TR-SERIES LIFTKLEEN PARTS DRYER

Transcription

1 Operation and Maintenance Instructions TR-SERIES LIFTKLEEN PARTS DRYER

2 SAFETY WARNINGS You will find various types of safety information on the following pages and on the labels attached to Graymills equipment. The following Safety Statements explain their meaning: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. or serious injury. DANGER indicates a hazardous situation which, if not avoided, will result in death WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION, used without the safety alert symbol, is used to address practices not related to personal injury. Never work with equipment you feel may be unsafe. Contact your Supervisor immediately if you feel a piece of equipment is in an unsafe condition. UNPACKING MACHINE When the machine is received, check the exterior packaging for damage or signs of improper handling. Report any shipping damage immediately to the freight carrier who delivered the equipment. If the exterior packaging is not damaged, proceed with the following: 1. Carefully remove the outer carton. 2. Remove all packing materials from inside the tank. 3. Do NOT connect the electric or air service until instructed to do so. INSTALLATION Site Preparation Before installing the TR-Series Dryer, careful consideration should be given to the place of operation. Place unit on a smooth, level surface. The work area should be well ventilated. Provide adequate lighting in the work area. Be sure to allow adequate room to bring work to and from the machine. Provide sufficient clearance around the machine for loading, unloading and servicing. GENERAL WARNINGS Follow all directions, Warnings, Cautions and Dangers for the cleaning material used. Do NOT DRY PARTS CLEANED WITH gasoline, alcohol, carburetor cleaners, metal strippers or chlorinated solvents. Use of such unauthorized materials can cause a health and safety hazard which might result in serious personal injury or death Dryer Operation Manual GENERAL WARNINGS, continued This DRYER UNIT uses heated air along with agitation to dry parts after cleaning with aqueous waterbased cleaners. High temperatures will cause increased risk of personal injury. Remember, any temperature above 115 F can cause burns. Equipment itself will be hot. Use caution. DRYER HEATS PARTS TO OVEN TEMPERATURES. DRIED MATERIAL WILL BE VERY HOT. USE APPROPRIATE PERSONAL PROTECTION, INCLUDING PROTECTIVE GLOVES. UNIT Must be properly grounded to prevent electric shock hazard. USE QUALIFIED ELECTRICIANS TO PERFORM THIS WORK. All electrical connections should conform to national/local codes and be made by qualified personnel. This unit has moving parts, pinch-points and close tolerances. Always stand clear of lift platform and lid when operating as the lid could unexpectedly open or the platform operate. Keep hands and fingers away from tank when operating platform. (See the OPERATION section.) Before performing any maintenance on this unit, be sure to disconnect electric power. GETTING STARTED Be sure the required electrical service was installed by a qualified electrician in compliance with all local and electrical codes. Consult the name plates on the machine and the SPECIFICATIONS Section of this manual for the electrical service requirements. To prevent electrical shock hazard, this equipment must be properly grounded. Provide the required compressed air supply to the installation site. Although the TR-Series Dryer is equipped with a 1/4 air connection, it is recommended that a 3/8 to 1/2 supply be provided, depending upon the length of the supply line. The TRSeries Dryer lift mechanism requires an air supply pressure of 80 psig minimum and 100 psig maximum for proper operation (do NOT exceed 100 psig). NOTE: Lift capacity is proportional to air supply pressure. Specified lift capacity is with 90 psig air inlet pressure. Example: Air inlet supply pressure of 70 psig will reduce lift capacity by 22%. SAFETY PROCEDURE Follow these instructions at all times. The internal surfaces of the dryer as well as the lift platform, parts and parts baskets may be EXTREMELY HOT. Be sure to use appropriate personal protective gear when unloading the machine. To prevent injury, keep hands and body clear of the lid, lift platform and lift mechanism at all times. When turning air on, off, or operating the lift platform, stay clear of the lid, the lift platform and operating mechanism, as the lid could unexpectedly open or the platform operate. Never operate unit without safety shroud fully in place. See Safety Procedure for CONNECTING AIR SUPPLY in the following section.

3 CONNECTING AIR SUPPLY While connecting the air supply (Figure 1) to the quick disconnect fitting (1A) on the rear of the lift column, make sure that the sleeve valve (1B) is pulled toward the quick disconnect fitting, thus disconnecting air from the lift mechanism. This will prevent sudden movement of the lift platform and sudden opening of the lid while the air is being connected. 1. After the air supply is connected, slide the sleeve valve forward toward the machine to turn on the air supply. (Follow Safety Procedure by keeping clear of lid and operating mechanisms.) 2. With the air connected and electrical power on, rotate the UP/ DOWN selector switch to DOWN and hold. The lift platform will drop and remain in the lowered position. 3. Momentarily rotate the UP/DOWN selector switch to the UP position. The platform should begin oscillating up and down with approximately 3 of stroke. 4. Rotate the UP/DOWN selector switch to the UP position and hold. The platform will rise and remain in the raised position. Release switch. Timer Instructions Before operating machine, set the cycle timer. Point the timer dial to the desired time. This machine will not run without a timed cycle to prevent overheating when under heat. Timer has been factory set with a maximum time of 60 minutes. To set the timed cleaning cycle function: 1. Turn off main power to the dryer at wall disconnect. 2. Rotate machine disconnect to the OFF position. 3. Set timer to desired drying cycle duration by adjusting the front dial. The markings on the front of the Timer Control unit are 1 to equals one hour, so each mark is equivalent to 6 minutes. NOTE: The timer has been set to a maximum of 60 minutes. The unit is capable of other time increments. Contact the factory for information on how to adjust these settings if necessary. 4. Turn on main power at wall disconnect. 5. Rotate machine disconnect to the ON position. 6. Set your desired time, based on the 6 minute increments. To Override Automatic Cycle The internal surfaces of the dryer as well as the lift platform, parts and parts baskets may be EXTREMELY HOT. Be sure to use appropriate personal protective gear when unloading the machine. The automatic cycle can be manually overridden by rotating the UP/DOWN selection switch to UP, twisting counter clockwise and holding for several seconds. The lid will open and the lift platform will rise to the load/unload position. This does not end the timer duration (timer is still counting). If the timer ends while the lift platform is up, no change will result. However, sending the lift platform down to resume process will not establish a new timer cycle if the previous one is still in effect. The lid will open and lift platform will rise as prescribed by the original timer cycle. To establish a new timer cycle, send the lift platform up to the load/unload position and turn the MAIN POWER switch OFF and back ON. Upon rotating the UP/DOWN switch to DOWN for a moment, a new timer cycle will start. Adjusting Platform Speed (Figure 2) Two sensors are located on the cylinder body. Leaving the lower sensor in place, adjust the upper sensor 1 to 3 above it. Placing the upper sensor more than 3 above will result in the lid arm contacting lid when agitating. Two independent speed control muffler screws (Figure 1, 1A) are provided to control the vertical speed of the platform. The UP and DOWN speeds of the platform should be equal when the platform holds the intended workload. The speed control muffler screws are located underneath the junction box. 1. To adjust the platform speed, first loosen the jam nut (1B) on the UP or DOWN speed control, as applicable. To prevent the lid from slamming upon opening, adjust control muffler screws (1A) down to an appropriate speed. 2. With everyone clear of the unit, adjust the speed control muffler screw with a thin bladed screwdriver. Screw the control out to increase platform speed and in to reduce speed. Retighten the jam nut after speed control adjustment has been made. OPERATION Follow all Safety Procedures and Warnings/Cautions listed below and in previous sections. NOTE: For best results, we recommend running a few heated drying cycles to get the unit primed for full operation with parts. 1. Keep clear during operation. Turn on machine power by rotating disconnect switch on side of machine to the ON position 2. Enable machine control by rotating MAIN POWER switch to RIGHT. 3. Rotate the UP/DOWN selector switch to the UP position and hold. The platform will rise and remain in the raised position. Release switch. 4. Load the parts to be dried in a parts basket and place the basket on the lift platform. Do NOT exceed weight limit (150 pounds for the T24 Series, 200 pounds for the T36 Series). Larger parts may be loaded directly on the lift platform. Use appropriate lifting techniques for heavy parts. 5. If heat (OPTIONAL) is desired for drying process, rotate HEAT selector switch to ON position (right). See TIMER INSTRUCTIONS. Set timer time segment (30 seconds to 1 hour) NOTE: This unit is provided with an Air Flow Sensor (see Figure 5) to prevent the Blower from overheating and burning out. If the Blower does not operate when you turn it on, check the air intake and if that is clear, check filters (see MAINTENANCE instructions). 6. Momentarily rotate the UP/DOWN selector switch to DOWN. The lift platform will drop and lid will close. 7. Once lid has closed, the blower will engage as will the heater (OPTIONAL). The machine will agitate up and down until timer expires. Stay away from lid at all times when unit is operating. 8. When timer expires, the platform will raise, the blower/heater will stop and the lid will open. The internal surfaces of the dryer as well as the lift platform, parts and parts baskets may be EXTREMELY HOT. Be sure to use appropriate personal protective gear when unloading the machine. NOTE: Because of the wide range of applications, the required drying time usually will be determined by experience under actual use conditions. Dryer Operaion Manual

4 Powering Down the Unit When the unit is not in use, it is recommended that the lift platform be sent to the bottom position and lid closed. In order to maintain this position indefinitely, turn the MAIN POWER switch to the OFF position. MAINTENANCE Follow all Lock Out procedures before performing any service or maintenance. Lock Out Procedures 1. When performing any maintenance tasks on the dryer, be sure that the master on/off air line valve is in the OFF position. 2. Disconnect the main air supply to the rack and/or lid cylinders to remove residual air pressure. 3. Turn electric power to machine OFF at main disconnect. 4. Unplug and/or disconnect all power to the machine. Before performing any repairs or internal maintenance on this machine, disconnect the electrical power supply and the compressed air supply. Review Connecting Air Supply. Follow all lock-out procedures (see above). be sure THE UNIT is cool. NOTE: Refer all electrical service to a qualified electrician. Daily 1. Check the air hose and connector for damage or wear. Replace damaged air hose or fitting immediately. 2. Check the lift mechanism for smooth operation. For problems with the lift mechanism, refer to the TROUBLESHOOTING Section. 3. To prevent damage to painted surfaces, wipe up any fluid spills immediately. V-Groove Roller Maintenance (Figure 3) 1. Remove clips (3D) from one side of housing on all four shafts. 2. Remove the Factory Set Plates. These plates are required to be reinstalled to assist in keeping the proper tension against the vertical shaft and rollers. 3. Release pressure on back rollers (3A) by loosening 3/8-16 jam nuts (3F) locking 3/8-16 bolts (3E) pushing against back roller shafts. 4. Once nuts are loose, back out the 3/8-16 bolts about 1/4 to 1/2 to relieve pressure off rollers. 5. Remove the Roller Cover by sliding up to unlock it from slots. 6. Push shaft out through housing and roller spacers (3B) and V-groove rollers (3A). 7. Inspect roller bearing, grease rollers at this time, damaged bearings or rollers should be replaced. 8. Inspect vertical shaft for wear. Damaged vertical shaft should be replaced. Adjusting the Stroke Length (Figure 4) 1. Remove clips (3D) from one side of housing on all four shafts. 2. Remove the Factory Set Plates. These plates are required to be reinstalle Replacing Foam Filters in Dryer Motor (Figure 5) Foam filters will need to be replaced when they collect contaminants that are brought in with air for the blower. The life of the filters will vary depending on your situation. Typically, the filters will need to be replaced once per year. Clogged filters will cause a drop in the air flow, and will be one reason that the air manifold closes and the heater will not operate or will shut off prematurely. Order part number This is a complete set of filters. To install: 1. Turn off main power to the dryer at wall disconnect. 2. Make sure the unit is cool before performing this operation. 3. See Figure 5. Loosen the 4 bolts that hold the heater cover in place (2 on the front, 2 on the top). Lift and pull the cover free. 4. Disconnect the blower from the heater and inlet manifold by disconnecting the two unions. Make sure that you have a work surface in ready to hold the blower. Note that the blower is heavy; be prepared with an assistant or tools to assure that you do not drop or harm it. 5. Remove the 4 bolts that hold the blower to the support. You will NOT have to disconnect the electrical cables from the blower, but the cord will limit your range of positioning. With assistance, place blower on a safe, level surface. 6. Working on the filter housing behind the blower, remove the 6 set screws with an Allen Wrench, opening the housing and releasing the filters. Note that there are springs in the top of the filter housing to put pressure on the filters. These must be left in place for proper operation. 7. Remove the used filters and replace with a fresh set. We recommend that you replace all the filters, rather than reusing partially soiled filters that may decrease the length between changes. 8. Close the filter housing, replace the set screws. 9. Put the blower back in position and tighten the 4 bolts. Check all connections. 10. Reattach the two unions. 12. Connect electricity and follow OPERATION procedures. REPLACEMENT PARTS LIST /2 HP Blower Filter Foam for 1-1/2 HP Blower Heater, 6kW, 460V, 3Ph V-ROLLER PARTS Number Description V-Groove Roller (3A) Spacer (3B) Shaft (3C) Clip (3D) LIFTER KIT ASSEMBLY TR2420 TR3626 Number Number Description Air Cylinder /4 Polyethylene Tubing Speed Control/Muffler Solenoid Valve, 5- Port way Toggle Switch way Toggle Switch Cylinder Position Sensor Filter Regulator with Gauge Dryer Operation Manual

5 Figure 1 Connecting Air Supply Figure 3 V-Groove Roller Maintenance Figure 2 Adjusting Platform Speed 2A 2A 2B 2B Figure 4 Adjusting Stroke Height 4A 4B Figure 5 Replacing Air Filters Dryer Operaion Manual

6 TROUBLESHOOTING GUIDE. FOLLOW ALL SAFETY PROCEDURES. PROBLEM PROBABLE CAUSES REMEDY Lift platform does not oscillate Lift platform does not remain in down position UP speed is different from DOWN speed Lift platform does not come to UP position Air valve assembly improperly adjusted Part has fallen under platform, preventing it from reaching lowest position of travel Not enough air pressure: 80 psig min., 100 psig max. Speed control muffler is improperly adjusted. Overloaded. Load exceeds recommended weight capacity Check sensors in back on cylinder: sensors have indicators; verify light illuminates when platform passes. Remove 2 hoses from main valve. Ensure air is passing through from cylinder. Bad valves should be replaced. Remove four slotted screws and platform grid, permitting access to lift part from tank. Check air supply, hoses, and connectors. Adjust the speed control muffler screws (Fig.1A) at the rear of the lift column. Tighten jam nuts (Fig.1B) when finished. Open lid and use chain hoist to remove heavy part. Lift platform bangs at full top or bottom position Air cylinder cushion screws require adjustment Rollers are squeaking Bearings need grease. Grease rollers. Lid won t open when rack comes to top Blower does not turn on Rust on wheels and/or vertical bar Air pressure may be too low to lift load and lid Sensor lodged in off position or foam filters are contaminated and blocking air flow Motor rotation is incorrect; air is moving in wrong direction. Screw in air cylinder cushion screws to reduce banging. Spray lubricant on wheels and/or vertical bar. Increase air pressure to 100 psig. Check sensor. If lodged, remove obstruction. If not lodged, check filters. Replace if contaminated. Check system wiring and direction of air flow. Correct if necessary. If your problem is not listed above or problems persist, please contact Graymills for further assistance WARRANTY Graymills Corporation warrants that the equipment manufactured and delivered hereunder, when properly installed and maintained, shall be free from defects in workmanship and will function as quoted in the published specification. Graymills does not warrant process performance nor does Graymills assume liability for equipment selection, adaption or installation. This warranty does not apply to damages or defects caused by operator carelessness, misuse, abuse, improper application, or abnormal use; the use of add-on parts or equipment which damages or impairs the proper function of the unit and modifications made by Buyer. Graymills obligation under this Warranty shall be limited to: Replacing or repairing (at Graymills sole discretion) any non-conforming or defective parts manufactured by Graymills within one year from the date of shipment to customer. Replacing or repairing (at Graymills sole discretion) thermoplastic parts cleaner tanks or lids that have cracked or split under normal use within five (5) years from date of shipment. Replacing or repairing components supplied but not manufactured by Graymills to the extent of the warranty given by the original manufacturer. Buyer must give Graymills prompt notice of any defect or failure and satisfactory proof thereof. This warranty does not apply to expendable parts which need periodic replacement due to normal wear. This warranty does not apply to rusting of mild steel components or tanks in product used with aqueous (water based) fluids. A new warranty period shall not be established for repaired or replaced materials or products. Such items shall remain under warranty for only the remainder of the warranty period of the original materials or products. If you believe you have a warranty claim, contact Graymills Customer Service at for a Return Merchandise Authorization number. Any returned material must have its RMA number on the outside of the package and be shipped prepaid or the shipment will be refused. Graymills will promptly examine the material and determine if it is defective and within the warranty period. The foregoing warranties are in lieu of all other warranties whether oral, written, expressed, implied or statutory. Implied warranties of fitness for a particular purpose and merchantability shall not apply. Graymills warranty obligations and Buyer s remedies thereunder (except as to title) are solely and exclusively as stated herein. In no case will Graymills be liable for consequential damages, loss of production or any other loss incurred because of interruption of service N Lincoln Avenue Chicago, IL fax info@graymills.com Graymills Corporation The information contained in this manual is intended to be accurate. However, the manufacturer retains the right to make changes in design which may not be included herein Dryer Operation Manual