bin arch breaking systems installation and maintenance manual
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Installation
Maintenance Manual
Bin Arch breaking System
(Models: BAS-020 • BAS-040 •BAS-050)
北 北科力通散料技术有限 司
Beijing bklitong bulk technology Co., LTD
www.bklitong.com info@bklitong.com
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INJECTOR HEADS OF SYSTEM INSTALLATION NOTES
Consult installation drawing (if provided) for proper injector heads location. It is important toadhere to the recommended locations as the type, number and location of injector heads havebeen selected for thorough " inject " coverage of the problem surfaces in bin or chute.
It is usually not necessary to clean out or empty the bin before installing the Injector heads.
CAUTION: NEVER ENTER A BIN WHILE INJECTOR HEADS ARE OPERATING.
If the material in the bin would have a tendency to run out of a hole cut in the bin wall, the levelof material in the bin should be dropped below the Injector head location before cutting the holesin the bin wall.
When welding, a continuous bead should be used to fasten the mounting to the bin wall onsteel bins.
PIPING INSTALLATION
Follow the piping schematic that is a part of this instruction manual.
Never use smaller pipe size fittings or valves than the ones shown.
It is important that the header be installed below the level of the Injector heads so that anycondensation that may form in the lines will not drain into the Injector heads. If the header mustbe installed above the level of the Injector heads, the feed lines for the individual Injector headsmust be taken off the top of the header (rather than the bottom) to minimize condensationdrainage into the Injector heads and solenoids. A full flow gate or ball valve is recommended asit allows one the Injector head to be taken out of service without shutting down the entire system.
Using flexible air hose in lieu of rigid piping from the header to the solenoids is recommendedfor ease of installation and for easy removal of the Injector head when service is required.
NOTE: USING SUITABLE SAFEGUARDS, always blow out all air supply lines thoroughly
before final hook up to solenoids. Dirt in supply lines may cause the solenoid valves
to malfunction.
When operating properly, and under material, the Injector heads are almost silent.If an Injector head begins to chatter, vibrate or "machine gun", it is generally caused by asolenoid valve malfunctioning due to dirt. If this occurs, SHUT OFF ELECTRIC & AIR SUPPLYand DISCHARGE AIR in system, then clean solenoid thoroughly (see troubleshooting).
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BAS-020 Injector head dimensions (no scale)
BAS-020Injector head
2.5mm
Mounting Coupling(for curved walls)
25mm
Ø43mm
32mm 31.5mm 43mm
3/4" NPT sch. 40connecting nipple (typ.)
62mm
Cone point
set screw (4 places)
"O" RingNational Part
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Injector head CONTROL BOX
The control box is the heart of the Injector head system. It is this device which fires the Injectorheads in a prescribed sequence and at a prescribed interval to assure on-demand or evendischarging of material from the bin, silo or chute. The firing order is from the discharge(lowest unit) and up.
The burst signal, sent from the control box to the solenoid valves, is typically set at 0.25seconds. It is this signal that is responsible for the actual firing of any given Injector head. Insome cases, more than one solenoid valve may be wired to the same output, to effectsimultaneous firing of two Injector heads.
The interval timer governs the "dwell" between successive firings.
The "dwell" should be set as long as possible without adversely affecting the flow of material. A longer "dwell" will conserve air.
External controls, There provide a DCS port with a switch which can start or stop the Bin Arch breaking System.
WARNING ○ NEVER ALLOW ANYONE TO LOOK INTO OR ENTER
BIN WHEN INJECTOR HEADS ARE OPERATING. ○ EYE OR OTHER INJURY MAY RESULT! SHUT OFF
ELECTRIC & AIR SUPPLY TO INJECTOR HEADS ANDDISCHARGE AIR IN SYSTEM BEFORE INSPECTING OR
SERVICING INJECTOR HEADS.
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TYPICAL SYSTEM COMPONENTS
Mounting Coupling
injector head
Diaphragm Valve
Hopper
Flexible Hose
Pipe Header Loop
supply pipe
Ball Valve Pipe port
Full-flow Moisture Trap
Air Supply
Full-flow Regulator
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BAS-020 Mounting Coupling Installation
TYP 6
Bin Inside Wall
MountingCoupling& Assembly 25mm
43mm
90 DegreeCountersink After Correct Injectorhead Position isDetermined
Align Front of CouplingFlush With Inside of Bin Wall
BAS-020 Mounting Coupling Installation 1. Cut hole in hopper wall, diameter to fit (The 40mm diameter of coupling is recommended
to allow coupling to pass through curved wall).
2. Remove O-Ring, and apply splatter-guard in O-Ring groove. Align coupling flush with inside of vessel wall and weld continuous bead to exterior of wall.Replace O-Ring after flange has cooled. O-Ring groove should be cleaned and free ofdebris or residue before replacing O-Ring.
3. Slide Injector head into position, so that front of body of Injector head is aligned withfront of coupling. This will properly position piston head within the bin.
4. After position of Injector head is determined to be correct, small countersink holes shouldbe drilled in Injector head body, to allow cone point set screw to engage fully with body.
Note: On sharply curved bin walls, body of Injector head will extend slightly into the bin at top &bottom (12:00 & 6:00 positions), and should be flush at sides (3:00 & 9:00 positions).
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DRAWING
DISEGNO
DESSIN
DIBUJO
ZEICHNUNG
TEKENING
DRAWING
DISEGNO
IM901-10-1-4
ASCO/JOUCOMATICP.O. Box 3, 3925 ZG Scherpenzeel, The NetherlanTel. +31 33 277 79 11- Fax +31 33 277 45 61
SERIES353
TORQUE CHART
C
B
A
ITEMS
11±1
20±3
0.6±0.2
NEWTON.METRES
100±10
175±25
5±2
INCH.POUN
GB * Supplied in spare part kitFR * Livrées en pochette de rechange
DE * Enthalten im ErsatzteilsatzES * Incluido en Kit de recambioIT * Disponibile nel Kit parti di ricambio
NL * Geleverd in vervangingsset
Ø
Spare part kitCode pochette de rechangErsatzteilsatz
Código del kit de recambioKit parti di ricambio
Vervangingsset
Catalogue numberCode électrovanne
KatalognummerCódigo de la electrovalvula
Codice elettrovalvolaKatalogus nummer
=~
C113-444
C113-444
SCG353A43
SCG353A44
3/4
1
1*
2
3
4
5*
6*
A
B
7*
8*
9*
10
C
11
12*
13
IN
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TROUBLE SHOOTING
PROBLEM POSSIBLE CAUSE
1. Diaphragm Valve fails to operate (open)
1. No pressure in header2. Low or no power to coil3. Coil inoperative4. Pilot valve plunger jammed shut5. Pilot orifice blocked6. Secondary bleed-hold blocked7. Main diaphragm perforated8. Secondary diaphragm perforated9. Pilot valve connecting line too long10. Silencer, if fitted, may be blocked
2. Diaphragm Valve fails to shut 1. Pilot valve plunger jammed open2. Foreign matter under pilot valve3. Secondary diaphragm spring broken
4. Foreign matter under secondarydiaphragm
5. Main diaphragm spring broken 6. Foreign matter under main diaphragm7. Main diaphragm seating disc damaged8. Main bleed hole blocked9. Secondary bleed hole blocked
10. Leak in line connecting pilot valve
3. Unable to build header pressure
1. Excessive leakage from main diaphragmseat
2. Broken main valve spring 3. Secondary diaphragm not seating
4. Foreign matter under mainor secondary diaphragma) seat or under pilot valve seat
5. Air supply line too small
6. Compressor too small
4. Sluggish operation of diaphragm valve 1. Partial blockage of one of the bleed-
holes2. Silencer, if fitted, may be blocked
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SPECIAL NOTE To prevent premature failure of a diaphragm valve, special attention must be paid to thequality of the compressed air/gas being handled.
An adequate moisture and oil removal system must be incorporated that takes intoaccount:
relative humidities likely to be experienced ambient temperatures
system operating temperatures
pressure drops (and associated temperature drops) through the valve and also throughthe blow tube holes (dew point problem)
Also, small traces of chlorine and other aggressive gases, often present in filter systems,can be absorbed in wet areas resulting in corrosion and premature failure.
Apart from valve failures, systems may not perform to expectation for a number of
reasons including the following:
inaccurate mounting/positioning of theInjector head(s) relative to the vessel wall
inadequately sized header and/or air supply incorrect pulse time
incorrect intervals between pulses
improper adjustment or wear ofInjector head(s) piston head
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Maintenance
一. After the control device is powered on, 5V, 12V and 24V LED indicator on the circuit board is not lit. It is necessary to
check if power line is loose with connection terminal, if 0.315A fuse of power supply is broken, if power transformer isnormal and if there is any phenomena like a broken line, loose soldering, etc. in the power supply part.
二.If 5V or 12V LED indicator is not lit, it shows that there is a short circuit in the load, and some component is damaged.
It is necessary to check one by one. If load is disconnected, 5V or12V is still abnormal, and 3-terminal stabilizedcircuit must be checked to see if it is normal.
三.If 24V LED indicator is not lit, the general status is that there is overload or short circuit of electromagnetic pulse valve
and lead at the load side.
四. After the control device is powered on, nixie light display and key input is normal:
(1)Output LED indicator is not lit and electromagnetic pulse valve does not work. And it is possible that SD-M-3002circuit is damaged.
(2)Output LED indicator is lit and electromagnetic pulse valve does not work. And it is possible that thecorresponding electronic switch tube is damaged.
五.If a electromagnetic pulse valve is always magnetized, it must be checked if the corresponding electronic switch tube
is in electric leakage or broken-down.
六.If electromagnetic pulse valve is not always magnetized, it must be checked if the connection outside of the terminal
of common lead of the valve is correct and reliable.
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ASME HORIZONTAL AIR RECEIVERS 30, 60, 80 Gallon
DIMENSIONS Port size (NPT)
Tank Size
Gal A B C D E F 1 2 3 4 5 6
7 8
14 X 48 30 14 48 33 14 5 9/16” 9 ½” 1 ½” ½” ¾” ½” ¾” - - ¼”
20 X 48
60
20
48
26
18 ½”
7 7/8”
12 ¾”
2
1 ½”
1 ½”
1 ½”
1
¾”
¼”
-
20 X 63 80 20 63 36 18 ½” 9 12 ¾” 2 1 ½” 1 ¼” 1 ¾” ¾” ¼” -
All dimensions in inches
All receivers are built in accordance with the ASME section VIII Division I code latestaddition. All vessels are “U” stamped and registered with National Board.Note: California requirements special – please call.Design pressure to 200 PSIG, test pressure 300 PSIG.
Design temperature: -20 to 650 F.Type 1, 2:1 elliptical heads. All seams submerged arc welded.
Painted with one coat of standard gray shop primer.
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ASME VERTICAL AIR RECEIVERS: 30, 60, 80 gallon
F
1/4"
NPT
G
F
ASME F
Name-
plate
TL
HT
OD
B C
G
A
D
1/2" NPT
E
(Bolt
Circle) 9/16" X 7/8" SLOT (4 places)
Gal
OD
Length (TL)
Height (HT)
A
B
C
D
E
F (NPT)
G (NPT)
30 16 38 40.81 12.56 30.06 25.06 2.81 15 .75 1.5
60 20 48 50.75 13.75 39.75 33.75 2.75 17 .75 2
80
24
46
49.19
13.06
39.31
34.31
3.19 21
1.25
2
All dimensions in inches
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ASME STANDARD HORIZONTAL AIR RECEIVERS 120, 200, 240 Gal.
DIMENSIONS Port size (NPT)
Tank Size
Gal A B C D E 1 2 3 4 5 6 7
24 x 69 120 24 69 42 22 10 2 1 ½” 1 ½” 1 ½” 1 ¾” ¼”
30 x 72 200 30 72 38 28 12 2 2 2 2 1 1 ¼”
30 x 84 240 30 84 50 28 12 2 2 2 2 1 1 ¼”
All dimensions in inches
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INJECTOR HEAD MAINTENANCE INSTRUCTIONS
Maintenance Requirements Inspection of all components every 6 months is recommended for signs of wear or fatigue. Failureto perform routine inspections may result in sudden failure and possible contamination of materialand/or damage to production equipment.
Isolation Should it be necessary to overhaul any Injector heads while the system is working, it will benecessary to first close the valve(s) isolating the Injector head(s) on that part of the hopper.Next, switch on the Injector head control system for one full cycle. This will allow compressedair to clear from all isolated pipes around the hopper, by cycling all Injector heads within thesystem at least once.CAUTION: to avoid injury, pressure must be relieved from header piping beforemaintenance is started.
Dismantling Having first disconnected the electrical leads and the air piping, the Injector head may bewithdrawn by loosening hex setscrews or lock nut and removing Injector head from mountingflange/plate or coupling.(NOTE: mark Injector head body to insure proper re-alignment with interior wall.)
At the work bench the solenoid valve should be unscrewed from the Injector head.
Holding the front of the valve cap in a vise, loosen and remove the jam nut and elastic stop nutfrom the valve stem.
The compression washer, compression spring, spring guide and valve stem can then be
taken out. Inspect all parts for signs of wear or fatigue. Particularly note threads of thevalve stem and the front seat of the valve cap. Replace worn or damaged parts.
Reassembly Reassemble valve assembly. Tighten elastic stop nut to 3mm (1/8") of internal stop (front springguide). Check 1/8" dimension by manually pushing on rear of valve stem to extend(front) cap from body. Reinstall jam nut, and tighten against elastic stop nut. Reassemble withsolenoid and place back in hopper.
IMPORTANT: Front of Injector head valve body must align with interior ofhopper wall.
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Jam Nut
Elastic Stop Nut
Compression Washer Set Screws
Compression Spring MountingCoupling
Spring Guide“O” Ring
Valve Body
MountingFlange
RubberGasket
Valve Stem(Piston)
BAS-020 Injector head assembly with mounting
Qty DESCRIPTION CARBON STEEL STAINLESS STEEL
1
Valve Body
VB-020 VB-020-SS
1*
Valve Stem
VCW-020 VCW-020-SS
1*
Spring Guide
SG-020 SG-020-SS
1*
Compression Spring
CS-020 CS-020-SS
1*
Compression Washer
CW-020 CW-020-SS
1*
Elastic Stop Nut
ESN-020 ESN-020-SS
1*
Jam Nut
JN-020 JN-020-SS
1
Mounting Coupling
MC-020 MC-020-SS
1
O-Ring**
OR-020 OR-020
Note: (*) denotes part included in rebuild kit.Order RK-020 for carbon steel construction, RK-020-SS for stainless steel construction.
**For temperatures above 250 F, specify Viton O-ring (OR-020-V) .
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Flexible Hose Assemblies
Specifications
¾ i.d. X 24 overall length
Bellows③: SUS 316L
Wire Braids④:SUS304
Temperature Range: -20CF to 180 C
Working Working Pressure: 16Kgf/cm2
Nipples①②: SUS 316L , ¾" NPT
Bellows O.D. : 30.5mm
Total length: normal 500-600mm (also according to client.)
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