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Version 20090811Part#14137003
OMI+_Maint_EN_20090811.pdf
OMI+
On Machine Inspection
Maintenance Handbook
OMI+_Maint_EN_20090811 OMI+ page 2
Borgwaldt KC 7741 Whitepine Road Richmond, Virginia 23237 USA Tel: +1 (804) 271-6471 (General Inquiries) Tel: +1 (804) 743-9790 (Technical Support) Fax: +1 (804) 275-9070 Email: [email protected]: www.borgwaldt-kc.com
Schnackenburgallee 15 D-22525 Hamburg Tel: +49/40/853138-0 Fax: +49/40/850 56 00 Email: [email protected] Internet: www.borgwaldt.de
Safety: Before installing, operating or maintaining this instrument, you must read the enclosed Handbooks.
Refer to this Handbook for further information regarding the indicated hazard.
Equipment covers should not be removed until all power is turned off and disconnected. Access to internal components should be performed by a trained technician.
Handbooks may be provided printed, or electronically on CD, for your convenience. Copyright: The contents of any BKC Manuals are expressly for the use of our customers. Any reproduction or distribution with the written permission of Borgwaldt KC is prohibited. All rights reserved. Handbook Images:
• Photos or graphic images are listed in the Table of Figures. References to these images, contained in the Handbook’s text, are in [brackets] format.
OMI+_Maint_EN_20090811 OMI+ page 3
Table of Contents Table of Figures ....................................................................................................................... 4 Safety...................................................................................................................................... 5
General Safety Information .................................................................................................... 5 Definition of Terms and Symbols ............................................................................................ 6
Guarantee................................................................................................................................ 7 Main Areas............................................................................................................................... 8 Maintenance Schedule and Cleaning........................................................................................... 9
Summary Overview ...............................................................................................................9 Daily .................................................................................................................................. 10
Hopper Cleaning: ............................................................................................................. 10 Weight Unit Cleaning........................................................................................................ 11 Size Unit Cleaning ............................................................................................................ 12 PDV Unit Cleaning............................................................................................................ 13
Weekly ............................................................................................................................... 14 PDV Sleeves Replacement................................................................................................. 14 Sensor Cleaning ............................................................................................................... 18
Monthly .............................................................................................................................. 19 PDV Filter Maintenance..................................................................................................... 19 PC Filter Cleaning............................................................................................................. 21
Annually ............................................................................................................................. 22 Size Unit Drive Belt Replacement....................................................................................... 22 PDV Air Filter Replacement ............................................................................................... 23 PDV O-rings..................................................................................................................... 24 PDV Unit Hose Replacement ............................................................................................. 24 PC Cleaning ..................................................................................................................... 25 Air System Maintenance ................................................................................................... 27 Exterior Case Maintenance................................................................................................ 28
Maintenance Parts .................................................................................................................. 29
OMI+_Maint_EN_20090811 OMI+ page 4
Table of Figures Safety Symbols......................................................................................................................... 6 MainAreas 01a.......................................................................................................................... 8 HopperAreas 01...................................................................................................................... 10 WeightUnit 01 ........................................................................................................................ 11 WeightUnit 02 ........................................................................................................................ 11 MainAreas 10 ......................................................................................................................... 12 SizeUnit 01a........................................................................................................................... 12 PDV Unit 01 ........................................................................................................................... 13 PDVunit 01............................................................................................................................. 14 PDVunit 02............................................................................................................................. 14 PDVunit 04............................................................................................................................. 15 PDVtools 02b ......................................................................................................................... 15 Sleeves 02b ........................................................................................................................... 15 SleeveRightWrong 03.............................................................................................................. 16 Inner Head Assembly.............................................................................................................. 17 Sensors 01............................................................................................................................. 18 PDV tools 03 .......................................................................................................................... 19 PDV CambFilter 01.................................................................................................................. 19 PDV CambFilter 02.................................................................................................................. 20 PDV CambFilter 03.................................................................................................................. 20 ComputerPCB 03 .................................................................................................................... 21 SizeDriveBelt 01 ..................................................................................................................... 22 PDV Filter 01.......................................................................................................................... 23 0-Rings 01 ............................................................................................................................. 24 PDV Hoses 01 ........................................................................................................................ 24 ComputerPCB 03 .................................................................................................................... 25 ComputerPCB 01 .................................................................................................................... 25 BottomRearView 01 ................................................................................................................ 25 CaseBottom 01....................................................................................................................... 26 BottomViewRear 01 ................................................................................................................ 27 MistMicroFilter 01 ................................................................................................................... 27 AirFilter 01 ............................................................................................................................. 27 RearDoor 01 .......................................................................................................................... 28
OMI+_Maint_EN_20090811 OMI+ page 5
Safety General Safety Information
WARNING ! The operating safety of the instrument should be considered critical for every user. The instrument should only be used as intended and described in this Manual. CAUTION ! Before starting up and operating the unit, the operating personnel must receive instruction in the correct use of the unit. Personnel must be made aware of the risks associated with operating the unit. Personnel must be familiar with the warning symbols. The instrument may be operated only by trained and experienced personnel. If a certain task requires more extensive qualifications, it will be indicated in the appropriate section of this Manual. It is our intention to offer you safe, state-of-the-art products now and in the future. Please help us achieve this goal. Please inform us of any of the following:
• Interruptions/faults in unit operation • Defective or malfunctioning parts • Problems when operating or handling the machine
OMI+_Maint_EN_20090811 OMI+ page 6
Safety
Definition of Terms and Symbols
This section explains the terms and symbols referring to safety that appear in these operating instructions or on the unit and packaging.
The following terms and symbols are used on the Packaging, Equipment, or in this Handbook:
DANGER ! Indicates imminent, potential risks or hazards. Failure to comply with the stated instructions can result in death or serious injury. This term always appears with a warning symbol.
CAUTION !
When this symbol is present in a dialog box, as illustrated, disconnect electrical power before opening the enclosure. This procedure, if performed incorrectly, or in not performed by a properly trained technician, may result in electric shock.
WARNING !
When this text is present in a dialog box, as illustrated, special care must be taken when performing these instructions. This procedure, if performed incorrectly, or if not performed by a properly trained technician, may result in equipment damage.
NOTE !
When this text is present in a dialog box, as illustrated, special care must be taken when performing these instructions. This procedure, if performed incorrectly, or if not performed by a properly trained technician, may result in the operation of the equipment being compromised.
Safety Symbols
OMI+_Maint_EN_20090811 OMI+ page 7
Guarantee Borgwaldt KC provides a 12 month warranty on all instrumentation from time of dispatch unless otherwise stated. Any technical changes or repairs performed without Borgwaldt KC’s consent during the guarantee period releases us from our obligations stated in the guarantee. If you should have any question regarding maintenance and/or the correction of any problems, please contact Borgwaldt KC.
To maintain the Warranty Guarantee, the Instrument must only:
1. Be installed as described in the Installation Handbook. 2. Be operated as described in the User Handbook. 3. Be maintained as described in the Maintenance Handbook. 4. Be repaired by a BKC authorized technician. 5. Be maintained with BKC original parts.
OMI+_Maint_EN_20090811 OMI+ page 8
Main Areas
Touch Screen Display
Hopper
Weight Unit
Size Unit
Pressure Drop /Ventilation
Unit
Mounting Stand
Computer
Collection Bin
Floor Bracket
MainAreas 01a
OMI+_Maint_EN_20090811 OMI+ page 9
Maintenance Schedule and Cleaning Summary Overview
This Handbook contains detailed instructions for performing the following tasks. Daily
• Hopper Cleaning • Weight Unit Cleaning • Size Unit Cleaning • PDV Unit Cleaning
Weekly
• PDV Unit Sleeves Replacement • Sensor Cleaning
Monthly
• PDV Filter Maintenance • Vacuum Computer (PC) Filters
Annual
• Size Unit Drive Belt Replacement • PDV Unit Air Filter Maintenance • PDV Unit Vent or PD Head O-Rings Maintenance • PDV Hose Replacement • PC Cleaning • Air System Maintenance • Exterior Case Maintenance
OMI+_Maint_EN_20090811 OMI+ page 10
Daily
Ensure that Power is disconnected from the OMI.
NOTE: Compressed Air should not be used to clean the instrument. NOTE: Removal of tobacco dust should be achieved using a vacuum source to pick up the dust particles.
Hopper Cleaning:
1. Lift the Top Cover and slide-up the Front Plate to remove. [HopperAreas 01]
2. Clean the path where product samples
travel through the Hopper, using vacuum [HopperAreas 01]
Top Cover
HopperAreas 01
Touch Screen
Drum
Front Plate
OMI+_Maint_EN_20090811 OMI+ page 11
(Daily continued)
Weight Unit Cleaning 1. Lift the Release Knob, and slide-open the
Weight Drawer. [WeightUnit 01]
2. Clean the Weight Drawer and components using vacuum. Note- Use only vacuum to clean the Rod Weight Scale area. [WeightUnit 02]
3. The Rod Weight Scale should be carefully vacuumed free of loose tobacco and dust. Be sure that the Sample Holder is protected from shocks, as shocks can damage the balance. [WeightUnit 02].
Weight Unit
Release Knob Sample Holder
WeightUnit 01
NOTE: Special care should be taken not to sweep dust particles into the top of the Weight
Cell cover.
Weight Scale
Entry Funnel Sample Holder
WeightUnit 02
OMI+_Maint_EN_20090811 OMI+ page 12
(Daily continued)
Please ensure that you comply with all safety measures required to work with this equipment.
Size Unit Cleaning Size Unit1. The Size Unit drawer is located near the
middle area of the OMI+. [MainAreas 10]
2. Lift the Release Knob [SizeUnit 01a], and slide-open the Size Unit Drawer. [SizeUnit 01a]
3. Clean loose tobacco and dust from the
Size Unit. Clean the Size Unit and components using vacuum pressure air.
MainAreas 10
Release Knob Drawer
SizeUnit 01a
OMI+_Maint_EN_20090811 OMI+ page 13
(Daily continued)
PDV Unit Cleaning 1. Lift the Release Knob, and slide-open the
PDV Unit Drawer. [PDV Unit 01]
2. Clean the PDV Unit and components using vacuum.
Release Knob Measuring Head Assembly
PDV Unit 01
Special care must be taken when performing these instructions. This procedure, performed incorrectly, or not performed by a properly trained technician, may result in equipment damage.
CAUTION!
OMI+_Maint_EN_20090811 OMI+ page 14
Weekly
Ensure that Power is disconnected from the OMI.
PDV Sleeves Replacement 1. Unscrew the top of the Measuring Head
Assembly, by rotating it in a counterclockwise direction. [PDVunit 01]
2. After the top has been unscrewed, gently pull-out the top and interior areas of the Measuring Head Assembly [PDVunit 02].
top of Measuring Head Assembly
PDVunit 01
PDVunit 02
OMI+_Maint_EN_20090811 OMI+ page 15
(Weekly continued) 3. Unscrew the Lower Inner Head Assembly
from the Top of the Measuring Head Assembly. [PDVunit 04]
4. Push the Extraction Tool into the O-Ring Assembly to remove the inner portion of the O-Ring Assembly. [PDVtools 02b] • Special care should be taken to keep
the Tool and Bobbin parallel to the Head Body. [PVTtools 02b]
5. Replace all PDV sleeves once a week. [Sleeves 01], [Sleeves 02b], and [Sleeves 02c]
Measuring Head Tip and Paper Ventilation
and Paper Drop Assembly
Lower Inner Head Assembly
PDVunit 04
Extraction Tool
PDVtools 02b
Filter Bobbin Assembly
Sleeves 01
Cigarette Bobbin Assembly Sleeves
Sleeves 02b
Sleeves 02c
Sleeve
OMI+_Maint_EN_20090811 OMI+ page 16
(Weekly continued)
• Ensure that the new Sleeves are correctly aligned and centered. [SleevesRightWrong 03]
6. Clean any buildup of dirt that could prevent the Sleeves from sealing around the rod.
SleeveRightWrong 03
Correct • Good circle • In center
Incorrect • Bad circle • Off center
Incorrect • Good circle • Off center
Incorrect • Bad circle (twisted) • In center
OMI+_Maint_EN_20090811 OMI+ page 17
Inner Head Assembly
OMI+_Maint_EN_20090811 OMI+ page 18
(Weekly continued)
Sensor Cleaning 1. Clean all sensors, using optical grade
cleaning materials (e.g. “Lens Wipes”) to clean the surfaces of the Sensors. [Sensors 01]
Note: In the photo below, enlarged views of the sesnors are shown with location arrows. [Sensors 01]
Sensors 01
OMI+_Maint_EN_20090811 OMI+ page 19
Monthly
PDV Filter Maintenance 1. The Cambridge fiberglass filter should be
replaced in the PDV Certified Flow Orifice on a semi-annual basis.
2. The tools required for this maintenance
are: [PDV tools 03] • A 13mm wrench • A Filter Housing Removal Wrench
(supplied in the OMI+ Calibration Test Piece kit)
3. Using a 13mm wrench, remove the air line fitting on the top of the filter housing (located on the front of the PVE drawer. [PDV CambFilter 01]
Important: Please ensure that the air hose is not twist-damaged during removal or twisted after replacement.
PDV tools 03
Air Fitting
PDV CambFilter 01
OMI+_Maint_EN_20090811 OMI+ page 20
(Monthly Maintenance continued) 4. Unscrew the clear plastic filter housing
(use Housing Removal Wrench) [PDV CambFilter 02].
Housing Removal Wrench
PDV CambFilter 02
Cambridge Filter O-ring
PDV CambFilter 03
Manifold Plug
Right Side of OMI+
Manifold and Plug 03a
5. Vacuum the dust particles from the Cambridge filter and then carefully remove the O-ring and filter. [PDV CambFilter 03]
6. DO NOT allow dust or dirt particles to fall
into filter housing (The Certified Flow Orifice is directly behind it).
7. Vacuum and clean the filter housing.
Replace the Cambridge Filter.
8. Clean or replace the O-Ring, re-install the top filter housing and air fittings.
9. Check the manifold Block and clear tubing for any signs of debris, if debris is present then remove, this can be done by removing the plug [Manifold and Plug 03a] on the right hand side of the manifold block. Tubing can be cleaned by removing the tube and blowing through with an air gun, please ensure both ends of the tube are disconnected from the unit.
OMI+_Maint_EN_20090811 OMI+ page 21
PC Filter Cleaning
1. Using Vacuum, clean the two Fan Filters on the Rear of the Computer Unit. [ComputerPCB 03]
Filters
ComputerPCB 03
OMI+_Maint_EN_20090811 OMI+ page 22
Annually
Ensure that Power and Air are disconnected from the OMI.
Size Unit Drive Belt Replacement 1. Replace the Drive Belt used to rotate the
rod [SizeDriveBelt 01]. • Check the bearings and pulleys
that track the belt for smooth operation.
• Move the Release Mechanism as shown in [SizeDriveBelt 01].
• The belt can now be removed. • Replace with the Borgwaldt-KC
replacement.
Drive Belt 10032093
Press Release Mechanism in this direction
SizeDriveBelt 01
OMI+_Maint_EN_20090811 OMI+ page 23
(Annual Maintenance continued)
PDV Air Filter Replacement 1. The air filter [PDV Filter 02] in the OMI-
PDV needs to be checked by a properly trained technician, and cleaned if necessary.
2. Replace the PDV filter [PDV Filter 02] Annually (located in rear section of PDV drawer). To gain access to the filter, turn the Filter Cover counterclockwise. [PDV Filter 01] Among the possible symptoms of a dirty air filter are:
• erratic readings • the need to re-calibrate too
frequently
PDV Filter 01 Replace filter
PDV Filter 02
Cover
OMI+_Maint_EN_20090811 OMI+ page 24
(Annual Maintenance continued)
PDV O-rings 1. Replace the Measuring Head (Vent or
PD) O-rings. [O-Rings 03]
Measuring Head Assemblies
0-Rings 03
PDV Unit Hose Replacement 1. Replace the four PDV rotating hoses.
[HeadHoses 01]
Measuring Head Filter Rod Bobbin Assy.
• The hose connections are hand-tightened. If they have been over-tightened, use small pliers to loosen.
• Three of the hoses connect to the Manifold Block at the front of the PDV unit.
• The other two hoses connect to two valves behind the PDV Plate.
Rotating Hoses
PDV Plate Manifold Block
PDV Hoses 01
O-RingsO-Rings face left
O-Rings face right
Measuring Head Cigarette Bobbin Assemblies
OMI+_Maint_EN_20090811 OMI+ page 25
(Annual Maintenance continued)
PC Cleaning 1. It is recommended that the PC hard drive
should be backed up at least annually.
2. Remove 4 screws on PC shelf as marked on photo. [ComputerPCB 03]
3. After removing screws, using handle,
gently pull out the PC shelf to reveal the internals. [ComputerPCB 03]
4. Photo shows layout of PC and all
connections [ComputerPCB 01]
5. Vacuum the PC of all dust and debris. [ComputerPCB 01]
6. Replace the two PC Inlet Filters on the rear of the Computer Unit. [BottomRearView 01]
Rear View Filter Computer PCB Backplate Filter
Securing Screws
ComputerPCB 03
ComputerPCB 01 Filters
BottomRearView 01
OMI+_Maint_EN_20090811 OMI+ page 26
(Annual Maintenance continued) 7. Replace the one PC Outlet Filter on the
bottom of the Computer Unit. [CaseBottom 01].
8. When completed, push in the PC shelf and replace the securing screws.
View of Bottom of PC Case Filter
CaseBottom 01
OMI+_Maint_EN_20090811 OMI+ page 27
(Annual Maintenance continued) Rear View
Air System Maintenance Regulator 1. Locate the filter assemblies at the bottom-
rear of the OMI+. [BottomRearView 01]
• Twist to separate the outside Cover sections of the Mist Separator Micro Filter. [MistMicroFilter 01]
• Unscrew to remove the old filter, and replace the filter. [MistMicroFilter 01]
• Twist to separate the Cover sections of the Air Filter Assembly.
• Replace the filter.
Drain Filter Super Mist Separator Filter
BottomViewRear 01
Filter (99008197)
MistMicroFilter 01
Filter 99008195
Twist to separate sections of Cover
Cover
Twist to separate sections of cover
AirFilter 01
OMI+_Maint_EN_20090811 OMI+ page 28
(Annual Maintenance continued)
Exterior Case Maintenance 1. Vacuum the Upper and Lower Filters in
the Rear Door of the OMI+. [RearDoor 01]
RearDoor 01
OMI+_Maint_EN_20090811 OMI+ page 29
Maintenance Parts List of Maintenance parts for OMI+ and where used in this Handbook. • 10032093 Drive Belt for Size Module, used on Size Unit page 23 • 14032087 Filter, Dust OMI+ Rear Door Top page 26 • 14032088 Filter, Dust OMI+ Rear Door Bottom page 26 • 14132100 Filter material for Fan 90mm page 26 • 14132107 Filter material for Fan 40mm page 26 • 99003199 PVE Air Filter page 21 • 14134003 Pneumatic: Element, Super Mist Separator Assembly page 25 • 14034004 Pneumatic: Element, Air Filter page 25 • 99003170 3/8” Rotating Hoses (uncut) Page 22 Note: A PDV Maintenance Kit (99009032) is available from Borgwaldt KC, that includes items needed for Preventive Maintenance. This kit contains hoses that are cut to length.