Bin Arch Breaking Systems Installation and Maintenance Manual

8/17/2019 Bin Arch Breaking Systems Installation and Maintenance Manual

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Installation

Maintenance Manual

Bin Arch breaking System

(Models: BAS-020 • BAS-040 •BAS-050)

北北科力通散料技术有限司

Beijing bklitong bulk technology Co., LTD

www.bklitong.com [email protected]


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INJECTOR HEADS OF SYSTEM INSTALLATION NOTES

Consult installation drawing (if provided) for proper injector heads location. It is important toadhere to the recommended locations as the type, number and location of injector heads havebeen selected for thorough " inject " coverage of the problem surfaces in bin or chute.

It is usually not necessary to clean out or empty the bin before installing the Injector heads.

CAUTION: NEVER ENTER A BIN WHILE INJECTOR HEADS ARE OPERATING.

If the material in the bin would have a tendency to run out of a hole cut in the bin wall, the levelof material in the bin should be dropped below the Injector head location before cutting the holesin the bin wall.

When welding, a continuous bead should be used to fasten the mounting to the bin wall onsteel bins.

PIPING INSTALLATION

Follow the piping schematic that is a part of this instruction manual.

Never use smaller pipe size fittings or valves than the ones shown.

It is important that the header be installed below the level of the Injector heads so that anycondensation that may form in the lines will not drain into the Injector heads. If the header mustbe installed above the level of the Injector heads, the feed lines for the individual Injector headsmust be taken off the top of the header (rather than the bottom) to minimize condensationdrainage into the Injector heads and solenoids. A full flow gate or ball valve is recommended asit allows one the Injector head to be taken out of service without shutting down the entire system.

Using flexible air hose in lieu of rigid piping from the header to the solenoids is recommendedfor ease of installation and for easy removal of the Injector head when service is required.

NOTE: USING SUITABLE SAFEGUARDS, always blow out all air supply lines thoroughly

before final hook up to solenoids. Dirt in supply lines may cause the solenoid valves

to malfunction.

When operating properly, and under material, the Injector heads are almost silent.If an Injector head begins to chatter, vibrate or "machine gun", it is generally caused by asolenoid valve malfunctioning due to dirt. If this occurs, SHUT OFF ELECTRIC & AIR SUPPLYand DISCHARGE AIR in system, then clean solenoid thoroughly (see troubleshooting).


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BAS-020 Injector head dimensions (no scale)

BAS-020Injector head

2.5mm

Mounting Coupling(for curved walls)

25mm

Ø43mm

32mm 31.5mm 43mm

3/4" NPT sch. 40connecting nipple (typ.)

62mm

Cone point

set screw (4 places)

"O" RingNational Part


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Injector head CONTROL BOX

The control box is the heart of the Injector head system. It is this device which fires the Injectorheads in a prescribed sequence and at a prescribed interval to assure on-demand or evendischarging of material from the bin, silo or chute. The firing order is from the discharge(lowest unit) and up.

The burst signal, sent from the control box to the solenoid valves, is typically set at 0.25seconds. It is this signal that is responsible for the actual firing of any given Injector head. Insome cases, more than one solenoid valve may be wired to the same output, to effectsimultaneous firing of two Injector heads.

The interval timer governs the "dwell" between successive firings.

The "dwell" should be set as long as possible without adversely affecting the flow of material. A longer "dwell" will conserve air.

External controls, There provide a DCS port with a switch which can start or stop the Bin Arch breaking System.

WARNING ○ NEVER ALLOW ANYONE TO LOOK INTO OR ENTER

BIN WHEN INJECTOR HEADS ARE OPERATING. ○ EYE OR OTHER INJURY MAY RESULT! SHUT OFF

ELECTRIC & AIR SUPPLY TO INJECTOR HEADS ANDDISCHARGE AIR IN SYSTEM BEFORE INSPECTING OR

SERVICING INJECTOR HEADS.


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TYPICAL SYSTEM COMPONENTS

Mounting Coupling

injector head

Diaphragm Valve

Hopper

Flexible Hose

Pipe Header Loop

supply pipe

Ball Valve Pipe port

Full-flow Moisture Trap

Air Supply

Full-flow Regulator


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BAS-020 Mounting Coupling Installation

TYP 6

Bin Inside Wall

MountingCoupling& Assembly 25mm

43mm

90 DegreeCountersink After Correct Injectorhead Position isDetermined

Align Front of CouplingFlush With Inside of Bin Wall

BAS-020 Mounting Coupling Installation 1. Cut hole in hopper wall, diameter to fit (The 40mm diameter of coupling is recommended

to allow coupling to pass through curved wall).

2. Remove O-Ring, and apply splatter-guard in O-Ring groove. Align coupling flush with inside of vessel wall and weld continuous bead to exterior of wall.Replace O-Ring after flange has cooled. O-Ring groove should be cleaned and free ofdebris or residue before replacing O-Ring.

3. Slide Injector head into position, so that front of body of Injector head is aligned withfront of coupling. This will properly position piston head within the bin.

4. After position of Injector head is determined to be correct, small countersink holes shouldbe drilled in Injector head body, to allow cone point set screw to engage fully with body.

Note: On sharply curved bin walls, body of Injector head will extend slightly into the bin at top &bottom (12:00 & 6:00 positions), and should be flush at sides (3:00 & 9:00 positions).


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DRAWING

DISEGNO

DESSIN

DIBUJO

ZEICHNUNG

TEKENING

DRAWING

DISEGNO

IM901-10-1-4

ASCO/JOUCOMATICP.O. Box 3, 3925 ZG Scherpenzeel, The NetherlanTel. +31 33 277 79 11- Fax +31 33 277 45 61

SERIES353

TORQUE CHART

C

B

A

ITEMS

11±1

20±3

0.6±0.2

NEWTON.METRES

100±10

175±25

5±2

INCH.POUN

GB * Supplied in spare part kitFR * Livrées en pochette de rechange

DE * Enthalten im ErsatzteilsatzES * Incluido en Kit de recambioIT * Disponibile nel Kit parti di ricambio

NL * Geleverd in vervangingsset

Ø

Spare part kitCode pochette de rechangErsatzteilsatz

Código del kit de recambioKit parti di ricambio

Vervangingsset

Catalogue numberCode électrovanne

KatalognummerCódigo de la electrovalvula

Codice elettrovalvolaKatalogus nummer

=~

C113-444

C113-444

SCG353A43

SCG353A44

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1

1*

2

3

4

5*

6*

A

B

7*

8*

9*

10

C

11

12*

13

IN


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TROUBLE SHOOTING

PROBLEM POSSIBLE CAUSE

1. Diaphragm Valve fails to operate (open)

1. No pressure in header2. Low or no power to coil3. Coil inoperative4. Pilot valve plunger jammed shut5. Pilot orifice blocked6. Secondary bleed-hold blocked7. Main diaphragm perforated8. Secondary diaphragm perforated9. Pilot valve connecting line too long10. Silencer, if fitted, may be blocked

2. Diaphragm Valve fails to shut 1. Pilot valve plunger jammed open2. Foreign matter under pilot valve3. Secondary diaphragm spring broken

4. Foreign matter under secondarydiaphragm

5. Main diaphragm spring broken 6. Foreign matter under main diaphragm7. Main diaphragm seating disc damaged8. Main bleed hole blocked9. Secondary bleed hole blocked

10. Leak in line connecting pilot valve

3. Unable to build header pressure

1. Excessive leakage from main diaphragmseat

2. Broken main valve spring 3. Secondary diaphragm not seating

4. Foreign matter under mainor secondary diaphragma) seat or under pilot valve seat

5. Air supply line too small

6. Compressor too small

4. Sluggish operation of diaphragm valve 1. Partial blockage of one of the bleed-

holes2. Silencer, if fitted, may be blocked


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SPECIAL NOTE To prevent premature failure of a diaphragm valve, special attention must be paid to thequality of the compressed air/gas being handled.

An adequate moisture and oil removal system must be incorporated that takes intoaccount:

relative humidities likely to be experienced ambient temperatures

system operating temperatures

pressure drops (and associated temperature drops) through the valve and also throughthe blow tube holes (dew point problem)

Also, small traces of chlorine and other aggressive gases, often present in filter systems,can be absorbed in wet areas resulting in corrosion and premature failure.

Apart from valve failures, systems may not perform to expectation for a number of

reasons including the following:

inaccurate mounting/positioning of theInjector head(s) relative to the vessel wall

inadequately sized header and/or air supply incorrect pulse time

incorrect intervals between pulses

improper adjustment or wear ofInjector head(s) piston head


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Maintenance

一． After the control device is powered on, 5V, 12V and 24V LED indicator on the circuit board is not lit. It is necessary to

check if power line is loose with connection terminal, if 0.315A fuse of power supply is broken, if power transformer isnormal and if there is any phenomena like a broken line, loose soldering, etc. in the power supply part.

二．If 5V or 12V LED indicator is not lit, it shows that there is a short circuit in the load, and some component is damaged.

It is necessary to check one by one. If load is disconnected, 5V or12V is still abnormal, and 3-terminal stabilizedcircuit must be checked to see if it is normal.

三．If 24V LED indicator is not lit, the general status is that there is overload or short circuit of electromagnetic pulse valve

and lead at the load side.

四． After the control device is powered on, nixie light display and key input is normal:

(1)Output LED indicator is not lit and electromagnetic pulse valve does not work. And it is possible that SD-M-3002circuit is damaged.

(2)Output LED indicator is lit and electromagnetic pulse valve does not work. And it is possible that thecorresponding electronic switch tube is damaged.

五．If a electromagnetic pulse valve is always magnetized, it must be checked if the corresponding electronic switch tube

is in electric leakage or broken-down.

六．If electromagnetic pulse valve is not always magnetized, it must be checked if the connection outside of the terminal

of common lead of the valve is correct and reliable.


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ASME HORIZONTAL AIR RECEIVERS 30, 60, 80 Gallon

DIMENSIONS Port size (NPT)

Tank Size

Gal A B C D E F 1 2 3 4 5 6

7 8

14 X 48 30 14 48 33 14 5 9/16” 9 ½” 1 ½” ½” ¾” ½” ¾” - - ¼”

20 X 48

60

20

48

26

18 ½”

7 7/8”

12 ¾”

2

1 ½”

1 ½”

1 ½”

1

¾”

¼”

-

20 X 63 80 20 63 36 18 ½” 9 12 ¾” 2 1 ½” 1 ¼” 1 ¾” ¾” ¼” -

All dimensions in inches

All receivers are built in accordance with the ASME section VIII Division I code latestaddition. All vessels are “U” stamped and registered with National Board.Note: California requirements special – please call.Design pressure to 200 PSIG, test pressure 300 PSIG.

Design temperature: -20 to 650 F.Type 1, 2:1 elliptical heads. All seams submerged arc welded.

Painted with one coat of standard gray shop primer.


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ASME VERTICAL AIR RECEIVERS: 30, 60, 80 gallon

F

1/4"

NPT

G

F

ASME F

Name-

plate

TL

HT

OD

B C

G

A

D

1/2" NPT

E

(Bolt

Circle) 9/16" X 7/8" SLOT (4 places)

Gal

OD

Length (TL)

Height (HT)

A

B

C

D

E

F (NPT)

G (NPT)

30 16 38 40.81 12.56 30.06 25.06 2.81 15 .75 1.5

60 20 48 50.75 13.75 39.75 33.75 2.75 17 .75 2

80

24

46

49.19

13.06

39.31

34.31

3.19 21

1.25

2



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ASME STANDARD HORIZONTAL AIR RECEIVERS 120, 200, 240 Gal.

DIMENSIONS Port size (NPT)

Tank Size

Gal A B C D E 1 2 3 4 5 6 7

24 x 69 120 24 69 42 22 10 2 1 ½” 1 ½” 1 ½” 1 ¾” ¼”

30 x 72 200 30 72 38 28 12 2 2 2 2 1 1 ¼”

30 x 84 240 30 84 50 28 12 2 2 2 2 1 1 ¼”



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INJECTOR HEAD MAINTENANCE INSTRUCTIONS

Maintenance Requirements Inspection of all components every 6 months is recommended for signs of wear or fatigue. Failureto perform routine inspections may result in sudden failure and possible contamination of materialand/or damage to production equipment.

Isolation Should it be necessary to overhaul any Injector heads while the system is working, it will benecessary to first close the valve(s) isolating the Injector head(s) on that part of the hopper.Next, switch on the Injector head control system for one full cycle. This will allow compressedair to clear from all isolated pipes around the hopper, by cycling all Injector heads within thesystem at least once.CAUTION: to avoid injury, pressure must be relieved from header piping beforemaintenance is started.

Dismantling Having first disconnected the electrical leads and the air piping, the Injector head may bewithdrawn by loosening hex setscrews or lock nut and removing Injector head from mountingflange/plate or coupling.(NOTE: mark Injector head body to insure proper re-alignment with interior wall.)

At the work bench the solenoid valve should be unscrewed from the Injector head.

Holding the front of the valve cap in a vise, loosen and remove the jam nut and elastic stop nutfrom the valve stem.

The compression washer, compression spring, spring guide and valve stem can then be

taken out. Inspect all parts for signs of wear or fatigue. Particularly note threads of thevalve stem and the front seat of the valve cap. Replace worn or damaged parts.

Reassembly Reassemble valve assembly. Tighten elastic stop nut to 3mm (1/8") of internal stop (front springguide). Check 1/8" dimension by manually pushing on rear of valve stem to extend(front) cap from body. Reinstall jam nut, and tighten against elastic stop nut. Reassemble withsolenoid and place back in hopper.

IMPORTANT: Front of Injector head valve body must align with interior ofhopper wall.


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Jam Nut

Elastic Stop Nut

Compression Washer Set Screws

Compression Spring MountingCoupling

Spring Guide“O” Ring

Valve Body

MountingFlange

RubberGasket

Valve Stem(Piston)

BAS-020 Injector head assembly with mounting

Qty DESCRIPTION CARBON STEEL STAINLESS STEEL

1

Valve Body

VB-020 VB-020-SS

1*

Valve Stem

VCW-020 VCW-020-SS

1*

Spring Guide

SG-020 SG-020-SS

1*

Compression Spring

CS-020 CS-020-SS

1*

Compression Washer

CW-020 CW-020-SS

1*

Elastic Stop Nut

ESN-020 ESN-020-SS

1*

Jam Nut

JN-020 JN-020-SS

1

Mounting Coupling

MC-020 MC-020-SS

1

O-Ring**

OR-020 OR-020

Note: (*) denotes part included in rebuild kit.Order RK-020 for carbon steel construction, RK-020-SS for stainless steel construction.

**For temperatures above 250 F, specify Viton O-ring (OR-020-V) .


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Flexible Hose Assemblies

Specifications

¾ i.d. X 24 overall length

Bellows③: SUS 316L

Wire Braids④:SUS304

Temperature Range: -20CF to 180 C

Working Working Pressure: 16Kgf/cm2

Nipples①②: SUS 316L , ¾＂ NPT

Bellows O.D. : 30.5mm

Total length: normal 500-600mm (also according to client.)


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Documents

Bin Arch Breaking Systems Installation and Maintenance Manual