INSTRUCTION MANUAL FOR THE USE
AND MAINTENANCE OF THE
TURBO DRYER Type RKB70A
Serial N°
BELCHEM FIBER
MATERIALS GMBH
11/23
Country
Year
GERMANIA
2011
Customer
BEFORE INSTALLATION AND OPERATION OF THE MACHINE READ CAREFULLY THIS
HANDBOOK AND FOLLOW ALL THE INDICATIONSTHIS MANUAL HANDBOOK IS A PART
OF THE MACHINE AND MUST STAY WITH THE MACHINE DURING ALL ITS LIFE
INDEX
1
IDENTIFICATION OF THE DOCUMENT . . . . . . . . . . . . . . . . . . Pg. 6
1-1 USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 7
1-2 FOREWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 7
2
DECLARATION OF RESPONSIBILITY
. . . . . . . . . . . . . . . . . . Pg. 8
3
GENERAL RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 10
3.1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . Pg. 10
3.2 SAFETY ON USING RADIO FREQUENCY DRYER . . . . . . . . . . . . . . Pg. 13
3.2 FURTHER SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . Pg. 13
3.3 GENERAL OUTLINES OF THE PROCESS . . . . . . . . . . . . . . . . . Pg. 14
3.4 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . Pg. 15
3.5 INFORMATIONS FOR ASSISTANCE AND MAINTENANCE OF THE MACHINE
. . Pg. 16
3.6 PRECAUTION TO CARRY DURING OPERING . . . . . . . . . . . . . . . Pg. 16
3.7 INFORMATIONS FOR DEFINITIVE OUT OF ORDER AND DEMOLITION OF THE MACHINE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 16
4
DESCRIPTION OF THE MACHINE AND TECHNICAL FEATURES . . . . . . . Pg. 17
4.1 TECHNICAL FEATURES FOR RKB70A . . . . . . . . . . . . . . . . . . Pg. 17
4.2 DIMENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 18
4.3 DESCRIPTION OF THE MACHINE . . . . . . . . . . . . . . . . . . . . Pg. 19
4.4 SAFETY DEVICES
. . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 23
4.5 OPERATOR POSITION . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 26
4.6 RESIDUAL RISKS . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 27
4.6.1 HIGH VOLTAGE DIAGRAM . . . . . . . . . . . . . . . . . . . . . Pg. 29
4.6.2 RADIO FREQUENCY FIELD
. . . . . . . . . . . . . . . . . . . . Pg. 29
4.7 WARNING SIGNS. . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 30
5
TRANSPORT OF THE RF DRYER COMPONENTS TO INSTALLATIONPOINT . .
INDEX
Pg. 32
1
6
SETTING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . Pg. 33
6.1 AMBIENT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . Pg. 33
6.2 ASSEMBLY OF THE FRAME
. . . . . . . . . . . . . . . . . . . . . . Pg. 35
6.3 FEEDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 36
6.3.1 ELECTRICAL FEEDER
. . . . . . . . . . . . . . . . . . . . . . Pg. 37
6.3.2 AIR DUCT FEEDERS . . . . . . . . . . . . . . . . . . . . . . . Pg. 38
6.3.3 COMPRESSED AIR . . . . . . . . . . . . . . . . . . . . . . . . Pg. 38
6.4 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 39
6.4.1 SWITCHING THE RF FOR THE FIRST TIME . . . . . . . . . . . . . . Pg. 39
6.4.2 TEMPERATURE CHECKING . . . . . . . . . . . . . . . . . . . . Pg. 39
6.4.3 MOISTURE CONDENSATION . . . . . . . . . . . . . . . . . . . . Pg. 39
7
REMOTE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . Pg. 40
7.1 REMOTE CONTROL PANEL DESCRIPTION . . . . . . . . . . . . . . . . Pg. 40
7.2 FUNCTION MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 44
7.3 CONTROL PANEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . Pg. 45
7.3.1 MAIN PAGE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . Pg. 45
7.3.2 PAGE TO MANUAL USE OF THE MACHINE . . . . . . . . . . . . . . Pg. 46
7.3.3 PAGE TO AUTOMATIC USE OF THE MACHINE . . . . . . . . . . . . Pg. 48
7.3.4 PAGE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 51
7.3.5 PAGE UTILITY. . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 53
7.3.6 PAGE WORK CARD . . . . . . . . . . . . . . . . . . . . . . . . Pg. 54
7.3.6.1 RECIPE CREATION . . . . . . . . . . . . . . . . . . . . . . Pg. 55
7.3.6.2 LOADING OF A RECIPE . . . . . . . . . . . . . . . . . . . . Pg. 55
7.3.6.3 OPTIMIZATION ON LINE OF A RECIPE . . . . . . . . . . . . . . Pg. 56
7.3.7 PAGE MEMORY ALARM . . . . . . . . . . . . . . . . . . . . . . . Pg. 57
8
USE OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . Pg. 59
8.0 LOADING THE BOBBINS CARRIER. . . . . . . . . . . . . . . . . . . . Pg. 59
8.1 MANUAL WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 61
STOP MANUAL WORKING CYCLE . . . . . . . . . . . . . . . . . . . . Pg. 63
8.2 AUTOMATIC WORKING . . . . . . . . . . . . . . . . . . . . . . . . Pg. 64
MODIFICATION OF WORKING PARAMETERS . . . . . . . . . . . . . . . Pg. 65
STOP OF AUTOMATIC WORKING CYCLE . . . . . . . . . . . . . . . . . Pg. 66
8.3 STOP OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . Pg. 67
2
INDEX
8.4 OVERLOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 68
8.5 SET OF THE TEMPERATURE OF HOT AIR
. . . . . . . . . . . . . . . . Pg. 69
8.6 PROCEDURE TO FOLLOW IN CASE OF FIRE . . . . . . . . . . . . . . . Pg. 70
8.7 TRIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 71
8.8 SPECIAL REQUIREMENTS ON USING RADIO FREQUENCY DRYER . . . . . . Pg. 71
9
MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 72
9.1 ORDINARY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . Pg. 73
10 ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 79
10.1 FANS AND MOTORS LIST . . . . . . . . . . . . . . . . . . . . . . . Pg. 80
10.2 ELECTRICAL COMPONENTS LOCATION . . . . . . . . . . . . . . . . . Pg. 82
10.3 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . Pg. 84
10.4 INLET / OUTLET LIST . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 85
10.5 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 86
10.6 SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 88
10.7 CONTRACT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . Pg. 89
INDEX
3
1 IDENTIFICATION OF THE DOCUMENT
INSTRUCTION MANUAL FOR THE USE AND MAINTENANCE OF THE
TURBO DRYER
COMPOSED OF 87 PAGES
The present document is part of the machine and must be available nearby the
machine. If machine is sold to third party, this document must follow the machine. In
case of loss customer must ask a new copy to RF SYSTEMS.
TYPE OF MACHINE:
TURBO DRYER TYPE RKB70A
(RADIO FREQUENCY + HOT AIR)
FOR USE:
DRYING /POLIMERISATION OF FIBERS
IN FORM OF YARN PACKAGES (nr. 108
PACKAGES DIAMETER 270mm
SERIAL NUMBER N° :
11-23
YEAR OF CONSTRUCTION :
2011
MANUFACTURER :
RF SYSTEMS S.r.l.
Via Torre, 7
SOLAGNA (VI) ITALY
PHONE:
+39-0424 558322
FAX:
+39-0424 559088
e-mail:rfsystems@rfsystems.it
RESPONSIBLE :
Ing. GRANDO Patrizio
DATE:
03/03/2011
4
1- IDENTIFICATION OF THE DOCUMENT
1-1
USE
- The following plant is meant for drying/polymerisation of fibers in form of yarn packages and is based on the latest
technique of radio frequency heating
- The instructions contained in this handbook composed of n°87 pages are intended to provide the user with necessary
information for the efficient operating of the dryer.
The directions should be followed carefully and no other adjustments or modifications should be attempted except under
the authorization of RF SYSTEMS.
1-2
FOREWARD
RF SYSTEMS is always available for advice or assistance in the event of difficulty being experienced in the operation
and/or maintenance of the equipment.
This handbook is a part of the machine and must stay with the machine during all its life.
In case that machine is sold to other end user, this handbook must accompany the machine.
For safety reasons the machine can be used only by personal in confidence with this handbook.
Before installation and operation of the machine read carefully this handbook and respect its indications.
RF SYSTEMS is exempted of any kind of responsibility for anything due to non reading of the instruction manual and
inobservance of instructions of this manual.
The handbook must stay with the machine till its complete demolition
The handbook must be conserved in a safe place and accessible to authorized personal only.
In case of loss user must ask immediately a new copy to RF SYSTEMS srl
Information on the handbook are confidential and cannot be copied or given to third person without written agreement
from RF SYSTEMS srl who reserves itself to do without advise all the modifications considered opportune.
RF SYSTEMS srl reserves itself the right to update the relative handbooks and the production without obligation to update
the previous production and relative handbooks.
In the handbook all draw, all dimension and all picture of components are indicative and not binding.
The dryer has been designed and manufactured for the drying / polimerisation of fibres in form of yarn packages after
centrifugation. The drying operation is done by mean of the radio frequency technology combined with hot air.
The dryer working with N°108 bobbins (2 layers of 54 bobbins each one) with following dimensions : Ø=270mm
H= 280mm.
The bobbins holder platform must be loaded with all the packages loaded on the special supports of the bobbins holder,
in order to maintain the thickness constant. It is absolutely forbidden to have NON UNIFORM load e non uniform
moisture on the bobbins loaded. The bobbins must be uniform in dimensions, type of fiber, weight and moisture
The bobbins are properly closed by mean of special lever fasteners.
The loading has to be done always and only with bobbins formerly appropriated centrifuged in order to have residual
moisture at following values: 45% wool; 18% acrylic man made fibre; 35-40% mix acrylic-cotton; 50% cotton; 60% viscose
NB : UNLEVELED QUANTITY OF MOISTURE AND WATER TO EXHAUST CAUSE FIRE RISKS.
In case of overheating the product may burn even after some hours. The operator must also check every time the
temperature of the product at the end of the drying cycle, and check the product before stocking.
The loading and unloading of the bobbins on the bobbins holder has to be done manually by an operator before to be
introduced inside the drying chamber. It is forbidden to do loading and unloading inside the drying chamber.
When the bobbins holder has been loaded it will be introduced in the drying chamber by mean of the special trolley which
has to be taken out from the drying chamber before to start the working cycle.
Before to load the bobbins holder inside the drying gallery, the operator must make sure that anti fall cylinder is in safety
position (the piston rod has to be completely outside and the door has to be at the higher position).
In order to operate properly, For any reason, the operator never has to go inside the drying chamber.
For each shift only one operator has to work with the machine. Contemporary use of the machine by several operators
has not been foreseen.
Before to start and during all the closing operation of the door, the operator has to make sure that no foreign person
(person exposed to danger ) is present inside the drying chamber and near the moving zone of the door. On the contrary,
the operator HAS NOT to start the closing operation of the door or has to stop it immediately and take away this person.
The working area around the machine has to be free of any type of material which may hamper or compromise the
freedom of movement of the operator.
The working floor around the machine must be levelled.
In order to operate safely with the machine, the operator must occupy exclusively the working positions indicated in this
manual and control the machine during all the working process.
At each end of shift, the bobbins holder trolley must be obligatory taken out from inside the machine.
It is mandatory check the product at the outlet of the dryer
It is mandatory check the product before the stocking operations.
It is forbidden to use the machine for uses different of which it has been destined.
The respect of the instructions indicated in this handbook is requisite for the application of the warranty. In case they will
not be respected the warranty will not be applied.
1- IDENTIFICATION OF THE DOCUMENT
5
2 DECLARATION OF RESPONSIBILITY
1/2
Solagna lì 03-03-2011
DICHIARAZIONE DI CONFORMITA’
Noi/
We/
Dichiariamo sotto la nostra esclusiva responsabilità che la machina:
Declare under our sole responsibility, that the product:
TURBO DRYER
TYPE RKB70A
(1 X 70 KW Radifrequency +
24Kw hot Air)
Machine Serial Nr:
11-23
Year of construction :
2011
Installed Power :
125 KVA
Power RF:
70 KW
Work frequency:
27 Mhz
6
2- DECLARATION OF RESPONSIBILITY
2/2
RF SYSTEMS S.r.l. declare under it sole responsibility that the turbo dryer type RKB70 serial nr. 11/23 is in
compliance with CE Machine Directives, 98/37, 91/368, 93/44, 93/68 and 89/336 CEE (electromagnetic
compatibility).
The machine is also in compliace with the following standard:
- CEI 44-5-EN60204/1 year 2004- Electrical equipments of industrial machinery
- EN 60519-1 Safety in electro heat installation
- CEI EN 60519-9 Particular requirements for high frequency dielectric heating installations
- EN 55011-(CISPR11) Limits and methods of measure of the characteristics of radio interference of
industrial, scientific and medical apparels.
The president
Il presidente
Ing. Grando Patrizio
2- DECLARATION OF RESPONSIBILITY
7
3 GENERAL RULES
FOREWARD: SAFETY FIRST
3.1
SAFETY INSTRUCTIONS
DANGEROUS AREA: Every area inside or beside the machine where the presence of a exposed person involves a risk
for the health see fig. 1.1 Pag.11
EXPOSED PERSON:
All the persons inside the dangerous area.
Operator of the machine:
person involved on the running of the machine with enough knowledge of the machine,
basic of radio frequency drying, basic of the safety devices and location and using only the control panel actuators.
Instruited persons:
dangers with the dryer
persons adequately advised or supervised by skilled persons to enable them to avoid
Skilled persons:
persons with technical knowledge and sufficient experience to enable them to avoid
dangers which machine may create.
For the substitution of the spare parts use only original components and authorized by manufacturer.
The use of non original components avoids automatically RF SYSTEMS of any responsibility.
For each damage, reparation or maintenance speak to our assistance service and use only
specialized personal.
BEFORE SERVING WORK IS CARRIED OUT, THE RF DRYER MUST BE SHUT DOWN AND THE MAIN SWITCH MUST
BE SWITCHED OFF AND SECURED AND LOCKED IN THIS POSITION TO PREVENT UNAUTHORIZED RECLOSURE.
1) The use of the equipment is allowed only with normal light conditions. It is forbidden to use the machine with not enough light
2) Access of the machine should be carried out by qualified staff and in top safety conditions
3) Before to operate the machine check that all panels are well closed. All doors must be closed during operation
4) Under no circumstances the machine can run without protections
5) It is forbidden to use the machine with protections out of order
6) Use the dryer only with air filters installed.
7) Dry only textile products bobbins formerly appropriated centrifuged in order to have residual moisture at following
values : WOOL : 30% - COTTON 50% .
NB : UNLEVELED QUANTITY OF MOISTURE AND WATER TO EXHAUST CAUSE FIRE RISKS.
8) Do not enter inside forbidden area (see fig.1.1 pag.11) or touch parts inside the forbidden area
9) before to load the bobbins holder inside the drying gallery, the operator must make sure that anti fall cylinder is in safety
position ( the piston rod has to be completely outside and the door has to be at the higher position )
10) Before to start and during all the closing operation of the door, the operator has to make sure that no foreign person (
person exposed to danger ) is present inside the drying chamber and near the moving zone of the door. On the contrary,
the operator HAS NOT to start the closing operation of the door or has to stop it immediately and take away this person.
11) For each shift only one operator has to work with the machine. Contemporary use of the machine by several operators
has not been foreseen.
12) At each end of shift, the bobbins holder trolley must be obligatory taken out from inside the machine.
13) The operator must also check every time the temperature of the product at the end of the drying cycle
14) In case of overheating the product may burn even after some hours. The operator must also check every time
theproduct before stocking.
8
3- GENERAL INFORMATION
Electrical risks
Main switch
The dryer is equipped with a magneto thermic switch. It is intended to cut off the supply from all the installation by
separating the installation from the electrical supply
This is to ensure the safety of persons carrying out work on or in the vicinity of live parts involving a risk of direct contact
The main switch must be locked in position OFF during maintenance.
Control circuits
All control devices are clearly indicated by letters, words, numbers and symbols.
All boxes have sufficient mechanical strength and are IP40 protection.
The start push button is installed on the control box and is located in order to avoid the risk of accidental starting.
The stop push button is located on the control panel
The emergency push button is located on the control panel in easy position; this is intended to remove, as quickly as
possible, hazards which may occur unexpectedly.
Attention: if pressed turn off the radiofrequency, the fans and
the auxilliary ciscuits and open the door to the dryng chamber.
Electrical equipment
•
•
•
•
Overcurrent:
All the circuits are protected against overcurrent
Protection again electric shock: The machine is protected against electric shock
Protection against live part:
All the enclosure and conductors provide isolation
Wire gauge:
All wire gauges are in respect of standard CEI EN 60204-1
• Static charges - stray fields:
All static charges are suppressed by means of earthing, screning and
providing sufficient distances.
Access door to the dryng chamber
• When it is closed it prevents the emission of RF towards outside. Its position is controlled by switch connected
to control circuit wich allow the running of RF only when the access door is closed.
Mechanical Risks
Parts in movement:
1)
All moving parts are protected by panels. Panels can be opened only with special tools.
2)
door to the drying chamber movement : in order to close the door, the operator must set the manual running mode
and close it with the 2 apposite buttons located in the front of the machine in correspondence with the place with the
maximum visibility on the dangerous zone. This operation is only manually by the operator. During this operation, the
operator must occupy exclusively the working positions indicated in this manual. Before to start and during all the closing
operation of the door, the operator has to make sure that no foreign person ( person exposed to danger ) is present inside
the drying chamber and near the moving zone of the door. On the contrary, the operator HAS NOT to start the closing
operation of the door or has to stop it immediately and take away this person.
3)
Maintaining the door open : with the door completely open, a special cylinder, in addition to the electro magnetic
brake installed on the motor, guarantees that the door stay open in case of breakage of the brake.
For the normal running of the machine the removable panels on the drying gallery ARE NOT PROTECTED WITH MICRO
SWITCH. To remove the panels it is necessary to use 2 different tools.
Maintenance
The maintenance operation must be done with the machine stopped and with the power supply
main switch locked at position OFF.
“OFF” and
3- GENERAL INFORMATION
9
Noise Risk
The level of noise around the machine is lower than 70 dB.
Fire Risks
The machine is designed to dry goods with a high risk of fire.
The risk of fire is due to overheating of the goods to be dried.
The operator must also check every time the temperature of the product at the end of the drying cycle in order to
avoid the risk of fire.
If the goods are overheated the risk of fire hazard is very high. The goods can start to burn inside the material and get
burning after a few hours. The operator must also check every time the product before stocking.
In order to avoid risks of fire for the product and also the machine, it is essential that the loading of the bobbins holder
is done loading always with same number of bobbins in order to maintain constant the thickness of the product loaded.
Only product of the same type and only product properly centrifuged has to be loaded.
The bobbins to be dried must be uniform in dimensions, weight, moisture and type of fibers. It is forbidden to process
on the same batch bobbins with different fibers, moisture or dimensions,
UNLEVELED QUANTITY OF MOISTURE AND WATER TO EXHAUST CAUSE FIRE RISKS.
At each shift, the operator must take out the bobbins holder from the inside of the machine.
The machine is equipped with an manual anti fire deviced. The activating lever of the valve is located on the front part of
the machine in well visible and reachable position. When this lever is pulled, the machine stops completely ( the main
switch is cut) and water is injected inside the drying gallery.
CUSTOMER MUST SUPPLY SUITABLE CO2 EXTINGUISHER NEAR THE DRYER
Electromagnetic risk
The dryer is made in compliace with the standard of the European rules EN12198-1 year 2000.
Persons with pacemaker or other electronic device cannot operate the machine
Temperature
All the parts of the machine which can be in contact with operator are below 60°C in normal condition of working.
The hot temperature zone (roughly 80-100°C) where the steam battery is located is isolated inside the protected
zone by lateral panels. There is a plate in this zone with the indication of dangerous temperature.
Explosive atmosphere
The machine cannot operate in zones exposed to danger of explosion
10
3- GENERAL INFORMATION
3.2
SAFETY ON USING RADIO FREQUENCY DRYER
1) Operation of radio frequency equipments involves the use of dangerous voltage (15KV).
2) Operating personnel must every time observe safety regulations.
3) Do not make adjustments inside the equipment and do not open doors with the main power switch supply “ON”.
4) Always cut off the power supply before removing covers or other protective devices. Also ensure that the power supply
cannot be switched on accidentally. To avoid possible danger always disconnect power, discharge capacitors and then
connect to earth circuits then earth circuits prior to touch them.
5) The following rules must be strictly observed:
- KEEP AWAY FROM LIVE CIRCUITS
Under no circumstances should any person be permitted to reach within, or in any manner gain access to any enclosure
with the power supply line switches to the equipment closed.
6) DO NOT ADJUST OR SERVICE ALONE
Under no circumstances should any person reach within a unit for the purpose of servicing or adjusting the equipment
without the immediate presence or assistance of another person capable of control and rendering aid.
7) Maintenance people should be qualified and accustomed to dealing with high voltage equipment.
- DO NO OPEN PANELS OR DOORS WITH THE MAIN SWITCH “ON”
Under no circumstances should any panel or doors be removed without the main switch has been disconnected first.
8) FORBIDDEN AREAS WITH MAIN SWITCH ON:
fig.1-1
1- DRYING CHAMBER
2- RADIO FREQUENCY GENERATOR
3- HIGH VOLTAGE TRANSFORMER
4- RECTIFIER BRIDGE
9) Some goods can burn after few hours after the
drying so operator must very carefully check the
goods after the drying
10) RF EMISSION: Under normal circumstances the
RF dryer is protected against leakages of RF
interferences. RF seals and contact area at the doors or
metal shields must be in perfect condition.
11) The RF dryer contains components with any
potentially lethal high voltage . Under normal
circumstances, access to these components is possible
only through the use of special keys.
RF SYSTEMS S.r.l. denies any responsibility for fire due to overdying of the product without the control by
the operator of the product at the outlet of the dryer
3.2 FURTHER SAFETY INSTRUCTIONS
FURTHER ZONES WHERE IT IS FORBIDDEN TO OPERATE WITH MAIN SWITCH ON
5- BOX WITH FAN
6- AIR HEATING ZONE
Dangerous zones not for the presence of radio frequency but for the presence of other devices.
7- MOVING ZONE OF THE DOOR.
Dangerous zone during the closing operation of the door. It is forbidden to stay inside this area while the operator is
activating the closing system of access door to drying chamber.
3- GENERAL INFORMATION
11
3.3
GENERAL OUTLINES OF THE PROCESS
The application of dielectric technology in the field of drying is worldwide known.
We have many examples in glass industry, food processing, tobacco treatment, rubber manufacturing, textile industry.
In general it can be said that whenever water evaporation with hot air systems leads to a less than satisfactory result
in terms of quality of the operation and required time, dielectric technology is the right answer. The water molecule has
a polar behavior and therefore it can follow the line of force of an electric field. In an alternate field, the molecule is
made to follow the force lines of the field and during this movement it will interfere with other molecules of water that
are present in the body to be dried out. During the process, molecules will collide continuously, thus increasing the
overall energy level of the material; this explains why the temperature increases up to a point where the level of the
internal energy will be high enough to allow the water to turn into steam. This technology acts on a selective basis
meaning that heat development is proportional to the actual quantity of water. The absorbed power depends on the
present quantity of water.
Experience in textile industry
In textile industry, radio frequency allows to dry natural and man made fibers in staple, hank, cone, package and top
form normally immediately after hydro-extraction with good uniformity and better final handling. The generator works
on a frequency of 27MHz and is stabilized and suppressed complete to suit international interference regulations with
overload protection. Experience in the field of drying textile fibre by means of RF machines is growing rapidly.
Applications
Package and bobbins: After the removal of free water by hydro extraction these are dried with Radio frequency
combined with forced air. RF energy is transformed inside each package in proportion to its moisture content.. Drying
yarn packages by means of RFand forced air is the only means whereby the packages are heated uniformly , evenly
and with low cost of drying. n
The maximum moisture for the bobbins after centrifuge is:
•
•
•
•
•
- 45%
wool
- 18%
acrylic, man made fibre
- 35-40% mix acrylic-cotton
- 50%
cotton
- 60%
viscose
Advantages
• - the need for massive foundations and site preparations is completely eliminated and installation is easily and
•
•
•
•
rapidly carried out.
- flexibility : one set of equipment can dry packages, tops, hanks, loose stock and bagged products
- productivity improvement
- possibility to monitor costs accurately, often a difficult task with conventional drying
- reduction of energy costs by 50-60%
12
3- GENERAL INFORMATION
3.4
GENERAL INFORMATION
Description of the symbols used on this manual:
PERSONS WITH PACE MAKER OR ELECTRONIC DEVICE CANNOT OPERATE THE MACHINE
ATTENTION:
indicates information about safety and precaution
STOPPED MACHINE:
indicates that operation must be done with machine “OFF”
KEEP AWAY FROM LIVE CIRCUITS: indicates to disconnect electrical and pneumatic feeders
OPERATOR:
person experienced in charge of the machine with the only use of the panel control and
of loading and unloading of the goods, person who checks the quality of the goods at the outlet
MECHANICAL: person with mechanical knowledge who can run the machine and operate on
mechanical parts. Normally not adapt for electrical part.
ELECTRICAL:
person with electrical knowledge who can operate on the electrical devices to regulate,
maintain or repair the machine.
MANUFACTOR TECHNICAL:
persons with sufficient knowledge and experience to enable him to
operate on difficult situation or make special regulation.
3- GENERAL INFORMATION
13
3.5
INFORMATIONS FOR ASSISTANCE AND MAINTENANCE OF THE MACHINE
For the substitution of the spare parts use only original components authorized by manufacturer.
The use of non original components avoids automatically RF SYSTEMS of any responsibility.
For each damage, reparation or maintenance speak to our assistance service and use only specialized personal.
3.6
PRECAUTION TO CARRY DURING OPERING
The room temperature must be in the limits of : minimum of + 7° C and maximum of +30° C.
Since the room is frequently obtained above roof level, its temperature in summer is often higher than the outside air
temperature, which is generally measured in the shade.
The max room temperature of 30°C must under no circumstance be exceeded. If higher outside air temperatures are
possible, either additional cooling must be provided for the inlet or the generator power must be reduced in accordance
with the following:
INLET AIR
20°C
22°C
25°C
30°C
REDUCTION OF POWER
100% (65KW)
90%
80%
60%
Please take note that even continue operating in these conditions is guaranteed we suggest, in order to have longer use
of the components, to maintain ambient temperature no more than 30°C.
Measures must be taken to prevent air from entering the generator via the exit air duct while the unit is OFF. It is
necessary to operate the machine with only the cooling fans running for about 30 minutes prior to startup the radio
frequency.
3.7
INFORMATIONS FOR DEFINITIVE OUT OF ORDER AND DEMOLITION OF THE MACHINE
If the machine has to be definitively dismantled , this operation must be done accordingly with local laws regarding the
issuing of wastes and following CEE instructions
CEE 75/442 regarding issuing of generic wastes for ambient protection
CEE 78/319 regarding issuing of toxical and noxious wastes
CEE 75/439 regarding issuing of used oils
RF SYSTEMS is always available for advice or assistance in the event of difficulty being experienced in the
operation and/or maintenance of the equipment.
14
3- GENERAL INFORMATION
4 DESCRIPTION OF THE MACHINE AND TECHNICAL FEATURES
4.1
TECHNICAL FEATURES FOR RKB70A
SUPPLY
SUPPLY VOLTAGE
THREE PHASES 380 V - 50 HZ.
The nominal voltage should be within 5% (temporary
excursions of + 5% and -10% are permitted)
otherwise customer must install a suitable
stabilizer.
MAX POWER ABSORBED FROM THE MAINS
125 KVA
MAX CURRENT ABSORBED
220 A
GAUGE WIRE
3x90 mm² + GROUND 70 mm² minimum.
RF GENERATOR
TOTAL POWER RADIO FREQUENCY GENERATOR
70 KW ( 1 X 70 KW )
MAX POWER RADIO FREQUENCY
65KW
WORK FREQUENCY
27 MHz
COOLING SYSTEM
FORCED AIR
MAX ROOM TEMPERATURE
TA = 35°C
MAX EXHAUST AIR TEMPERATURE
TU = 85°C
OSCILLATOR
CAVITY TYPE WITH HIGH OVERALL EFFICIENCY
FREQUENCY STABILITY
WITHIN LIMITS
RADIATED FIELD
WITHIN LIMITS
GRID CURRENT MAX WITH NO LOAD
2,3 A TO 2,5 A
GRID CURRENT MIN WITH FULL LOAD
1,4 A
TRIODE TYPE
RS3060 CL
FILAMENT TRIODE VOLTAGE
10V + 1% - 3%
IF HIGHER POWER MUST BE REDUCED
AIR CIRCUIT
FAN CONSUMPTION
22KW
BATTERY RESISTOR POWER (ELECTRICAL HEATER)
24KW
PRODUCTIVITY
N° OF PACKAGES PER BATCH (LOAD)
108 (2X54)
MAX QUANTITY OF WATER REMOVED PER HOUR
MAX 140 l/h (indicative)
MOISTURE TO REMOVE
60%
4- TECHNICAL FEATURES
15
4.2
DIMENSION
(Machine dimensions) all dimensions are indicative and not binding fig.1
Ref.
A
B
B1
C
D
E
F
G
H
I
L
DIMENSIONS
16
MAX LENGTH
7400 mm
MAX WIDTH
3000 mm
WIDTH MACHINE
2124 mm
MAX HEIGHT
3600 mm
GALLERY LENGTH
4700 mm
AIR MODULE LENGTH
1600 mm
FILTER LENGTH
920 mm
BOBBINS HOLDER PLATFORM WIDTH
1500 mm
BOBBINS HOLDER PLATFORM LENGTH
3500 mm
BOBBINS HOLDER PLATFORM HEIGHT
790 mm
MAX BOBBINS HOLDER PLATFORM LENGTH
4100 mm
4- TECHNICAL FEATURES
4.3
DESCRIPTION OF THE MACHINE
The dryer RKB70A is composed of one RF unity of 70 KW plus one HOT AIR unit of 25KW.
(Machine description) fig.2
4- TECHNICAL FEATURES
17
The radio frequency dryer type RKB70 is made up of one unit of 70 kW water cooled and is composed of the following
components:
n°1 drying gallery complete with electrode systems
n°1 power electrical box
1
n°1 high frequency generator 70kW air cooled
n°2 trolleys for loading and unloading the material
DRYING GALLERY
The drying gallery is made of the following components:
Supporting frame :
Equipped with upper footpath to get accessibility to the generator and air fans fitted on the top of the drying gallery. The
lower part of the supporting frame is closed with panels.
Box :
This is a very rigid structure made of aluminium alloy plate; on each side inspection panels are provided. At each end
of the gallery, frequency traps ensure total absence of RF radiation escaping out of the gallery.
The grounded electrode is the gallery bottom plate, whereas the positive electrode is made of a longitudinal element
which can be moved upward and downward so as to adjust the intensity of the electromagnetic field into the material.
1A
Electrodes system :
The upper electrode is basically made of an aluminium alloy frame plate or alluminium roller. The electrode is matched in
order to provide a given profile of voltage versus the overall length of the electrode. The grounded electrode, made by the
carrier of the bobbins, is the lower part of the dryng gallery and is made of a perforated plate for blowing the hot air
(60°-100°C) trough the packages. The cycle time and temperature of air are controlled by the PLC.
Air ventilation and exhaust system :
The hot air is heated by a electrical resistors battery (24 Kw) and is propelled
through the carrier (grounded electrode) and blown towards the packages.
The moisture is exausted outside via an air fan.
Power transmission line:
Transmission RF lines are arranged with coaxial cables.
18
4- TECHNICAL FEATURES
2
HIGH FREQUENCY GENERATOR
Oscillator :
The high frequency generator is made of an oscillator and an electronic tube (triode). The oscillator has an L-C type of
oscillating circuit (cavity type) driven by an electronic tube. This cavity type circuit ensures a very high overall efficiency,
together with a remarkable stability of the working frequency with no electromagnetic interfering due to harmonic waves.
Electronic tube :
The second component which qualifies the high frequency generator is the electronic tube: this is of metal-ceramic type,
air cooled. It is normally equipped with overload devices.
Air module:
The hot temperature air which goes through the circuit is propelled via ducting system back to the drying gallery in order to
assist the heating process, to maintain a high dew point value and improve the overall efficiency of the dryer. the
generator is electrically connected to the drying gallery by an induction systems; the tuning between the generator and the
load is normally set at the commissioning and adjusted on the basis of the indications given by the customer.
3 MAIN SWITCHBOARD
This is normally equipped with a blower for component cooling down and heat removal.
It includes:
- High voltage transformer :
With dry isolation and its own overload protection. Two secondary taps will permit the accurate setting of the volatage
on installation at the final site
- Rectifier :
Three-phase full wave type, it is made of 6 bars of avalanche diodes sets.
4
POWER AND CONTROL CIRCUITS :
This part of the circuitry drives and controls:
• position of electrodes
• power transferred to the load
• grid current
• anode and grid dissipation
• air cooling flow and temperature
• start up sequence
All components are sized for a continuous service operation; their quality meets a high reliability standard
5
LATERAL SIDES SUPPORT FOR BOBBINS HOLDER PLATFORM
6
TROLLEY FOR THE LOADING OF THE BOBBINS HOLDER PLATFORM
7
BOBBINS HOLDER PLATFORM
8
ACCESS DOOR TO THE DRYING CHAMBER
4- TECHNICAL FEATURES
19
9
REMOTE CONTROL PANEL
located in the inlet set it consists of :
• PLC
The machine is equipped with SIEMENS S7-300 fully automatic touch screen PLC. The PLC allows to control:
- RF Power
- height of electrodes and electrode movement
- cooling system
- freezing of RF power during operation conditions (for example, if we instruct the PLC to limit the RF power to 70
kW, the machine should not be able to absorbe extra).
- overload.
- emergency.
- motors and fans.
- display of time run for a complete cycle including air, RF and combi drying zones.
• TOUCH SCREEN PANEL:
The operator with the fully automatic touch screen, has the possibility of:
- setting of receipts accordingly to material to treat and reproducibility of these receipts.
- setting automatic/manual operating.
• SELECTOR OF MANUAL OR AUTOMATIC FUNCTIONING.
• EMERGENCY RED PUSH BUTTON.
• MANUAL START RF - MANUAL STOP RF - RESET FOR OVERLOAD PUSHBUTTON, COMPLETED WITH LAMP.
• AUTOMATIC START RF - AUTOMATIC STOP RF PUSHBUTTON, COMPLETED WITH LAMP.
9A
BY WAYS MANUAL TERMINAL FOR OPENING AND CLOSING THE DOOR
10
NOT PRESENT
11
EXHAUSTED MOTOR
12
GRID CURRENT INDICATOR
13
MAIN SWITCH BOARD
14
BOX WITH PLATES OF ELECTRODE
15
FAN 22KW (HOT AIR MODULE)
16
AIR FILTER
17
ELECTRICAL BATTERY RESISTORS 24 KW (HOT AIR MODULE)
17A
HOT AIR TEMPERATURE REGULATOR
18
ELECTRICAL BOX AIR MODULE FOR FAN
19
PNEUMATIC EQUIPMENT AND CIRCUITS
20
4- TECHNICAL FEATURES
4.4
SAFETY DEVICES
Fig.4
4- TECHNICAL FEATURES
21
REF
DESCRIPTION (see fig.4 pag.21)
1
MAIN SWITCH: equipped with lock and under voltage coil
2
EMERGENCY BUTTON: When the emergency button is press the radio frequency OFF, every fan
and motor is OFF and the door open immediatley.
2A
PUSH BUTTONS FOR COMMAND DOOR OPENING AND CLOSING : they are located on the electrical
panel’s side and so are in frontal position of the machine. From this position we have the
maximum visibility on the dangerous zone of the machine (sliding zone of the door, dring
chamber). Both movements of closing and opening of the door have to be done activating
two buttons which are located at a distance which requires the use of both hands, in this
way the operator can open and close the door only staying close to the panel, in safe
position,. Before to close the door, the operator must be check that there is no persons
inside the machine. The moving of the doors is possible only for the time when the two
buttons are pushed. As soon as one is released, the door is stopped instantaneously at
the point where it stays. In this way, the operator can stop immediately the moving of the
door in case of urgency.
3
On the electrical power box, electrical ciruit box, generator box and fan box, the doors
are electrically locked by means of a special micro switch (item 3a - 3b).
4
DOORS LOCKS BY KEYS : the access doors to the fan’s box and to the air filter. During
the use of the machine, these doors must be closed with the apposite keys. Main switch
has to be switched off before any intervention in these zones. Attention : dangers of
getting trapped and squeezing, and dangers of electrocution !!!!
FIXED ALLUMINIUM PANELS ON THE DRYING GALLERY:
the 4 panels on the gallery allow
to have no leakage of radio frequency outside the gallery. In order to avoid arcing the
cover must be carefully fixed. To remove the covers 2 different tools are needed.
5
MANDATORY: (IT IS ABSOLUTELY FORBIDDEN TO REMOVE THIS COVER 10.000V IT IS ABSOLUTELY
FORBIDDEN USE THE MACHINE IF NO HAWE INSTALLED THIS PANEL IN THE DRYING GALLERY).
If one of the 4 panel is remove the machine doesn’t trip out. Be very careful do not
open the panel without first disconnected the main switch and locked in position OFF
in order to avoid electrical shock. REMIND 10000V INSIDE THE GALLERY DANGER OF DEATH.
6
DOOR ENTRY TROLLEY: NB: it has to be closed before to start the radio frequency. It prevents
the emission of electromagnetic waves outside the tunnel and avoid any contact with the high
voltage of the electrode (10.000V). The moving of the door is done by mean of an auto braking
motor. Two electric limit switchs stop the running of the door when it arrives in position
completely open, limit switch 6A and when it arrives in position completely closed, limit
switch 6B.
Another extra limit switch, 6C, stops the closing in case that limit switch 6B will not
works. Both during the automatic running and the manual running, the closing of the door is
done only through the operator by mean of the apposite double button. During the use of the
machine in automatic, the door opens automatically at each end of the cycle.
7
FAN PROTECTION: all fans are equipped with special grid in order to avoid the
possibility to enter in contact with wheel.
8
CONTROL PANEL:it can be opened only with a special tool. No electrical locks are present
9
10
FIXED COVERS: they are fixed with 4 screws. They enable not to reach moving parts.
MANDATORY: DO NOT REMOVE THIS COVER.
PLASTIC PLATE TPM
Plastic plates with signal of risk of death (indications of the high voltage
diagram, see chapter 4.6.1)
22
4- TECHNICAL FEATURES
REF
DESCRIPTION
PLASTIC PLATE TFE
10A
Plastic plates with signal of risk of death ( IT IS ABSOLUTELY FORBIDDEN TO ENTER
INSIDE THE MACHINE 10.000V)
11
SAFETY SWITCH DOOR CLOSED:only when the door is total closed the machine is ready to
start
12
NOT PRESENT
13
ANTI FALLING CYLINDER OF THE DOOR : WARNING !!! IT IS ACTIVATED ONLY WHEN THE DOOR IS
COMPLETELY OPEN. It maintains the door in position open even in case of breakage of the door
opening motor’s brake. Before to load the bobbins holder inside the drying gallery, the
operator must make sure that anti fall cylinder is in safety position (the piston rod has to
be completely outside and the door has to be at the higher position).
14
PERIMETRAL PANNELS : the machine is protected on both sides by panels made of non conducting
material. It is forbidden to remove these panels. If the panels are moved for maintenance,
they have to be reinstalled before to restart to work with the machine.
15
NON OPENING PANELS
ALLUMINIUM PANELS ON THE GENERATOR BOX
MANDATORY: IT IS ABSOLUTELY FORBIDDEN TO REMOVE THIS COVER OR USE THE MACHINE IF NO HAWE
INSTALLED THIS PANEL IN GENERATOR BOX.
16
If one of the 2 panel is remove the machine doesn’t trip out. MANDATORY: Be very
careful not open the panel without first disconnected the main switch and locked in
position OFF in order to avoid electrical shock, RISK OF DEATH, 10.000V.
To remove this panel 2 different tools are needed.
Before to start to operate with the machine, the operator must make sure that the shelters have not been
moved from the machine or forced and that the electric devices of protection are active and running
well. In case of abnormalities, the operator has to repair it before to start to work.
4- TECHNICAL FEATURES
23
4.5
OPERATOR POSITION
Fig.5
IN ORDER TO OPERATE PROPERLY AND IN SAFE CONDITIONS THE MACHINE MUST BE USED BY ONLY ONE
OPERATOR PER SHIFT, WHO HAS TO SURVEY FOR ALL WORKING CYCLE LONG.
NB : during operation of the machine, the operator has to stay on working positions (1-2-5)
fig. 5 only for the time needed.
During the survey the operator has to stay at more than 2 meters of distance
POS.
fig.5
DESCRIPTION
1
SETTING AND CHECK OF THE WORKING PARAMETERS, USE OF THE MACHINE BY MEAN OF THE COMMANDS
LOCATED ON THE CONTROL PANNEL. During the whole working cycle the operator has to preside
the machine checking from control panel the real values of working in order to intervene
instantaneously in case of disfunction and/or fire.
2
CLOSING AND OPENING OF THE DOOR BY MEAN OF RELATIVE BUTTONS, ACTIVATION OF THE ANTI FIRE
DEVICE. From this position we have the maximum visibility on the working zone of the door.
In case of presence of unrelated persons with the working and/or trolley for the loading of
the bobbins and/or other materials, the operator has not to activate the closing or the
opening of the door and eventually stop it instantaneously.
3
LOADING OF THE BOBBINS ON THE APOSITE BOBBINS HOLDER : WARNING : the operator must always
load the bobbins holder after he has taken it outside of the tunnel. It is strictly
forbidden to load the bobbins holder inside the tunnel.
4
LOADING OF THE BOBBINS HOLDER : in order to unload the bobbins holder you have only to
introduce the trolley inside the tunnel making sure that all the cylinders are closed,
pushing it till limit, hold up the bobbins holder by mean of the apposite hydraulic pump
installed on the trolley and taking it completely outside the tunnel. Before to do unloading
the operator has to make sure that the door is completely open and that the cylinder anti
fall is completely out ( rod under the door )
5
LOADING/UNLOADING OF THE BOBBINS HOLDER:
Before to unload the product the operator must make sure that:
- red led STOP MANUAL ref.5 fig.21 page 43 is OFF.
- the door is completely open and anti fall cylinder is completely out ( the piston rod
must be under the door )
Unloading of the bobbins holder : insert the trolley inside the drying chamber after making
sure that the 4 pistons are down. Push the trolley till limit switch, hold on the bobbins
holder using the apposite hydraulic pump installed on the trolley and let it go out
completely. After he has taken the bobbins holder out from the drying chamber,operator must
check the contacts brass of the bobbins holder(trolley) if presence of any dark signs or
arcs he must shut down the dryer, enter inside the drying chamber and cheks the efficiency
of the fixed brass contacts and ask for necessary maintenace before to continue with a new
loading of material
Loading of the bobbins holder: insert the trolley inside the drying chamber without
reaching the limit switch but stopping the wheels of the trolley in correspondence to the
apposite positioning slides, let the bobbins holder go down activating the control knob for
the discharging of the oil of the pump, push forward the bobbins holder till it slides in
position, remove the trolley. See chapter 8.0.
24
4- TECHNICAL FEATURES
4.6
RESIDUAL RISKS
see description at next page
Draw indicative and not binding
4- TECHNICAL FEATURES
Fig.6
25
see fig. n°6 previous page
1
TUNNEL: DANGER OF DEATH : IT IS STRICTLY FORBIDDEN TO START THE WORKING CYCLE WITH
PERSONS INSIDE THE TUNNEL. BEFORE TO CLOSE THE DOOR AND START THE WORKING CYCLE, THE
OPERATOR MUST MAKE SURE THAT THERE IS NOBODY INSIDE THE TUNNEL (10.000V).
2
DOOR’S WORKING ZONE: danger of getting trapped and squeezing: Activation of the door is done by mean of an
electric motor with electro mechanic brake which guarantees the stopping at actual position. Nevertheless it is possible that
brake doesn’t work and that door closes very quickly. The operator must, before to go to take position for loading and
unloading, make sure that the door is completely open, that the rod anti falling ref n°13 fig. n°4 page 21 is completely outside (
when the door is stopped at the top limit it is any centimetres over the rod of the cylinder), and check that nobody is inside the
machine. If the door is not completely open, the operator must the manual running mode and open it with the apposite
buttons. In case of necessity of maintenance on the door and its moving parts, he must set the door in position of lower limit.
3
FAN BOX : risk of electrical shock. It is forbidden to open the box with the machine with MAIN SWITCH ON
4 CONTROL PANEL: risk of electrical shock. It is forbidden to open the control panel with the machine with MAIN SWITCH ON
5
GENERATOR OF RADIO FREQUENCY AND VARIABLE CAPACITOR: DANGER OF DEATH: risk of
electrical shock: it is forbidden to open the removable cover with the MAIN SWITCH ON. Keep in mind that the
removable covers are not electrically locked and inside the generator there is high voltage 10000 VDC
6
METALLIC PARTS: The machine is not equipped with metal detector. It is forbidden to operate goods with
metallic parts, the high voltage of the electrode can make arcing and generate fire of the goods.
7
THE LIVE ELECTRODE, RISK OF DEAD: whit the RF on has high voltage which, if brought in to contact with
skin, may cause dead. Never touch live electrode with had, tools or any objects such as bars. Never reach forbidden area
with the radio frequency on operation.
8
WORKING ZONES : PRESENCE OF ELECTRO MAGNETIC FIELD : When the generator is on, even if the
value of electro magnetic field is lower than security values, there is an electro magnetic field in working position and
around the machine. Persons with pace maker are not allowed to use the machine. Also, the operator must take
away eventual persons with pace maker who could be near the machine. The operators have to stay near and
around the machine only for the strict time needed and have to survey the correct operating of the machine only
at a distance of more than 2 meters.
9
DANGER OF FIRE DUE TO OVERHEATING: in order to avoid dangers of fire for the product and the machine it
is mandatory to do the loading of the bobbins holder loading each time at full load in order to have constant thickness of
the product loaded. It is mandatory to load at each time same type of product and only product previously centrifugated.
Ths bobins must be uniform in size, weight and moisture.
UNLEVELED MOISTURE AND QUANTITY OF WATER TO REMOVE ORIGIN DANGERS OF FIRE. The operator must
check the drying level when unloading the dried product and eventually modify the set working parameters.
Every time the dryer is turn OFF and at the end of the cycle, it is necessary to discharge the dryer in order to avoid the risk of fire
due to overheating. Please take note that the goods can burn after many hours and the operator have to check that the product is
not to hot at the exit many hours . Normally on an RF dryer if the product if over heated can burn from the inside after many
hours so the operator cannot see the risk of fire . The only way to avoid any fire is to check at the exit that the product is
not too hot and there is no bad smell. THE OPERATOR MUST ALSO CHECK EVERY TIME THE TEMPERATURE OF THE
PRODUCT AT THE END OF THE DRYING CYCLE, AND CHECK THE PRODUCT BEFORE STOCKING.
10
DANGER OF FIRE DUE TO ARCS : fire may be generated from arcs between the bobbins holder and the brass
contacts inside the drying chamber. These arcs are due to unproper positionning of the bobbins holder inside the drying
chamber. When the operator takes out the bobbins holder from drying chamber he has to control visually the presence of
eventual arcs or burnings and, if necessary, ask to a maintenance’s technician to intervene before to continue to operate
with the machine. In case that arcs occur frequently contact RF SYSTEMS who will give detailed intructions for the
execution of an extraordinary maintenance for the brass contacts and the supports of the bobbins holders.
11
FIXED ALLUMINIUM PANELS ON THE DRYING GALLERY: Risk of arcking . The doors must be look carefully
in order to avoid an arcking between the frame and the door. Each lock must have the two signs set toghether.
12
DANGEROUS TEMPERATURE : before to do any intervention on the steam battery it is mandatory to shut the steam
alimentation, shut down completely the machine and wait that the temperature of the steam battery and the parts connected to it
arrives below the minimum safety temperature of 40°C. The operator has to wear apposite gloves for temperature protection.
13
AIR FILTER BOX: danger of getting caught and crushing: when the machine is in function, It is forbidden to
insert the hands in each of its parts which are in movement. Before to do any maintenance, the operator must shut down
the machine positioning the main switch in position 0 and locking the knob.
14
LOAD OF THE BOBBIN HOLDER: danger of pressing: during the position of the bobbin holder inside the tunnel
operator must have one hand on the trolley handle and one in the handle of the hydraulic pump.
15
-
MAINTENANCE SHOULD BE CARRIED OUT BY QUALIFIED STAFF AND IN TOP SAFETY CONDITIONS:
MAIN SWITCH OFF AND LOCKED
FEEDERS OF PNEUMATIC CIRCUIT DISCONNECTED.
26
4- TECHNICAL FEATURES
4.6.1 HIGH VOLTAGE DIAGRAM
Draw indicative and not binding
4.6.2 RADIO FREQUENCY FIELD
Draw indicative and not binding
4- TECHNICAL FEATURES
27
4.7
WARNING SIGNS
TVA
TAT
TI1
TVAC
TI2
TCE
TAT
TP
TPM
TAT
TFE
TPM
TVA
TAT
TVA
TAT
TVA
TFE
TPM
(Plates list) fig.7
28
4- TECHNICAL FEATURES
The dryer is equipped with the following plates (see fig.7 pag.29):
Q.tà
ITEM
DESCRIPTION
01
TI1
Metallic identification plate located in the inlet of the machine which shows
the name of manufacturer with address, phone and fax numbers.
01
TI2
Metallic identification plate with information required for mark CE: Name of
manufacturer and address, Mark CE, Type of dryer, Year of construction,
Serial number, Installed power
01
TCE
Metallic plate with signal of risk to work near the machine for personal with
by pass and pace maker( electromagnetic fields )
01
TVAC
09
TAT
Metallic plates with warning sign of high voltage(15000Vac) inside the
elements with the name of manufacturer.
04
TVA
Metallic plate with warning sign of high voltage( 110-220-400Vac ) inside the
elements with the name of manufacturer.
04
TPM
Plastic plates with signal of risk of death
02
TFE
Plastics plate with signal of risk of death and indication forbidden to stay
indide the machine (presence of 10.000VDC- Danger of death)
02
TP
Metallic plates with warning sign it is forbidden to enter and to introduce
metallic parts during the operating of the machine.
Plastics plate with signal the presence of dangerous temperature
SUBSTITUTION OR TAKE OUT OF ABOVE MENTIONED PLATES IS FORBIDDEN. IF ONE PLATE
RESULTS DAMAGED OR TAKE OUT , END USER MUST INFORM IMMEDIATELY RF SYSTEMS SRL.
4- TECHNICAL FEATURES
29
5 TRANSPORT OF THE RF DRYER COMPONENTS TO THE POINT
OF INSTALLATION
The dryer is shipped in a few pre assembled parts:
TUNNEL - RF GENERATOR - TRANSFORMER BOX -TROLLEY+ BOBBINS HOLDER PLATTFORM-ETC
The single parts are fixed on wood pieces in order to more easily with fork lift.
The fork lift must be strong enough to support the weight of each part.
The fork lift must be used on parts signed with the arrows.
The transportator routes must be cleared and if necessary, the door openings in the building must be enlarged as
appropriate to the dimensions of the biggest piece.
DURING THE MOVEMENT PLEASE TAKE CARE OF THE GRAVITY CENTER
FORKLIFT LENGTHS MINIMUM 2,2 mt
THE WEIGHT OF EACH PIECE IS INDICATED ON THE PIECE AND ON THE PACKING LIST
All the transport at movements must be carried out by specialized persons.
RF-SYSTEMS is not responsible for failures caused by transportation loading and unloading of the
machine.
30
5- TRANSPORT
6 SETTING INSTRUCTIONS
Our dryer is a robust self-contained, free standing assembly line, only requiring the services of electrical power plus an
exhaust air duct. The machine is sent in a few pre assembled and pre wired parts, i.e :
1) Main body equipped with gallery
2) Generator and fans
3) Switchboard equipped with transformer
4) Fan and air module + steam battery
5) Air filter
6) Remote control panel
7) Panels, triode, etc.
Installation is very easy and has to be carried out in accordance with the installation drawings.
8)The machine must be set up in a place high enough for the generator to be lifted off when necessary therefore at least
one meter must be left between the generator top and ceiling
Minimum distance to walls and ceiling 1000mm.
Minimum distance to other equipment 5000mm.
IMPORTANT: Use only stainless steel bolts for connections
6.1
AMBIENT CONDITIONS
AMBIENT CONDITIONS Clean and with no dust, No explosive atmosphere
LAY-OUT
The room must be be clean, with enough light and with dimensions that
enable to move easily around the machine for the normal operation and for
the maintenance. No vibration of the rooms floor are allowed, floor must
be levelled.
MINIMUM DISTANCE TO OTHER ELECTRICAL DEVICES 5m
TEMPERATURE AND
MOISTURE
The ambient moisture must be below 60% and the room temperature below
30°C. In that case room air can be used for cooling (2500m³/h). If the
moisture and the temperature are too high, air for cooling must be taken
from the outside. The drop of pressure of the ducts must be below 30mm of
water. It is important that the intake air is clean, the intake circuit
duct should therefore be positioned sufficiently far away from other
exhaust air duct. An anti bird grille, whose must should not be to fine,
must be fitted in front of the intake duct. In case where the intake duct
is above the roof level, the intake duet must be fitted with a cover to
protect against water.
EXHAUST AIR
An anti bird grille, whose must should not be to fine, must be fitted in
front of the exhaust duct. The exhaust duct must be fitted with a cover to
protect against water.
FLOOR
In dry rooms, a smooth concrete floor is sufficient in the case of wet
floors, the machine should be placed on a concret base.
Before the machine positionning verify the total weight of machine.
6- POSITIONING AND INSTALLATION
31
Fig.8
Minimum distance to other equipment 5000mm.
32
6-POSITIONING AND INSTALLATION
6.2
ASSEMBLY OF THE FRAME
• No indication is given because each assembly phase has to be followed by the technicians of the manufacturer
with the assistance of the specialized personal available from customer.
6- POSITIONING AND INSTALLATION
33
6.3
FEEDERS
CAUTION!!! ALL THE FEEDERS ARE IN CHARGE OF CUSTOMER
THEY MUST BE CARRY OUT PERFECT AND IN FULL OBEDIENCE OF
CURRENT REGULATIONS.
These connections have to be carried out in the following order:
6.3.1:
6.3.2:
6.3.3:
ELECTRICAL FEEDER
AIR DUCT FEEDER ON RF GALLERY
AIR COMPRESSED FEEDER
(Ref. 1 fig.12)
(Ref. 2 fig.12)
(Ref. 3 fig.12)
Fig.12
34
6-POSITIONING AND INSTALLATION
6.3.1 ELECTRICAL FEEDER
REF. 1 fig.12 pag.34
• Three phases 400V- 50 Hz see fig.13 ref.CF , ground to the power transformer see fig.14 ref.T
• The distribution systems complete with the master switch and fuse disconnections should be installed in the vicinity
•
of the machine (max 15 meters away) in the same room and in such a way as to be easily reach. The master switch
should be capable of being locked in the OFF position by means of padlock.
If fluctuation of inlet voltage is more than +1% -3% a suitable voltage stabilizer must be fitted by customer
fig.13
fig.14
USER:THREE PHASES + GROUND 90 SQUARE MILLIMETERS GAUGE WIRE
MINIMUM
POWER ALIMENTATION
POWER INSTALLED
MAX CURRENT ABSORBED
400V 50 Hz THREE PHASES + GROUND
125 KVA
220 A
6- POSITIONING AND INSTALLATION
35
6.3.2 AIR DUCT FEEDERS
REF. 2 fig.12 pag.34
• Exhaust section frame ref FV see fig.15 are 355 x 250 mm
• Air flow rat 2500 m³/h
• Max temperature in duct 80°C
• A rair channel within the duct with an external outlet must be provided in order to ensume that rain water or
condensation with the exhaust air cannot flow back to the machine.
• The exhaust air duct must be fitted with a cover to protect again rain.
• Measures must be take to present the formation of condensation.
fig.15
Fig.16
6.3.3 COMPRESSED AIR
REF.3 fig.12 pag.34
PRESSURE MAX
CONSUMPTION
7 Bar
2 Liters/hour
USE COMPRESSED AIR FREE OF WATER
fig.17
36
6-POSITIONING AND INSTALLATION
6.4
COMMISSIONING
After the completion of installation, the following further checks must be done:
• All screw and terminal connection which may have became loose in transit must be checked to see that they
•
•
•
are thight
All the components connected with protective devices must be connected in order to provide protection against
shock in the case of a fault.
All components which could become damaged by works traffic, sush as inlet group, drying gallery, outlet group
etc, must be provided with additional protection in the form of covers and railings.
A check must be made to see of the warning signs have bee fitted. Otherwise advise immediately RF Systems.
6.4.1 SWITCHING THE RF FOR THE FIRST TIME
• Check three phases are ON and the same value
• Check the direction of rotation of the motors
• Check the heater voltage (10V +1% -5%) of the triode (see electrical diagram) and adjust if necessary by
means the variable plug on the filament transformer. The following value with no load must be display: grid
current between 2,3 A and 2,5 A radio frequency power below 2 kW.
6.4.2 TEMPERATURE CHECKING
The max room temperature air is 20°C.
The max outlet temperature is 80°C.
Check that the exhaust air thermostat is set to 80°C.
Since the room temperature is frequently abbined above roof level, its temperature in summer is often high than the
outside air temperature, which is generally measured in the shade.
The max outlet temperature if 80°C must under no circumstances be exceeded. If higher intake air temperature is
possible, either additional cooling must be provide for the inlet air or the generator power must be reduced as follow.
INLET AIR TEMPERATURE
20°C
25°C
30°C
MAX RF POWER
100% (65KW)
80%
60%
6.4.3 MOISTURE CONDENSATION
In order to avoid problems due to moisture condensation it is advisable to operate the machine with only the cooling fans
running for about 30 minutes prior to start up the radio frequency.
6- POSITIONING AND INSTALLATION
37
7 REMOTE CONTROL PANEL
7.1
REMOTE CONTROL PANEL DESCRIPTION
fig.20
fig.21
38
7- REMOTE CONTROL PANEL
Ref.
DESCRIZIONE
PANNELLO OPERATORE TOUCH SCREEN
1
SELECTOR ON - OFF AUXILIARY
This kind of selector has 3 positions with central position as non-working
position : turning the selector towards right, the auxiliary circuits and
consequently motors and fans and all devices on the machine are activated ;
turning the selector towards left, the auxiliary circuits are disconnected .
SELETTORE FUNZIONAMENTO
AUTOMATICO / MANUALE
3
OPERATOR PANEL TOUCH SCREEN TYPE
Panel where it is possible to check and set the parameters for the functioning of
the machine.
SELETTORE ON-OFF AUSILIARI
2
DESCRIPTION
MANUAL / AUTOMATIC SELECTOR
Selector to change the function mode of the machine, automatic or manual .
Changing from manual to automatic and vice versa , all the values of the
parameters about the cycle in progress , past time , litres of water etc., are
cancelled ( NB: only parameters regarding the present cycle are deleted not the
working parameters previously set)
PULSANTE DI START RF MANUALE
4
This button is working when machine is preset for manual function ( selector nr. 3
in manual position ), and only after that door is closed. It starts radiofrequency.
Green light on shows that radiofrequency is on . This light is when the
radiofrequency is on, on both for machine set for manual or automatic function.
PULSANTE DI STOP MANUALE
5
PUSH BUTTON AUTOMATIC STOP RF
It is working when the function selector is positioned on automatic way and only
after that door has been closed. It stops immediately automatic working cycle, if
the cycle is re-started pushing button START CYCLE AUTO, the cycle starts from
where it has been suspended. Red light on =automatic working cycle suspended.
PULSANTE RESET-RIPRISTINO
8
PUSH BUTTON AUTOMATIC START RF
It is working when the function selector is positioned on automatic way, and only
after that door is closed. Red light on = automatic working cycle in progress.
Push this push button for five seconds in order to start the machine.
PULSANTE DI STOP RF AUTOMATICO
7
PUSH BUTTON MANUAL STOP RF
This button is working when machine is preset for manual function (selector nr. 3
in manual position), and only after that door is closed. It stops radiofrequency.
Red light is on when it is possible to start working (everything is ready, doors
are closed, the trolley is in the tunnel, etc.) This light is on both for machine
set for manual or automatic function. When radiofrequency is running this light is
off .
PULSANTE DI START RF AUTOMATICO
6
PUSH BUTTON MANUAL START RF
PUSH BUTTON RESET
Reset the machine after one reset. The blu lamp is turn on after one reset
WARNING !!! When an overload occurs wait at least 60 seconds before to press start
( opening time of variable resistor).
PULSANTE “+” AUMENTA POTENZA
10
PUSH BUTTON “+” INCREASE POWER
It is working only when the machine is functioning manually: increase the power
supplied.
7- REMOTE CONTROL PANEL
39
Ref.
DESCRIZIONE
PULSANTE “-” DIMINUISCE POTENZA
11
PUSH BUTTON DECREASE ELECTRODE
TUNNEL POSITION
It is working only when machine is functioning manually . It brings down the upper
plate of the internal electrode . The electrode goes down for the time that the
button is pressed and anyway until the switch limits the fall.
To start the machine is necessary thet the switch limits of fall are pressed
PULSANTE ALZA POSIZIONE
ELETTRODO TUNNEL
13
PUSH BUTTON “-” DECREASE POWER
It is working only when the machine is functioning manually: decrease the power
supplied.
PULSANTE ABBASSA POSIZIONE
ELETTRODO TUNNEL
12
DESCRIPTION
PUSH BUTTON INCREASE ELECTRODE
TUNNEL POSITION
It is working only when the machine is functioning manually. It brings up the
upper plate of the internal electrode. The electrode goes up for the time that the
button is pressed until the switch limits the climb .
continue at next page.
7- REMOTE CONTROL PANEL
40
Ref.
DESCRIZIONE
PULSANTE EMERGENZA
14
PUSH BUTTON TO OPEN THE DOOR
This button is operating only if machine is stopped and only if the function selector nr.3
is in manual position. Pushing it with ENABLE BUTTON n°18 it controls door opening.
PULSANTE CHIUSURA PORTA
17
ENABLE BUTTON FOR OPENING/CLOSING THE DOOR
Pushing together this button and the button to open/close the door, it enables the
movement of the door, as you stop pushing this button the door’s movements stops
immediately.
PULSANTE APERTURA PORTA
16
EMERGENCY BUTTON
When this pushbutton is pressed, the radiofrequency is turned off, the auxilliary
circuits is turned off, the fans are turned off, the door is open and the working cycle
is interrpted. To restart the machine is necessary turn ON the auxiliary with selector
ON - OFF AUXILIARY n°2.
PULSANTE DI ABILITAZIONE APERTURA /
CHIUSURA PORTA
15
DESCRIPTION
PUSH BUTTON TO CLOSED THE DOOR
This button is operating only if machine is in stop . Pushing it together with ENABLE
BUTTON n°15 it operates door closing .
7- REMOTE CONTROL PANEL
41
7.2
FUNCTION MODE
The function mode of the machine are two (2), AUTOMATIC and MANUAL.
The selection of the running mode is made through the selector MANUAL/AUTOMATIC n°3 fig.21.
AUTOMATIC: machine runs with special recipes done by
end-user accordingly to the product to dry, the parameters for
working like power, electrode position ecc… are setted
automatically by the machine.
The automatic cycle is divided in 5 different working phases. Hot
air, hot air + radio frequency, cooling. The parameters are
chosen by the operator at each phase.
During automatic use page of fig.22
See chapter 8.2 .
Fig. 22
MANUAL:
Before to start to work in manual , the different uses have to
enabled to the running
Fig. 23
The machine runs manually by mean of the touches on the
control panel
the machine runs by setting the power.
During the manual use page di fig.24 is visualized
See chapter 8.1.
Fig. 24
42
7- REMOTE CONTROL PANEL
7. 3
CONTROL PANEL DESCRIPTION
The control panel is a touch screen type, to set a command is enough to tough with a finger the symbol of the image of
the push button that you want to press or to the value that you wants to modify.
Take care not to give too much pressure on the panel in order not to damage it.
When the push button is pressed the color of the background changes from white to grey and indicates that the command
is received .
7.3.1 MAIN PAGE DESCRIPTION
To the MAIN PAGE, fig.25,
access to all the
setting and control pages of the machine :
1: push the pushbutton MANUAL item.n°1 to
visualize the page dedicated to the manual use of
the machine, see chapter 7.3.2 For every
description .
2: push the pushbutton AUTOMATIC item.n°2 to
visualize the page dedicated to the automatic use
of the machine, see chapter 7.3.3 For every
description .
3: Push the pushbutton SETUP item.n°3 to
visualize the pages allows to modify the
parameters of the machine, to set accordingly
with specifications of the product, see chapter
7.3.4 For every description .
fig.25
4: Push the pushbutton UTILITY item.n°4 to set the state of the control panel, see chapter 7.3.5 For every description .
5: push the pushbutton WORK CARD item.n°5 to visualize the page dedicated to the use and creation of recipe to use the
machine in automatic mode, see chapter 7.3.6 For every description .
6: push the pushbutton MEMORY ALARM item.n°6 to visualize the list of alarms occurred from last use of the machine
see chapter 7.3.7 For every description .
7- REMOTE CONTROL PANEL
43
7. 3.2 PAGE TO MANUAL USE OF THE MACHINE
This page is visualized when the selector man-auto is set in manual position or when selected from main page.
PAGE N°1/3
In this page it is possible to :
1- set the max power of working of the machine: SET MAX POWER, ref. N°1 fig26
2-read values of working of the machine: ABSORBED RF POWER , CONDENSATATOR POSITION, ELECTRODE
TUNNEL POSITION, OUTLET TEMPERATURE ref.n°2 fig.26
From this page it is possible to go to MAIN PAGE with touch MENU ref.n°3 fig.26 and do RESET of an alarm with touch
RESET ALARMS ref.n°4 fig.26.
Fig. 26
44
7- REMOTE CONTROL PANEL
PAGE N°2/3
In this page it is possible to :
1 ref.n°1 fig.32 read values of working of the machine: POSITION ELECTRODE TUNNEL, WEIGHT OF PRODUCT
Fig. 27
PAGE N°3/3
In this page it is possible to :
1 ref n°1 fig.33 : pressed on time = activate the related use; pressed the second time = deactivate the related use.
2 ref n°2 fig.33 : indicator of the state of the uses: ON = use activated; OFF = use deactivated
Fig. 28
7- REMOTE CONTROL PANEL
45
7. 3.3 PAGE TO AUTOMATIC USE OF THE MACHINE
This page is visualized when selector man-auto is set in automatic position or when page is selected from MAIN PAGE
PAGE N°1/3
In this page it is possible to see fig.29:
ref.n° 1:
function mode setted indicator
ref n° 2:
visualisation of the working phase
ref.n° 3:
time of the working cycle indicator
ref.n° 4:
Max RF Power indicator
ref.n° 5:
outlet air temperature indicator
ref n° 6:
visualisation of the height of the plate of the electrode on the drying chamber
ref n° 8:
visualisation of the number of the reset and automatic restarts occurred during the last 10 minutes, when
the machine arrives at 4 it stops. The intervention of a technician is needed in order to check the reason of
the resets and restart the cycle.
ref n° 11:
visualisation of the presence of the trolley
ref n° 12:
visualisation of the quantity of litres of water to remove ( set at field 3 fig.30 pag.52 )
NB : it updates when the radio frequency starts.
NB : the value may be modified setting directly the new one. It may be modified in the case that it never reaches the set
value, preventing in this way the completion of the currently working phase. Setting the value at 0 the machine goes to the
successive working phase.
ref n° 13:
visualisation of the quantity of litres of water currently removed from the product
ref n° 14:
visualisation of the set length of time of the currently working phase (setted on fields Step 1-2-3-4-5
fig.31pag.53)
ref n° 15:
visualisation of the time of the currently working phase past at present
ref n° 16:
visualisation of the working power set for the currently phase.
NB : if a value lower than 5 kW is set, the radio frequency shuts down and restarts at the successive phase. The value may
be modified setting directly the new one, without going to other pages.
ref n° 17:
visualisation of the actual value absorbed by the product
ref n° 18:
visualisation of the set value of opening of the capacitor.
NB : The value may be modified setting directly the new one, without going to other pages. It may be modified in the case
that it never reaches the set value, preventing in this way the completion of the currently working phase. Setting the value
at 0 the radio frequency stops and the machine goes to the successive working phase.
ref n° 19:
visualisation of the actual value of opening of the capacitor
Fig. 29
46
7- REMOTE CONTROL PANEL
PAGE N°2/3 see fig.30
In this page it is possible to :
1 the total weight of wet product which has been
loaded
2 the total weight that the product has to have
after drying
3 the number of litres of water to remove
4 parameter for the calculation of the quantity of
water removed during the drying cycle with radio
frequency. This parameter is not constant but
varies accordingly to the time for drying with hot
air and to the temperature of the hot air
Use the below table in order to reset the values
shown during the testing
PRODUCT NAME
Const. Kg H2o / KWh
Fig. 30
Hot air time
Hot air
temperature
Note
5 set value of opening of the variable capacitor ( value of power RF )
6 visualisation of the quantity of water presently removed from the product
7 visualisation of the present value of opening of the variable capacitor
7- REMOTE CONTROL PANEL
47
PAGE N°3/3 see fig.31
In this page set THE PARAMETERS RELATED TO THE 5 PHASES OF THE AUTOMATIC WORKING CYCLE.
Fig. 31
PHASE 1:
DRYING WITH HOT AIR
Only the duration of the phase is set : in this phase we have only the
running of the fan and the activation of the steam battery in order to heat the air. The temperature of the air is set on the
apposite regulator see Chapter 8.5
PHASE 2:
DRYING WITH HOT AIR + RADIO FREQUENCY : the following parameters have to be set : duration of
the working phase, duration that we want to work with the fan on, RF power that we want for working.
Attention:
if during this phase the RF power decrease at value setted, the radiofrequency is turned off and machine
change automatically the working phase (go to phase 3). To set The value Power Level to Stop RF, see ref.5 fig.32
chapter 7.3.4.
In this phase the radio frequency is continuously on and we may choose the working time of the fan.
PHASE 3 :
SAME AS PHASE 2 : plus the possibility of working with a different RF power
Attention:
if during this phase the RF power decrease at value setted, the radioradiofrequency is turned off and
machine change automatically the working phase (go to phase 4). To set The value Power Level to Stop RF, see ref.5
fig.32 chapter 7.3.4.
PHASE 4 :
SAME AS PHASE 2-3 : plus the possibility of working with a different RF power
Attention:
if during this phase the RF power decrease at value setted, the radioradiofrequency is turned off and
machine change automatically the working phase (go to phase 5). To set The value Power Level to Stop RF, see ref.5
fig.32 chapter 7.3.4.
PHASE 5 :
COOLING only the duration of the phase is set : in this phase we have only the running of the fan in order
to blow only cool air.
ref.n°5 fig.32 (next page):
Power Level to Stop RF:
if during the Phase 2 and 3 of automatic working cycle
the RF power decrease at value setted, the radioradiofrequency is turned off and machine working with the next phase
(example: from phase 3 to phase 4).
48
7- REMOTE CONTROL PANEL
7.3.4 PAGE SETUP
This pages allows to modify the parameters of the machine, to set accordingly with specifications of the product.
The utility allows to set the state of the control panel.
To change the utilities it is necessary to insert the Password “85” .
WARNING !!! USE THE MACHINE WITH THE MAXIMUM OF CAUTION! A
WRONG SETTING OF THE PARAMETERS CAN CREATE BIG
DAMAGES TO THE PRODUCT AND TO THE MACHINE!!
In order to enter in the menu SETUP it is necessary
1 from principal page MAIN MENU’ push touch SETUP ref.n°3 fig.25
2 insert the password
3 push again touch SETUP ref.n°3 fig.25, display of fig.32 appears and choose parameter to set
In this page are setted:
ref.n°1 fig.32:
GENERATOR POWER the maximum power with which the machine has to work
ref.n°2 fig.32: MAX POWER RANGE “KW/SEC” : each second PLC controls that power doesn’t go lower of
this value. If power decreases too quickly it means that a flash is forming or that there is an abnormality in the
working and the machine stops immediately.
NB: we recommend to set the value a 3 KW. Max 5 KW.
ref.n°3 fig.32: Power RF Range Reg. when irradiated power reaches the setted RF power value, PLC automatically
let it go down or up in order to maintain the power constant
NB: delta regulation RF power recommended : 2 kw
ref.n°4 fig.32:
F.S Watt Meter:this parameter is setted from RF SYSTEMS tecnician, is not necessary modification.
ref.n°5 fig.32: Power Level to Stop Rf:
if during the Phase 2 and 3 of automatic working cycle the RF
power decrease at value setted, the radioradiofrequency is turned off and machine working with the next phase
(example: from phase 3 to phase 4).
Fig. 32
7- REMOTE CONTROL PANEL
49
Page SETUP 2/5 :
In this page it is possible to :
ref. n°1 fig.33
Max water to remove : set the max quantity of water to remove for each load
ref. n°2 fig.33
N° of cycles partial : n° of cycles done from last reset cycles counter
ref. n°3 fig.33
N° cycles total : total cycles done ( value cannot be set at zero )
ref. n°4 fig.33
Push button to Reset the number of cycle Partial
fig.33
Page SETUP 3/5 4/5 5/5 not used
7- REMOTE CONTROL PANEL
50
7.3.5
PAGE UTILITY
In this page is possible:
1 item. n°1 fig.34 The pushbutton “CHANGE LANGUAGE“ allows to select two languages English or Italian
2 item. n°2 fig.34 The pushbutton “ SETUP OP “ allows to enter in a system menù of the panel and it is used only to
maintenance of the panel. Allow only to the specialized technical.
3 item. n°3 fig.34 The pushbutton “ LOGIN “ allows to insert
the password to enter to the protected functions. Allow only to
the specialized technical.
fig.34
4 item.n°4 fig.34: The pushbutton “ARROW RIGHT” is usable
only with password to level 9 and allows to enter to the page of
personalization of the user password see fig.35.
fig.35
7- REMOTE CONTROL PANEL
51
7.3.6 PAGE WORK CARD
fig.36
N°
DESCRIPTION
1
TOUCH MENU : send to the principal main page
2
TOUCH AUTOMATIC : send to the page of the automatic cycle
3
DATA RECORD NAME : champ for selection of the form of the product to load
4
TOUCH ARROW DOWN : displays the list with the different forms of the products.
5
Display of the number associated to the form of the product
8
Display of the number associated to the type of material of the product
9
ENTRY NAME : where to introduce the parameters and the values of the recipe.
10
CREATE : touch for doing a new recipe
11
SAVE : touch for saving a new recipe or modified one( overwrite displaied recipe)
12
SAVE WITH NAME: touch for saving the selected recipe
13
CANCEL : for the elimination of the selected recipe
14
TO PLC : touch for transferring
15
FROM PLC : touch for the display of the recipe with which the PLC is actually working.
NB : displaying the actual in use recipe it is possible to modify it in a flash, that
means modifying the data directly on PLC without to be obliged to change the recipe in
memory. It is also possible to modify the recipe in memory or to save it with another
name.
16
Touch not utilizable
52
changing
its name
displaid recipe to PLC and active it.
7- REMOTE CONTROL PANEL
7.3.6.1
RECIPE CREATION
fig.38
fig.37
To create one recipe following this indication:
fig.39
1 in order to create a new recipe, press touch CREATE ref.n°10 fig.37 ; it appears the page with the
alphanumeric touches with which name of recipe has to be written. When name has been written, memorize the
recipe pushing touch ENTER
2 -press touch arrow down ref. n°4 in order to let display the list of the name of the recipe created
3 on the list which appears press the name of the recipe; when selection has been done the selected material will be
displaid ref.n°3 along with the number associated to the recipe ref.n°5
4 when selection af the recipe have been done, on the area of the corp of the recipe ref.n°9 the list with the parameters to
introduce will be displaid,
5 In this page it is possible set the parameter to automatic working see fig.38-39
7 press on each single parameter in order to let display the page with numeric touches in order to write desired values.
NB : on the upper part of the setting page appears the range ( minimum and maximum values referred to the
parameter to set)
8 when introduction of parameters is finished, let memorize the recipe pressing touch SAVE ref.n°11. The created
recipe can be also saved with another name pressing touch SAVE WITH NAME ref.n°12or canceled pressing touch
CANCEL ref.n°13 .
9 the recipe actually created, in order to be operational, must be transferred to PLC. Transfer to PLC has to be done
WITH MACHINE STOPPED, pressing touch TO PLC ref.n°14
7.3.6.2 LOADING OF A RECIPE
1- Select the name of RECIPE ref.n°3 fig.37 pressing first the touch with arrow down ref. N°4 fig.37 in order to let display
the list with the recipe to working; when selection has been done the selected material will be displaid.
2- when selection has been done, the selected recipe appears on area DATA RECORD NAME and the list of the
parameters which compose the recipe n°9 will be displaid
3- At this moment the recipe is only displayed. In order to be operational it has to be transferred to PLC pressing touch TO
PLC ref.n°14 fig.37.
4- when the recipe is transferred at PLC is necessary in order to use the machine in automatic mode set the time
and the RF Power value for each single working phase.
Press touch Automatic ref.2 fig.37 in order to go at
page AUTOMATIC 1/3, in this page press the touch ARROW RIGHT and go at page with the Parameters related to the 5
phases of the automatic working cycle, see fig.39 and set this parameters.
7- REMOTE CONTROL PANEL
53
7.3.6.3 OPTIMIZATION ON LINE OF A RECIPE
Once a recipe has been done and loaded on PLC, proceed as following :
1 press the automatic touch ref. N°2 fig.36, the page of automatic will be displaid see fig.40
2 start the machine in automatic mode proceeding as indicated forward at chapter 8.2.
3 wait that first dried product comes out of the machine and verify the correct drying. If drying is correct, proceed normally
with the working. If not press touch n°1 fig.40 and go to the page of visualization of the working parameters fig.41.
4 Modify the parameters till getting the correct drying
N.b. the parameters are immediately operational when they are written on the setting page for working.
5 data just set can be overwritten on recipe loaded on PLC, memorized in a new recipe or abandoned
OVERWRITING OF THE RECIPE :
1
press touch n°1 fig.41 to recall the page of the recipes
2
press touch n°15 fig.36 FROM PLC in order to display the loaded recipe( with which you are working )
3
-press touch n°11 fig.36 SAVE in order to overwrite the recipe with the dates previously setted.
CREATION OF A NEW RECIPE :
1
press touch n°1 fig.41 to recall the page of the recipes
2
press touch n°15 fig.36 FROM PLC in order to display the loaded recipe (with which you are working
3
press touch n°12 fig.36 SAVE WITH NAME in order to create a new recipe with the dates previously setted and
maintain also the recipe formerly loaded.
A quick way to create recipes for similar materials is to load the recipe of the similar product to dry, start the machine
fig.40
fig.41
54
7- REMOTE CONTROL PANEL
7.3.7 PAGE MEMORY ALARM
The presence of one alarm is signaled to the display, (appears the ALARM INDICATOR shows in fig.42A) .
When is present one alarm:
1 press the ALARM INDICATOR, appear the page shows in fig.42 than visualizes the number of alarm active with
one description
fig.42A
2 read on the display the description and the number of alarms.
3 Find the number of alarms on this table and read the instructions to check the problem
4 identified the alarm and solved the problem, press the pushbutton “ACK” item n°1 fig.42
5 Press the pushbutton “X” item.n°2 fig.42 to close the page of alarm and keep memorized the alarm,
6 return to principal PAGE and press the button RESET ALARMS ref.n°3 fig.42B in order to reset the visualization of the alarm
7 press the push button START (the green light turn OFF) to start again.
fig.42
Number
DESCRIPTION
fig.42B
INSTRUCTION TO FOLLOWING
0001
Main power Off
rotate the selector ON - OFF AUXILIARY
rif.n°2 fig.21 pag.44 in position ON
0002
Magnetic Switch Exit Cooling Fan SMA
Set to position 1 the magnetic switch SMA
0003
Magnetic Switch Filament SF
Set to position 1 the magnetic switch SF
0004
Magnetic Switch Cooling Motor SMT
Set to position 1 the magnetic switch SMT
0005
Magnetic Switch Electrode Motor SME
Set to position 1 the magnetic switch SME
0006
Magnetic Switch SMCV
Set to position 1 the magnetic switch SMCV
0007
Magnetic Switch Cooling Cabinet Motor SMC
Set to position 1 the magnetic switch SMC
0008
Magnetic Switch SR1-SR2 Resistors battery
Set to position 1 the magnetic switch SR1 or
SR2
0009
Magnetic Switch fan MV
Set to position 1 the magnetic switch MV
0010
Magnetic switch Filter SMF
Set to position 1 the magnetic switch SMF
0011
Magnetic Switch Start Resistors SRA
Set to position 1 the magnetic switch SRA
7- REMOTE CONTROL PANEL
55
0012
/ /
/ /
0013
Latch of air
Verify the presence of air compressed in the
pneumatic circuits.
0014
Magnetic switch motor door SMAP
Set to position 1 the magnetic switch SMAP
0015
Magnetic switch cooling cabinet fan
SMRQV
Set to position 1 the magnetic switch SMRQV
0016
/ /
//
0017
Overload Max Power setup
Maintain the machine in Stand by for 10 minutes
then reset the alarm and reboot the machine . If
the alarm starts again , verify the correctness of
set parameters , verify if the load is uniform and
composed of bobbins of the same type. If the alarm
persists it is compulsory the intervention of a
qualified technician ( mechanic ) in order to
verify if discharges have occurred .
0018
Intervention of Overload Relay
Press pushbutton RESET and restart the machine.
Attention!! If there are cuntinue oveloads checks
the generator
0019
Break Down Coil or Timer Relay TAF
Check the coil of relay TAF or the timer installed
to the relay TAF. If necessary change the relay.
0020
Break Down Coil of Relay RAC
Check the coil of relay RAC.If necessary change
the relay.
00210024
/ /
/ /
0025
Cooling relais Water / Air Fault
Check if the relais RRT is turned ON, check if
the air flow switch, the air thermometer and
magnetic switch SMT are turned On
0026
Ready relay not present
Relais RCM is turned OFF check the electrical
circuit to feeder the relay RCM.
0027
/ /
/ /
00280039
/ /
/ /
0040
Alarm Wrong thecnical paramiters
Parameters out of the allowed range have been set.
Alarm max power fluctuation x sec.
Maintain the machine in stand by for 10 minutes
then reset the alarm and reboot the machine. If the
alarm starts again , verify the correctness of set
parameters, verify if the load is uniform and
composed of bobbins of the same type. If the alarm
persists it is compulsory the intervention of a
qualified technician ( mechanic ) in order to
verify if discharges have occurred .
0047
56
7- REMOTE CONTROL PANEL
8
8.0
USE OF THE MACHINE
LOADING THE BOBBINS CARRIER
Always load the bobbins with bobbins carrier outside the drying chamber, see fig. 43
Fig.43
Always load completely the bobbins holder and only with same type of bobbins, see fig 44A
It is mandatory to load both rows see fig 44A
Load only bobbins previously centrifuged with levelled weight and moisture
A loading UNcomplete and/or with bobbins of different forms, different weight and moisture don’t allow
the proper running of the machine and may cause burning to the product and to the machine itself.
1Load the bobbins on the bobbins holder and fix properly with the special lever fastener
Be careful check the correct position of the bobbins in the bobbins holder
LEVER POSITIONS
TO UNLOCK
TO LOCK
1
3
2
2
Fig.44A
8- USE OF MACHINE
1
Fig.44B
Fig.44C
57
2- The trolley complete with bobbins carier is loaded inside the drying chamber by mean of the apposite handle of the
trolley, see position ref. STOP fig.45
Be carefull not to push the carrier more than the position indicated STOP fig.45 otherwise the carrier can
be loaded in a wrong way and have no good contact and make burning on the brass contact.
3- When the carrier is in position STOP, move the knob n°1 fig 45 and use the handle n°2 fig 45 in the hydraulic pump, the
bobbins carrier go down on the support shoulders.
POSITION STOP: RIGHT POSITION BEFORE PUSHING THE CARRIER
Fig.45
4 When the bobbins holder is supported by the sides, it is necessary to push it forward till it slides alone in the correct position.
5- Check that the carrier is in good position and there is a good contact between the carrier and the shoulders.
6- Remove the trolley.
The bobbins carier is in correct working position when:
The flange A and B are in good contact fig.46A
The contact between the bobbins holder C and the contact D is good,
The 4 wheels E have gone into the aposite slides and turn free.
After he has taken the bobbins holder out from the drying chamber, operator must check the contacts brass of
the bobbins carier if presence of any dark signs or arcs he must shut down the dryer, enter inside the drying
chamber and cheks the efficiency of the fixed brass contacts and ask for necessary maintenace before to
continue with a new loading of material
RIGHT POSITION AFTER
PUSHING THE CARRIER
WRONG POSITION BEFORE
PUSHING THE CARRIER
Fig.46
58
Fig.46A
8- USE OF MACHINE
8.1
MANUAL WORKING
1- Start the machine by turning the
MACHINE
main switch (MS) on the
2- Turrn on the auxilliary with selector n°1 fig.47, fans and air cooling
are energized and after an automatic start phase (of about 10
seconds) the generators are on and checks are carried out on its
efficiency as well as on safety circuits. At this point the red lamp “RF
OFF” ref.n°2 fig.47 is up and the dryer is ready to work.
3-roll selector of mode MANUAL/AUTOMATIC ref.n°3 fig.47 in mode
manual, the video will show the page MANUAL USE OF THE
MACHINE, see fig.48
4- Load the material, see instruction at chapter 8.0
5- close the door whit the push button ref. n°8 + 10 fig.52A page 63,
the indicator STOP RF MANUAL ref.n°2 fig.47 lights in order to
indicate the possibility to start the cycle.
fig.47
6- set power for working with machine on area SET MAX POWER ,
ref.n°2 fig.48. See schedule below for the powers suggested for the
various products to dry
7- Turn on the exaut Fan on area ref. n°1 fig.49 the indicator change
colour. is necessary turn on the exaust before to start the
radiofrequency.
It is possibile to switch on the fan and eventually the electrical resistore
battery in order to blow also the hot air on the bobbins, use the
apposite touches ref 2 and 3 fig.49
NB : in order to switch on the fan it is mandatory to :
1. have loaded the bobbins holder – 2. have closed the door – 3. have
switched on the exhauster
fig.48
IMPORTANT : If during the Manual process the working
power has been manually changed, ref. N° 2 fig. 48, you
have to go down slowly , roughly 2 kW each time and the
total decrease has not to be more than the value set on parameter
MAX POWER RANGE . If not the POWER CONTROL DEVICE
understands it as abnormality and stops automatically the machine
fig.49
CONTINUE AT NEXT PAGE
TABLE WITH RECOMMENDED RF POWER / TABELLA POTENZE RF RACCOMANDATE
PRODUCT
RECOMMENDED POWER
PRODUCT
RECOMMENDED POWER
COTTON / COTONE
50/60 KW
50% COTTON- 50% PES
40-50KW
AC / ACRILICO
30 KW
75% COTTON- 25% PES
60 KW
WOOL / LANA
50 KW
25% COTTON- 75% PES
30-40 KW
PES / POLIESTERE
40 KW
VISCOSE / VISCOSA
60-70 KW
8- USE OF MACHINE
59
8- Pressing the “RF ON” green button ref.n°4 fig.47 in order to start the radio frequency. The red lamp ref.n°2 fig.47 go off
while the green lamp RF ON ref.n°4 fig.47 keeps being on.
9- Increase manually the power:
9.1 push the button ELECTRODE TUNNEL POSITION n° 5 fig 47, the upper electrode go down down and the
power increase. When the electrode arrives at limit switch is stopped, verify on item n° 1 fig.48 .
9.2 if necessary more power, press the pushbutton ref.n°6 fig. 47 in order to use the variable condensator, verify
on display the condensator position and the RF POWER values, see ref.n°3 fig.48.
In order to work in manual way it is necessary to make the calculation of the time needed for drying the bobbins. In order to
do this use the following formula :
Considering :
-
the wet weight of the total goods (WW)
-
the required dry weight of the total goods (DW)
-
the total quantity of water to remove is
Y = WW-DW in kg water
the time of drying is given by the following formula:
Y x 60
Tp = --------------PxK
Tp = time of drying in minutes
Y = quantity of water to remove in kg
P = power in kW ( 3 kW recommanded)
K = parameter which varies from 1.2 to 1.8 accordingly to the desired drying time with hot air and to the temperature of
the dried air
fig.50
60
8- USE OF MACHINE
STOP MANUAL WORKING CYCLE
THE STOP OF THE MANUAL WORKING CYCLE IS DONE ONLY BY
OPERATOR.
Anyway the machine is equipped with a safety mechanical timer
which shuts down automatically the machine after 90 minutes that
radio frequency is activated, in case that operator doesn’t ultimate
the working cycle
1Push button STOP MANUAL CYCLE ref n°1 fig 51, the green
display ref n° 2 shuts down and display red ref n°1 lights.
IN ORDER TO RESTART THE MACHINE YOU HAVE TO
WAIT ALWAYS THAT CONDENSATOR RETURNS IN
HIGH POSITION AND STOPS.
2Push the button for electrode lifting ,ref n° 3 fig51, and maintain
it pushed till it arrives at upper limit switch. Check on display that it is
really stopped
fig.51
3Shut down the exhauster, the fan if it is on, and disable the running of the electrical battery resistors by mean of
the manual commands ref 5-6-7 fig 52
4-
open the door whit the push button ref. n°8 + 9 fig.52A.
NB : the door can be open only if radio frequency and the fan are shut down
fig.52
fig.52A
8- USE OF MACHINE
61
8.2
AUTOMATIC WORKING
1- Start the machine by turning the main switch (MS) on the MACHINE
2- Turn on the auxilliary with selector n°1 fig.53, fans and air cooling
are energized and after an automatic start phase (of about 10
seconds) the generators are on and checks are carried out on its
efficiency as well as on safety circuits. At this point the red lamp “RF
OFF” ref.n°2 fig.53 is up and the dryer is ready to work.
3- roll selector of mode Manual/Automatic ref.n°3 fig.53 in mode
AUTOMATIC, video will show the page AUTOMATIC USE OF THE
MACHINE see fig.54.
4- Load the material, see instruction at chapter 8.0
5- close the door whit the push button ref. n°8 + 10 fig.52A page 63,
the indicator STOP RF MANUAL ref.n°2 fig.53 lights in order to
indicate the possibility to start the cycle .
fig.53
6- press touch MENU ref.n°1 fig.54 in order to go to page MAIN PAGE
fig.25 pag.49 where to select the page WORK CARD, pressing
touch ref.N°5, see fig.52.
7 - Select the recipe with which to work; see indication in chapter
7.3.6.2 page 60.
8- Load the recipe in PLC pressing touch TO PLC ref.n°3 fig.55.
9- -press touch AUTOMATIC ref.n°4 fig.55 to return to page
AUTOMATIC of fig.54.
10press
the pushbutton START ref.n°4 fig.53 and
maintain it pressed for 5 seconds, the green lamp START
AUTO ref.n°4 fig.53 turn ON.
11- Verify that drying is correct, and if necessary, change some
parameters of the recipe proceeding as indicated on chapter
7.3.6.3 OPTIMIZATION ON LINE OF A RECIPE a pag.60
Is possible to change some parameters to working
proceeding as indicated at chapter PARAMETERS
MODIFICATION at next page
fig.54
ATTENTION!!!
1 When the machine is in STOP, the counter of the currently
litres, ref n° 2 fig 54, indicates the value referred to the last
cycle done. When pushing the button START AUTO CYCLE
and the electrode is gone down in position, the counter
goes to zero and the counting starts
2 when the fan running, the writing HP FAN becomes dark, the
indicators of TIME ON and TIME OFF become dark and time runs
in order to make evident if fan is running or not.
3 If during the automatic cycle STOP is pushed, the MANUAL
cycle starts all the parameters related to current cycle are
cancelled.
4- When, during the automatic cycle , the indicator START
RF MANUAL ref.n°6 fig.53 lights it means that a working
cycle with radio frequency on is in progress
fig.55
5- When, the machine running with phase number 2 or 3 the RF power decrease at the value Power Level to Stop
RF (setted at pag setup 1/5 see indication in this manual pag.51) the machine go to the next working phase
62
8- USE OF MACHINE
MODIFICATION OF WORKING PARAMETERS
It is possible to modify the value of the power and the value of
opening of the capacitor displaying directly on related fields,
see ref n° 1 fig 56
fig.56
It is also possible to go to page 2 of the automatic cycle
pushing the touch “ARROW RIGHT” ref n° 2 fig 56. From page
2 it is possible to modify the weight of the dried product in order
to modify the quantity of water to remove see fig 57
NB : before to modify these parameters push the touch
STOP RF AUTO because the changes have to be done
with machine in STOP
fig.57
It is possible also to go to page 3 of the automatic cycle pushing
the touch “ARROW RIGHT” ref n°2 fig.57
In this page the time duration of each working phase and
eventually the power may be modified.
Setting one of these times to zero the machine starts to
execute the following phase
ONCE THAT THE PARAMETERS OF THE LOADED
RECIPE HAVE BEEN MODIFIED IT IS POSSIBLE TO
FORGET THESE CHANGES, TO SAVE IT ON THE RECIPE
CURRENTLY LOADED OR TO SAVE IT ON ANOTHER
RECIPE SEE CHAP 7.3.6.3 Page 58.
fig.58
8- USE OF MACHINE
63
STOP OF AUTOMATIC WORKING CYCLE
1- STOP OF THE CYCLE DONE MANUALLY BY OPERATOR
Push the touch STOP AUTO CYCLE ref n° 1 fig 59, the green indicator
ref n°2 shuts off and the red indicator ref n°1 lights
IN ORDER TO RESTART THE MACHINE YOU HAVE TO WAIT
ALWAYS THAT CONDENSATOR RETURNS IN HIGH
POSITION AND STOPS.
to restart the machine push the touch START RF AUTO, ref. n°2
fig.59, the working cycle re starts where it has been suspended.
fig.59
2- STOP CYCLE WHEN QUANTITY OF WATER TO REMOVE IS ACTIVED
when the quantity of water to remove is reached a 5th
phase starts in oreder to cool the product (cooling phase).
At the end of the total cycle the door open automatically .
The actual quantity of water to remove and the setting are
shown on windows n°1 figure 60.
3-STOP CYCLE AT COMPLETION OF THE 5
AUTOMATIC WORKING PHASES:
if during the working cycle the quantity of water set has
not been removed, the machine stops after the fifth
working phase, cooling phase.
See indications of the name of the working phase in
progress on field n°2 fig 60, the time set for this working
phase and the time currently passed ref 3 fig 60
fig.60
The machine is also equipped with a safety mechanical timer which, in case that working cycle is not finished,
shuts down automatically the machine after 90 minutes that radio frequency is on.
64
8- USE OF MACHINE
8.3
STOP OF THE MACHINE
1For a short stop just press the pushbutton “STOP RF AUTO” ref.n°1 fig.61 and leave everything as it is. In this
case, fans keep working.
The machine is ready to be re starter, the working cycle re starts where it was suspended.
In order to start again the machine after a small stop it is necessary wait that condensator turns in high position and then
press the pushbutton START ref.n°2 fig.61
In order to shut down completely the machine it is necessary to push the touch START ref n° 2 fig 61, turn selector
MAN-AUTO ref n°3 in MANUAL position, open the door with the push touch ref n°8 + 9 fig 61A and follow the shutting
down operations described on below point 2
2-
For a long stop, i.e. for more than 30 minutes or for short stop with out the presence of operator:
- wait THAT THE WORKING CYCLE IS OVER AND THAT THE DOOR OPENS,
- check red led STOP MANUAL ref.5 fig.21 is OFF.
- absolutely remove the bobbins holder from the tunnel
- wait 10 -15 minutes for the fans to take out nearly all the steam left
- turn OFF the auxilliary selector in the control panel
3
IN CASE OF DANGER push emergency button, ref. n°4 fig. 61, the Radiofrequency and the fans is
turned OFF (auxilliari circuits is turned off) and the door immediately is open, if necessary now is
possibile turn off the main switch.
fig.61A
fig.61
8- USE OF MACHINE
65
8.4
OVERLOAD
In case of overload on radiofrequency the machine stops immediately
DURING WORK IN MANUAL : at every overload the blue indicator
RESET lights up , ref. 1 fig. 65 , radiofrequency is stopped and the
variable resistor turns to rest position .
The operator has to :
1- verify the causes of the overload and solve them.
n.b. before to verify the causes of overload is necessary turn off
the main switch and lock. EVERY check is in charge at
maintenance people should be qualified and accustomed to
dealing with high voltage equipment.
2- wait that the capacitor reaches the limit switch position and stops
3- push RESET button , rif. 1 fig. 65 , the blue light goes out
4 – restart the work
DURING WORK IN AUTOMATIC : the machine resets automatically
3 overloads within a time period set by programme , and it makes also
3 re-start in automatic . In case of a fourth overload , machine stops
and reset indicator lights on , rif. n°1 fig. 65.
fig.65
During the automatic cycle both the green start indicators of
AUTOMATIC rif. n°2 fig. 65 and MANUAL rif. n° 3 fig. 65 light on ,
when an overload happens and the machine is making the re-start the
green indicator AUTOMATIC CYCLE stays on in order to indicate that
the automatic cycle is in progress , whereas the indicator START RF
MANUALE rif. n°3 fig. 65 lights off in order to indicate that
radiofrequency is stopped .
If four overloads occur the machine stops .
The operator has to verify the causes of the overload and solve them ,
reset the alarm from the operator panel by RESET ALARM button ,
make the reset by RESET button rif. n°1 fig. 65 and successively he
has to restart the work as at the beginning of a new working cycle .
fig.66
n.b. before to verify the causes of overload is necessary turn off the main switch and lock. Every check is in
charge at maintenance people should be qualified and accustomed to dealing with high voltage equipment.
N.B. : from the STOP due to an overload and the next AUTOMATIC START ,it takes about 60 seconds , it is the time that
the variable capacitor needs to reach rest position .
The time from an overload to another is of 20 seconds after that variable resistor has reached rest position .
The numbers of occurred overloads are memorized , they are shown on indicator n°1 fig. 66 . If the maximum time period
set for the count from an overload to another pass and no other overload occurs , the contactor is reset .
66
8- USE OF MACHINE
8.5
SET OF THE TEMPERATURE OF HOT AIR
THE REGULATION OF THE TEMPERATURE HAVE TO BE DONE WHEN MACHINE IS WORKING IN AUTOMATIC
DURING A PHASE OF WORK WITH HOT AIR ( PHASE 1-2-3-4) OR WHEN MACHINE IS WORKING IN MANUAL
AFTER THAT FUNCTION OF FAN AND OF STEAM BATTERY IS ENABLED , SEE CHAPTER 8.1 Fig.49.
In order to regulate the temperature:
1 – pushing the knob n° 1 fig. 67
2 - rotate the knob, see fig. 67
Fig.67
SETTED TEMPERATURE ______°C
8- USE OF MACHINE
(max temperature to set = 100°)
67
8.6
PROCEDURE TO FOLLOW IN CASE OF FIRE
ATTENTION!! The user must install a fire extinguisher CO2 near the door of the machine.
1 press the emergency pushbutton in order to stop the Radiofrequency, the fan and open the door automatically.
2 AT THIS MOMENT THE OPERATOR HAS TO VERIFY THE STATE OF THE PRODUCT AS FOLLOWING :
IF PRODUCT IS NOT BURNING :
A.
insert the trolley and remove the bobbin carrier without entering in the tunnel
B.
once it is outside the tunnel and verify if it is necessary intervene with extinguisher
IF PRODUCT IS BURNING :
A.
intervene quickly with extinguisher without entering in the tunnel, directing the jet on the product and on the inside
walls of the tunnel
B:
alert the personal to provide himself of CO2 extinguishers in order to accelerate the extinguishing phase.
C.
when fire is put out, without entering in the tunnel, extract the bobbin carrier and, if necessary, continue the
extinguishing phase.
IN ORDER TO LIMIT FIRE RISK IT IS ESSENTIAL TO CHECK THE PRODUCT AT THE END OF THE CYCLE
WHEN THE TROLLEY IS TAKE OUT AND VERIFY IF IT IS NECESSARY TO CHANGE THE DRYING
PARAMETERS .
IT IS MANDATORY CHECK THE PRODUCT BEFORE THE STOCKING OPERATIONS.
fig.69B
68
8- USE OF MACHINE
8.7
TRIAL OPERATION
During the operation of the dryer, the following must be checked:
• Check the grid current limit of 2,5 A under no load conditions
• Check the grid current with full power is above the min value of 1,4 A.
• If the maximum permissible anod current is reach, a trip is carried out, to start again the machine operate must
press reset push button.
If many trips occur this indicate arcing in the machine so operator must call an electrical technical to check the machine
8.8
SPECIAL REQUIREMENTS ON USING RADIO FREQUENCY DRYER
1)
The dryer can accept only hydro extract goods with even moisture content
2)
Possible fire hazard when dealing with unextracted packages.
3)
Properly hydro extraction is important prior to RF dryer.
4)
Load product with same dimensions and similar moisture contents.
5)
Good with different size are not allow they can get burns.
6)
The machine cannot accept metallic dystuff (ex. Chrome)
7)
Do not enter metallic parts. Metallic in the gallery cause electrical discharges which may throughly ruin belt and
set the drying material on fire
8- USE OF MACHINE
69
9 MAINTENANCE
BEFORE TO DO ANY INTERVENTION OR MAINTENANCE OPERATION SET
MAIN SWITCH IN POSITION OFF AND LOCKED.
WARNING!!! SAFETY FIRST
There is not much to be done to keep running costs low and the “machine capital” high in the years. If you follow the
present guide book, you will always have your machine in working order. It is easy to keep it with care: it will reward you for
the few attentions you have been paying to it.
DO NOT ADJUST OR SERVICE ALONE.
Under no circumstances should any person reach within a unit for the purpose of servicing or adjusting the equipment
without the immediate presence or assistance of another person capable of control and rendering aid.
Maintenance people should be qualified and accustomed to dealing with high voltage equipment.
DO NOT OPEN PANELS OR DOORS WITH THE MAIN SWITCH “ON” MAIN SWITCH MUST BE IN POSITION OFF
AND LOCKED
Under no circumstances should any panel or door be removed without the main switch disconnected first.
- Operating personal with by pass devices cannot operate the machine and stay near the machine when it is operating
Caution: Maintenance should be carried out by qualified staff and in top safety conditions, i.e. with
machine and voltage OFF and emergency button pressed. Before approaching the machine, be very
careful since high voltage is involved.
For the substitution of the spare parts use only original components and authorized by manufacturer.
The use of non original components avoids automatically RF SYSTEMS of any responsibility.
For each damage, reparation or maintenance speak to our assistance service and use only specialized
personal.
In case of use of product with contamination all the maintenances has to be done daily or weekly.
70
9- MAINTENANCE
9.1
ORDINARY MAINTENANCE
fig.70
9- MAINTENANCE
71
DESCRIPTION IN REFERRING AT FIG.70
REF
FREQUENCY
DESCRIPTION:
AIR FILTER CLEANING: take out the air filter and clening with compressed
air. If necessary change the filter.
Air filter cleaning is fundamental for a longer life of the valve and for
peak working and efficiency
EVERY WEEK
1
EVERY YEAR
REPLACE AIR FILTER ELEMENT.
DISCHARGE WATER CONDENSATE INSIDE THE AIR FILTER GROUP.
Is necessary pressed the pushbutton to the bottom
of filter.
ATTENTION!! to not damage the air components valve and
2
EVERY WEEK
cilinder) is necessary if the air compressed to feeder
the machine is free of water.
3
EVERY MONTH
CLEAN THE GRID TO FAN TO COOLING THE BOX and check the efficiency of the fan.
CLEANING AND LUBRICATE ELECTRODE MOVEMENT COMPONENTS:
1. clean the 4 screws and support with air compressed
2. lubricate the support with oil.
3. lubricate the chain with grase.
4
EVERY MONTH
72
9- MAINTENANCE
DESCRIPTION IN REFERRING AT FIG.70
REF
5
FREQUENCY
EVERY WEEK
EVERY WEEK
6
and check
EVERY DAY
DESCRIPTION:
CLEAN INSIDE THE DRYING CHAMBER :
ATTENTION : BEFORE TO ENTER INSIDE THE DRYING CHAMBER THE OPERATOR HAS TO
ASCERTAIN THAT THE DOOR IS COMPLETELY OPEN AND THAT THE ANTI-FALL CYLINDER
IS IN SAFETY POSITION WITH THE PISTON ROD COMPLETELY OUTSIDE. SELECT THE
MAIN SWITCH TURNING IT TO ZERO AND LOCK THE KNOB .
Aspirate any dust cumulations, frayed material from the floor, from the
slide of the trolley and of the door, from walls and from ceiling and from
the electrode structure .
CLEAN AND POLISH THE BRASS CONTACT :
ATTENTION : BEFORE TO ENTER INSIDE THE
DRYING CHAMBER THE OPERATOR HAS TO
ASCERTAIN THAT THE DOOR IS COMPLETELY
OPENAND THAT THE ANTI-FALL CYLINDER IS
IN SAFETY POSITION WITH THE PISTON ROD
COMPLETELY OUTSIDE. TURNING THE MAIN SWITCH
TO ZERO AND LOCK THE KNOB.
Aspirate any dust or dirt cumulations and
sand with fine sandpaper in order to
remove cumulation of carbon due to
discharges .
ATTENTION: EVERY DAY IT IS MANDATORY TO
CHECK THE EFFICIENCY OF THE CONTACT AND IF
THERE IS PRESENCE OF ARKS O BURNING IS
NECESSARY TO MAKE THE MAINTENANCE
IF NECESSARY CHANGE THE BRASS CONTACT, ISOLATOR OR DAMAGED PARTS.
CLEAN AND POLISH THE 2 BRASS CONTACT TO
THE BOBBINS HOLDER PLATFORM
7
EVERY WEEK
and check
EVERY DAY
Remove any dust or dirt cumulations and
sand with fine sandpaper in order to
remove cumulation of carbon due to
discharges .
ATTENTION: EVERY DAY IT IS MANDATORY TO
CHECK THE EFFICIENCY OF THE CONTACT AND IF
THERE IS PRESENCE OF ARKS O BURNING IS
NECESSARY TO MAKE THE MAINTENANCE
IF NECESSARY CHANGE THE BRASS CONTACT.
CLEANING AND LUBRICATE THE 2 SUPPORT
8
EVERY MONTH
AND THE 2 DOOR GUIDE:
1 cleaning the guide whit
air compressed and lubricate with
spray Grease.
2 lubricate the support with oil.
9- MAINTENANCE
73
DESCRIPTION IN REFERRING AT FIG.70
REF.
FREQUENCY
DESCRIPTION:
CLEANING THE AIR FILTER OF THE FAN:
Take out the air filter and clening with compressed air.
If necessary change the filter.
EVERY YEAR CHANGE THE AIR FILTER
9
10
EVERY
MONTH
EVERY
WEEK
VERIFY THE CORRECT FUNCTIONING OF THE DOOR ANTI-FALL CYLINDER :
execute a cycle of manual opening of
the doors using the special provided
buttons , make the door reach the
upper limit switch and verify that
the cylinder comes out completely
passing under the door.
If the cylinder does not come out,
verify the pneumatic and electric
circuit that controls the cylinder
and the electrical circuit following
the attached schemes .
CHECK THAT THE DOORS ARE CAREFULLY LOCKED.
Each lock must have the two signs set toghether.
11
EVERY
MONTH
12
/ /
74
NOT PRESENT
9- MAINTENANCE
DESCRIPTION IN REFERRING AT FIG.70
REF.
13
14
FREQUENCY
/
/
EVERY TREE
MONTH
DESCRIPTION:
NOT PRESENT
Check up and test at intervals (about every 3 months) the efficiency of:
- electrical contacts
- power transformer
- rectifier bridge
- power capacitors
- power contactor CP and CA (If necessary must be change)
- all electrical components in general
CLEAN WITH COMPRESSED AIR FREE OF WATER
MAINTENANCE IN CHARGE ONLY A PERSON WITH KNOWLEDGE TO ELECTRICAL CIRCUITS
careful and methodic cleaning of the triode dissipator by means of compressed air.
In order to clean the triode open panel of the generator box
Be careful no to touch the ceramic of
the triode whit the hands.
Clean moplen disc and the capacitor.
15
EVERY SIX
MONTH
16
EVERY SIX
MONTH
CHECK TIGHTNESS OF ALL NUTS AND SCREWS, IN PARTICULAR OF THE RADIO FREQUENCY
GENERATOR. IT IS A GOOD RULE TO INFORM RF SYSTEMS DEPARTMENT OF POSSIBLE
WORKING PROBLEMS.
MAINTENANCE IN CHARGE ONLY A PERSON WITH KNOWLEDGE TO MECHANICAL PARTS.
9- MAINTENANCE
75
DESCRIPTION IN REFERRING AT FIG.70
REF.
FREQUENCY
DESCRIPTION
CHECK IF THE SPINDLE ARE PROPERLY FIXED
If necessary fix the spindle, fixing
the screw. the screw are located in the
bottom side of bobbins holder platform.
IF NECESSARY CHANGE THE SPINDLE
EVERY
MONTHS
17
PIECES TO BE REPLAYED DUE TO NORMAL WEAR AND TEAR OF THOSE
PARTS WHICH ARE SUBJECT TO RAPID CONTINUEL WEAR
Check the efficiency to the caps of
the spindle
IF NECESSARY CHANGE
18
EVERY SIX
MONTHS
Change the rubber gasket to the flange
of hot air circuit.
19
EVERY SIX
MONTHS
The warranty of the machine is valid only if the problems are due to no observance of maintenance.
All parts which prove to be defective within said period shall be replaced or repaired free of charges, at condition
that the machine has been used and maintained in the correct manner and that no repairs or similar operations
have been done by anyone other than authorized personnel from our assistance organization.
76
9- MAINTENANCE
10
ATTACHMENT
10.1
FANS AND MOTORS LIST
10.2
ELECTRICAL COMPONENTS LOCATION
10.3
ELECTRICAL DIAGRAMS
10.4
INLET / OUTLET LIST
10.5
WARRANTY
10.6
SPARE PARTS LIST
10.7
CONTRACT DATA
10- ATTACHMENT
77
10.1
FANS AND MOTORS LIST
10- ATTACHMENT
78
Ref
DESCRIPTION
TYPE
SUPPLYER
REFERENCE
REF.
ELEC
Motor 3 phases 2p 22KW
400-690V
Fan
V.I.M.E.C.
Module air fan
V.I.M.E.C.
APRFC 801
2
Fan for cooling
air module
Motor 3 phases 4p 0.18 KW 4P
Fan
ABB
MEV
IM3081M2AA063B
SR1EA355
MRQV1
3
Fan for cooling
electrical
cabinet
Motor 3 phases 4p 0.18 KW 4P
Fan
ABB
MEV
IM3081M2AA063B
SR1EA355
MC1
MC2
4
Air duct exhaust
Motor 3 phases 4p 4KW 4P
Fan
V.I.M.E.C.
V.I.M.E.C.
112M-4
BP401/A
MA
5
Electrode motor
Motor 3 phases 4p 0.18KW 4P
Reducer P045 PA i=46 PAM63B5
ELVEM
HYDROMEC
6SM 63-B4
P045 i=46
ME
6
Variable
capacitor motor
Motor 3 phases 4p 0.18KW
Reducer P045 PA i=46 PAM63B5
ELVEM
HYDROMEC
6SM 63-B4
P045 i=46
MCV
7
Triode cooling
motor
Motor 3 phases 2p 7.5 KW B3
Fan
SIEMENS
V.I.M.E.C.
1LE10021CA134AA4Z
MPR 501
MT
8
Door movement
Motor 3 phase 4p P 0.55KW
Reducer
M.T.
VARVEL
TF80A/4CA
FRS50SC2480B5
MAP
1
10- ATTACHMENT
180M-2
MV
79
10.2
ELECTRICAL COMPONENTS LOCATION
See drawing ASSIEME-2 .
N°
DESCRIPTION
ELECTRICAL
DRAWING REF.
ITEM
Page
1
Interruttore generale
Main Switch
IG0
01
2
Pulsante emergenza
Emergency pushbutton
02ASB03
02A
3
//
4
Finecorsa porta aperta
Door open microswitch
7BSQ3
07B
5
Finecorsa porta chiusa
Door closed microswitch
7BSQ1
07B
6
Fine corsa Extra corsa porta in chiusura.
Micro switch extra course door
7BSQ2
07B
7
Fine corsa Piano porta rocche in posizione
Micro switch bobbins holder platform in position
7ASQ5
07A
8
Fine corsa porte cassone trasform. potenza chiuse
micro switch power transformer doors close
1SQ04
01
9
Fine corsa porte Cassone generatore chiusa
micro switch generator doors close
1SQ03
01
Fine corsa posizione Elettrodo
tunnel(alto-basso)conpleto di potenziometro per altezza
elettrodo
Switch electrode in the tunnel position (up-down)
complete with height tunnel electrode potentiometer
10ASQ1
14RP1
10A
14
11
Fine corsa posizione condensatore variabile
(aperto-chiuso)
Switch Generator electrode position (open-close)
10SQ1
10
13
Potenziometro apertura condensatore variabile
Potentiometer variable capacitor position
14RP2
14
14
Pressostato verifica presenza aria compressa
Air compressed pressure switch
BP1255
12
15
Sonda PT100 controllo temperatura aria in uscita
Probe PT100 Outlet air temperature
14PT1
14
16
Air flux switch
Flussostato aria
8FL1
08
18
Door close safe switch
fine corsa sicurezza porta chiusa
7ASQ6
07A
19
Elettro valvole
Electrical valve
YV05B
YV1254
05B
16A
20
Fine corsa porte cassone ventilatore chiuse
micro switch fan doors close
1SQ06
01
21
Fine corsa porta quadro di potenza chiusa
micro switch electrical cabinet door close
1SQ05
01
22
Trasformatore TA x lettura potenza RF
Transformer TA measuration of the RF power
TA
04
23
Resitenze riscaldamento aria
Resitors For Hot air
R1 -R2
06B
24
Termometro regolazione temperatura aria calda
Hot air regulation air temperature
05ATE1
06B
10
- 12
10- ATTACHMENT
NOTE
//
80
10- ATTACHMENT
81
10.3
ELECTRICAL DIAGRAM
FOLLOW NUMBER 35 SHEET
10- ATTACHMENT
82
10.4
INLET / OUTLET LIST
FOLLOW NUMBER 4 SHEET
10- ATTACHMENT
83
10.5
WARRANTY
RF SYSTEMS guarantees the machine for a period of one year from the date of shipment for mechanical parts, six
months from the date of shipment for electronic and electrical parts and 12 (twelve) months from the date of shipment for
the triode ( as per manufacturer warranty). In case of failure of the triode and application of the warranty the cession of a
new triode will be invoiced 12/12 less 1/12 for each month or fraction of month from date of shipment.
This warranty is valid only with test certificate signed by our technical organization or authorized personnel from RF
Systems S.r.l.
The general conditions of the warranty are valid at condition that abnormalities discovered are not due to inexperience,
negligence or wrong operating of the machine or non -observance of the instructions of the instructions manual.
Are also excluded from the warranty the damages caused by natural calamities, fires and each damage independent of
the normal use of the machine.
Transportation costs of the spare parts and eventual travel expenses , board and lodging of our technician will be in each
case at charge of customer and will be invoiced at presentation of the vouchers or paid directly by customer.
All parts which prove to be defective within said period shall be replaced or repaired free of charges, on condition that the
machine has been used and maintained in the correct manner and that no repairs or similar operations have been done
by anyone other than authorized personnel from our assistance organization. The guarantee is valid starting from the
date of delivery and can be used only by the first purchaser performing commissiong and startup. In case of request for a
guarantee, the RF Systems must check the condition of the dryer and its components in order to evaluate its applicability.
In case of inappropriate use of the machine, the guarantee is not valid.
In case the dryer show any material or manufacture defect or in case of anomalies or malfunctioning occurred during the
guarantee period, contact the agent or RF Systems for request for a guarantee. In case of a positive reply, new
components will be delivered to replace the faulty ones.
The applicability of the guarantee is binded to a definite and unreversable decision taken by the RF Systems.
This warranty shall not cover those components whose failure has been caused by :
- shipment and unloading
- unsuitable air, water and electric power supply
- weather and ambient conditions (frost and-or acid ambient ) or where foreign matter has been introduced into our
machine
- absence of high concentrations of dust and chemical smokes
- in case of damages due to carelessness
- any claim for damage, even to people or to objects, loss of profit or production, expense for hire and possible commercial
and moral damges are excluded from the guarantee.
- any claim related to motors assembled on the dryer is to be made to the single motor manufacturer.
- the guarantee is immediately invalidated in case of use or assembling of accessories or spare parts non-original from RF
Systems.
- Any sort of tampering with the machine and the its components will immediately invalidate the guarantee.
All faulty components replaced by new ones shall remain our property and must be returned - transportation charges
prepaid- to our factory.
Any repair or replacement that may be effected during the warranty period shall have no effect upon the date of
commencement of the term of said warranty and shall not entitle the purchaser to claim damages for lost output.
In case of repair or replacement that are not covered by this warranty, the services rendered by our engineers shall be
charged to the purchaser based on the total expenses actually incurred.
Each request of compensation for loss of production is explicitly excluded.
In case of non totally payment of the machine ( except when specified in the contract ), RF SYSTEMS maintains the
property of the machine till the total payment of the machine and customer is not entitled to ask for warranty conditions
application
10- ATTACHMENT
84
WARRANTY OF THE TRIODE :
RF Systems S.r.l. warranties the triode for a period of two thousands (2.000) working hours . In any case this warranty
period does not exceed twelve months (12 ) from date of delivery.
All faulty triode will be replaced by a new one with reduced price on basis of 2000 working hours less
the number of hours that triode ran.
This warranty is valid with following conditions :
- the nominal voltage is within 5% ( temporary excursions of + 5% and - 10% are permitted ).Otherwise customer must
install a suitable stabilizer.
- observance of maintenance instructions ( especially periodical cleaning of the air filters )
- ambient temperature within + 7°C and + 30° C
- air moisture within 20% and 80% of relative moisture
10- ATTACHMENT
85
10.6
SPARE PARTS LIST
In order to quickly work out problems due to a wrong manouevre of operator or wear of machine components, we have
supplied with the machine the following spare parts to keep in stock:
N°
DESCRIPTION
RF CODE
2
Alluminium band for mass
CTTUM00011SS
1
Potentiometer 10K
METUE00048SS
2
Locks for gallery’s door
TKTUC00056SS
TKTUC00057SS
TKTUC00058SS
Attention !!!: RF SYSTEMS can supply immediately the above spare parts only during the warranty period.
10- ATTACHMENT
86
10.7
CONTRACT DATA
DRYER TYPE
TURBO DRYER Type RKB70A
SOLD TO
BELCHEM FIBER MATERIALS GMBH
FOR USE AT
D-09599 FREIBERG
GERMANIA
CUSTOMER ORDER CONFIRMATION N°
10/112501
DATE OF ORDER
25/11/2010
RF SYSTEMS SERIAL NUMBER
11/23
DELIVERY DATE
DATE OF START UP
10- ATTACHMENT
87