 1 31 01 305V Non Return Valve Viton 1 31 01 305E Non Return Valve EDPM 1 14 31 13 755 Screw MFX 4x30 12 ...

Page 33: ...nit X Connect corresponding color tubing with matching control function port X Push the control tubing completely into control connectors X Set the timers A 5sec B 2sec X Turn the ON OFF knob on the left side of controller once to 1 X Put 4mm plug into port 8 level control X Put 4mm plug into port 6 fluidization X Put 4mm plug into port 44 jump using a 4mm tubing between port 42 and port 43 The co...

Page 34: ... X Connect corresponding color tubing with matching control function port X Push the control tubing completely into control connectors X Set the timers A 5sec B 2sec C 5sec X Turn the ON OFF knob on the left side of controller once to 1 X Put 4mm plug into port 8 level control X Put 4mm plug into port 6 fluidization X Put 4mm plug into port 44 jump using a 4mm tubing between port 42 and port 43 Th...

Page 35: ...VACUUM CONVEYORS 35 DIMENSION CONTROL UNIT CU 1A CU 1B CU 2A CU 2B WITH MOUNTING BRACKET ART NO 01 03 918 ART NO 01 03 919 ART NO 01 03 920 ART NO 01 03 921 ...

Page 36: ...4 550 01 04 552 ART NO 01 04 540 01 04 548 A Adjustable time for conveying B Adjustable time for pipe line emptying C Adjustable time for emptying of conveyor D 1 Start of conveyor 0 Stop of conveyor CU 1A Art No 01 04 550 CU 1B Art No 01 04 552 CU 2A Art No 01 04 540 CU 2B Art No 01 04 548 ...

Page 37: ...he bottom valve is closed when the conveyor is turned off Control unit CU 2A A Conveying time Adjustable 0 1 30 seconds C Time for emptying of conveyor Adjustable 0 1 30 seconds B Time for pipe line emptying for each conveying cycle Adjustable 0 1 30 seconds The bottom valve is open when the conveyor is turned off Control unit CU 2B A Conveying time Adjustable 0 1 30 seconds C Time for emptying of...

Page 38: ...VACUUM CONVEYORS 38 CONTROL UNIT CU 1B BOTTOM VALVE NC ART NO 01 04 552 ...

Page 39: ...VACUUM CONVEYORS 39 PNEUMATIC DIAGRAM CONTROL UNIT CU 1A BOTTOM VALVE NO ART NO 01 04 550 ...

Page 40: ...VACUUM CONVEYORS 40 CONTROL UNIT CU 1B BOTTOM VALVE NC ART NO 01 04 552 ...

Page 41: ...VACUUM CONVEYORS 41 CONTROL UNIT CU 2B BOTTOM VALVE NC ART NO 01 04 548 ...

Page 42: ...l connectors X Set the timers V1 5sec V2 2sec V1 01 04 477 V2 01 04 476 Timers do not contain stops They will continue turning changing from maxi mum setting to minimum setting X Replace timer X Replace O ring on compressed air inlet of the pump X Replace the O ring on the PPT R in the area of air leak X Check air supply pressure The control unit did not cycle X Material obstructing bottom door X ...

Page 43: ...VACUUM CONVEYORS 43 FUNCTIONS OF THE CONTROL UNIT A Adjustable time for conveying B Adjustable time for emptying of conveyor C Regulator for opening of valve ...

Page 44: ...VACUUM CONVEYORS 44 PNEUMATIC DIAGRAM COMPONENT LAYOUT ...

Page 45: ...VACUUM CONVEYORS 45 TIME SIGNAL DIAGRAM MOUNTING ...

Page 46: ...PIAB s regulator kit should always be used in order to ensure proper function Use the 1 2 regulator kit for 100 400 pumps Art No 01 04 490 or regulator kit 1 for 600 1600 pumps Art No 01 04 491 Indications on the control unit Nylon tube dimension OD ID Marking tube colour Port Function P in 6 4 Black 1 Air supply input Pump 4 2 Green 2 Starts vacuum pump Shock 4 2 Brown 3 Filter shock Close valve ...

Page 47: ...e timer is the portion that includes the adjustment knob Set this portion aside 3 The base of the timer is the portion that includes the mounting screws This will need to be disassembled further 4 On the top of the base there is a brass assembly that is pressed into the black plastic base Using a small screwdriver or knife pry this brass assembly out There is an o ring around the circumference of ...

Page 48: ...ction port X Push the control tubing completely into control connectors X Turn air supply to pump off Discon nect the air supply tubing from the VCC EP control Plug air supply tub ing into a pressure gauge turn air sup ply on to the pump and verify air supply pressure going to the VCC EP 40 to 100 psi X Verify air supply to pump and VCC EP control unit X Replace O ring on compressed air inlet of t...

Page 49: ... Fluidisation 2 Connected to 2 2 valve for start of fluidisation Filter shock 3 Connected to 3 2 valve for filter shock Discharge open 4 Connected to actuator to open bottom flap Discharge close 5 Connected to actuator to close bottom flap Electric inputs For electronic control signals to the connection block 2xØ6 mm Port label Nylon tube dimension OD ID Tube colour Port Function Air supply 6 4 Bl...

Page 50: ...VACUUM CONVEYORS 50 VALVE CONNECTIONS FOR THE VCC EP ...

Page 51: ...e manually reset X Place an air pressure gauge into port 8 on the CU controller and verify air pressure venting from port 8 is 30 40 psi X Push tubing into each respective fitting checking to make sure there is no air leaking from each fitting X Call PIAB 1 800 321 7422 to arrange repair or replacement Problem Possible Causes Possible Solutions Injection unit will not cycle X Air is shut off X Pin...

Page 52: ... Art No Feed pressure MPa psi Voltage VDC Housing material Degree of protection Weight g lb Operating temperature C F Level detector 01 00 267 0 2 0 6 29 87 24 PC POM IP 54 622 21 9 0 50 32 122 Switching hysteresis Operating temperature C F Degree of protection Cable Voltage VDC Output current max mA Max switching power W 10 of sensing distance 30 70 22 158 IP67 PVC 3x0 5 mm2 10 35 300 7 2 Art No ...

Page 53: ...VACUUM CONVEYORS 53 PNEUMATIC INJECTION VALVE ...

Page 54: ... the bottom and remove module by module After removing the material from the main body of the conveyor check to see if the material got past the filter If it did all of the parts above the filter should be cleaned out until there are no signs of the material This includes any tubing and the air shock Make sure the valve on the air shock is cleaned off and moves in and out easily Please refer to di...

Page 55: ...value in the table to the right above When the pressure drop during idling has risen and the vacuum level has decreased by approxi mately 5 10 kPa 1 5 3 Hg as compared to the start value this is an indication that the filter needs to be washed changed 5 Washing the filter A contaminated Pitex filter bag can be washed in stead of being changed The filter can normally be washed 2 4 times The filter ...

Page 56: ...he pump and the upper part of the filter unit and the air shock tanks All these parts are on the clean side of the filter i e they do not come in contact with the conveyed pow der Loosen the remaining clamp rings and dismount the modules seals see below and the filters see below The steel parts can be washed with water and detergent according to local regulations It is im portant to clean all part...

Page 57: ...VACUUM CONVEYORS 57 NOTES ...

Page 58: ...VACUUM CONVEYORS 58 NOTES ...

Page 59: ...VACUUM CONVEYORS 59 NOTES ...

Page 60: ...btinternet com ITALY ITALIA Srl Via Schiaparelli 10 IT 10148 TORINO Tel 39 011 226 36 66 Fax 39 011 226 21 11 piab piab it PIAB GIVES YOU SERVICE ALL OVER THE WORLD JAPAN Japan Ltd 3 11 23 Hikawacho Todo shi Saitama ken 335 0027 Tel 81 48 443 9148 Fax 81 48 443 9179 info piab co jp L ATIN AMERICA COLOMBIA Latin America Carrera 16 No 86A 76 SANTA FE DE BOGOTÁ Colombia Tel 57 1 636 1953 Fax 57 1 636...

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