MACHINERY AND MAINTENANCE DETAILS

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6 MACHINERY AND MAINTENANCE DETAILS

7 TUBER LINE: SL. No Machine name Details 1 Feed conveyor 2 Washer 3 Modular belt 4 Modular belt 5 BLANCHER Motor:2 HP,1440 RPM, 3 PH Gear box:ratio-150,o/p RPM-9.6,AMF 150 L PBL make Foot mounted motor Starter :SIEMENS MAKE-2 HP Drive sprocket:30 T,121.5 mm dia,1/2 "p*5/16" Driven sprocket:38 T, mm dia,1/2"p*5/16" Chain:M/S Chain with lock 1/2 "*5/8"1650MM Bearing:Pillow block bearing UCP-205 Tensioning bearing UCP-205 Rubber Belt-900 w*2 thk*6600 LG Flight height-50 mm,flight width-800 MM Pitch-250 mm Gear box:type-ame 200 L,Foot mounted reducer RATIO-1:200, O/P RPM. 7.2 Output troque-44.6 NM Motor:Prower-1 HP,1440 RPM 3 PH,59 hz,380 V Starter:SIEMENS MAKE-1 HP Drive sprocket-1/2"*5/16"-30 T,121.5 dia Driven sprocket-1/2"*5/16"-30 T,121.5 dia Bearing-Tensioning bearing-ucp-205 P.P Belt 450 w*3160 Lg Belt width-450, Fllight width-390 Flight height-100, Flight GAP-250 Belt thk-15 mm M.S Chain with lock- 1/2"-5/16"*1000 LG P.P Belt 450 w*4160 Lg Belt with-450, Flight width-390 Flight height-100, Flight GAP-250 Belt thk-15 mm M.S Chain with lock- 1/2"-5/16"*1000 LG Motor:0.25 HP,1440 RPM Gear box-ratio-960, O/P RPM-1.5 Planetary gaer box Model:-AG 4029X,,Foot mounted SIEMENS MAKE-0.25 HP Drive sprocket-5/8"*3/17"-17 T,86.39 MM dia Driven sprocket-5/8"*3/17"-17 T,86.39 MM dia

8 6 SLICER 7 INCLINED ELEVATOR Chain-M.S chain with lock1/2"*1500 Bearing- Pillow block bearing. UCP-205 Four bolt flange bearing. UCF-205 Tensioning bearing.uct-205 Modular belt:p.p Belt 600 W*14700 LG Belt width-600, Flight width-500 Flight height-100,flight GAP-250 Belt thik-15 mm Motor o/p RPM-2 HP,1000 RPM cutting knife-s.s 410 mat.blade Size 65 W*145 L*10 THK motor; 2 hp,1440 RPM,3 PH Gear box:amf 150L,Ratio-150, O/P RPM-9.6 PBL make foot mounted motor Starter:SIEMENS MAKE-0.25 HP drive sprocket:27t,109 mm dia,1/2"p*5/16" driven sprocket:27t,109 mm dia,1/2"p*5/16" FOOT GRADE RUBBER Belt 600 W*7750 LG Belt width-600, Fllight width-500 Flight height-100, Flight GAP-250 Belt thk-3 mm Chain-M.S chain with lock1/2"*1500 Bearing:Tensioning bearing-uct-206 Four bolt flange bearing. UCF-206 Thrust bearing:single thrust ball bearing-ntm make NO dia 150*I/D 100*width 38 Caster wheel sweling: nylon-4"*36 thk FEEDING BELT SL. NO DESCRIPTION 1 GEAR BOX DRIVEN PULLEY ELECTRIC MOTOR PULLEY RPM TIME pvc material food grade quality feeding belt-5mm thic 4 1/2"*1*B 5"*1*B minutes TOTAL DRYING TIME IN DRYER

9 SL. NO CONVEYOR BELT FROM TOP TO BOTTOM GEAR BOX DRIVEN PULLEY ELECTRIC MOTOR PULLEY RPM TIME 1 Belt no 1 6"*1*B 5"*1*B minutes 2 Belt no 2 6"*1*B 5 1/2"*1*B minutes 3 Belt no 3 8"*1*B 5 1/2"*1*B minutes 4 Belt no 4 10"*1*B 5 1/2"*1*B minutes 5 Belt no 5 10"*1*B 5"*1*B minutes Total drying Time 180 mins HOT AIR CONVEYOR SL. NO DESCRIPTION S.S 304 mesh belt 1 GEAR BOX DRIVEN PULLEY ELECTRIC MOTOR PULLEY RPM TIME 12"*1*B 5"*1*B minutes Grinding section: SL. No Machine name Details 1 FEED BELT CONVEYOR BEARING NO. NTM F206J, NTM T 206J Sprocket:15 teeth*3/4" Gear motor: 1 HP 40 RPM National make 2 INCLINED FEED BELT CONVEYOR BEARING NO. NTM F206J, NTM T 206J Sprocket:6"*3/4" pitch Gear motor: 2 HP 40 RPM National make 3 Hammer mill Bearing no. SKF 2310 Rotor pulley 6"*4 grew*c section Motor pulley:7"*4 grew*c section Motor Bharat Bijlee 10 HP 2860 rpm 4 Impact mill 500 dia SS BEARING NO:2310 Rotor pulley:7"*4 grew*c section Motor pulley:7"*4 grew*c section Motor 20 HP 2860 RPM 5 8" rotary air lock valve Bearing no: th teeth*3/4" sprocket Bearing no: Chopper M/C 500 dia SS 7 Dust collector Rotor pulley:16"*3 grew*b section Motpr pulley:5"*3 grew*b section Motor RPM PP filler bag 1500 LG * 161 dia snap bend solonoid valve air max make 1" dia

10 Machine details seed line: SL. No Machine name Details 1 Air classifier bearing UCP 207 V belt B-64 V Puley on air classifier shaft 5.5"*B sec*2 grove V Puley on air classifier motor shaft 4"*B sec*2 grove Rotary feeder sprocket on feeder shaft 15th teeth*1/2" piutch Rotary feeder sprocket on feeder geared motor 17"*1/2" pitch Rotary feeder drive chain 1/2" pitch*105 mtr 2 Screen separetor centre shaft bearing Suspension spring 8 nnwire dia*66mmod*50mm*15mm pitch*150mm lg V belt for m/c B-59 V belt for blower B-31 Rubber ball 30mm dia Screw mesh/perforate 60 dia,16gauge SS304 Screen mesh / perforate 2.5 dia,16 gauge SS304 Oil seal 40*72*10 3 Vaccum D stoner counter weight drive bushes M16*56mm dia*67/63 mm Shose post bushes M16*44 mm dia*65/50 mm Rear post for m/c VFD drive B 46 v Belt for fan C 58 Deck screen SS 304 Rubber pads 150*150*25 mm thick Ecentric drive bearing SCHB 211 Bearing block for ecentric drive shaft UCP 205 Bearing unit for fan unit UCP 208 Bearing for air lock UCF 205 Drive chain for air lock 1/2*1.5 mtrs Rubber for coupling STD 4 Gravity Separetor counter weight drive bushes M16*56mm dia*83/83 mm Shose drive bushes M16*56 mm dia*120/100 mm Front post bushes M16*56 mm dia*65/50 mm Rear post bushes M16*56 mm dia*67/63 mm V belt for M/C vfd Drive B-36 v Belt for fan C 77 Deck screen STD Rubber pads 300*150*25 mm thick Ecentric drive bearing SCHB 213 Fan shaft bearing UCP 209 Bearing block for ecentric drive shaft UCP Clean O grader Ecentric drive bearing SN 511

11 6 Pressure D stoner 7 Bucket Elevator Counter bearing for drive shaft 6204 Bearing for spring flate 6204 Bearing for main m/c drive 2215K V belt for m/c drive B72 Flate spring STD Rubber ball 30 mm dia counter weight drive bushes M12*36mm dia*38 mm Shose drive bushes M12*36 mm dia*38 mm Front post bushes M12*36 mm dia*38 mm Rear post bushes M12*36 mm dia*38 mm V belt B-44 Counter bearing for drive shaft UCF 205 Head pulley drive bearing UCF 205 Boot pulley drive bearing UCF 205 V belt motor to cwt A 65 V belt cwt to pulley A 59 Thermic Fluid Heater: SL. No Make Machine name Details 1 2 Alfa entech pvt ltd Alfa entech pvt ltd Boiler( Thermic Fluid Heater) Recirculation pump for boiler TYPE:Entek HSD/LDO thermic fluid boiler.model 1500 CAPACITY: KCAL/HR Out let temp. 300 degree calcious thermic fluid recommended HYTHERM 500 TYPE:Etanorm SYT SYT8 KSB order number: /01 Flow rate: Q 160 Mtr.cube/H Speed:n 2970 Kinetic viscosity:v 16.5 mn2/s Head: 77 mtr

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15 5 STAGE IMPERIAL DRYER (CONTINUOUS BELT DRYER) FOR TUBER LINE- PID FEEDING SIDE

16 5 STAGE IMPERIAL DRYER (CONTINUOUS BELT DRYER) FOR TUBER LINE- PID OUTLET SIDE

17 HOT AIR CONVEYOR FOR TUBER LINE- PID

18 TRAY DRYER FOR CHILLI LINE- PID

19 TRAY DRYER FOR SEED LINE- PID

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53 Installation- and maintenance instruction B70-2FH

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55 DESCRIPTION , COMPONENTS 1. Flame cone 2. Shrouded disc 3. Nozzle 4. Nozzle assembly 5. Ignition electrodes 6. Ignition cable 7. Ignition transformer 8. Photoresistor 9. Control box 10. Front plate, relay base 11. Switch l-ll 12. Indicating lamp Stage Cover, inspection glass 14. Indicating lamp Stage Switch 0-l 17. Electric panel 18. Contactor 19. Thermal overload protection 20. Motor 21. Locking device, flange 22. Solenoid valves 23. Connecting pipe pump-solenoid valve bloc 24. Air intake 25. Solenoid valve bloc 26. Nozzle assembly adjustment 27. Scale, air regulation 28. Connecting pipe, solenoid valve bloc-adjustment device 29. Air damper 30. Pump 31. Adjustment device

56 TECHNICAL DATA Type designation B 70-2FH DIMENSIONS 408 ø220 ø B 730 Length of burner tube Flange Measure B Burner head Standard Burner head Long design OUTPUT RANGE AND NOZZLES RECOMMENDED Oil capacity Output Recommended nozzle Recommended kg/h kw Mcal/h Angle Danfoss Monarch Pump pressure Burner head B PLP 14 bar The net calorific value of 11,86 kwh/kg for light oil has been used. RECOMMENDED NOZZLE Because of different boiler types existing on the market, with varying combustion chamber designs, it is not possible to state a definite spray angle or spray pattern. Note that the spray angle and the spray pattern change with the pump pressure. BURNER HEAD 10,0-13,0 3,5-4,0 2,0-3,0 8,0-10,

57 TECHNICAL DATA DIMENSIONS OF FLANGE 14 (ø310)ø ø205,

58 GENERAL INSTRUCTIONS GENERAL RULES The installation of an oil burner should be carried out in accordance with local regulations. The installer of the burner must therefore be aware of all regulations relating to oil and combustion. Only oil suitable for the burner should be used and then in combination with a suitable oil filter before the oil pump of the burner. If the burner is replacing an existing burner make sure that the oil filter is replaced or cleaned. The installation must only be undertaken by experienced personnel. INSTALLATION INSTRUCTIONS General installation instructions accompany the burner and should be left in a prominent place adjacent to the burner. ADJUSTMENT OF BURNER The burner is from the factory pre-set to an average value that must then be adjusted to the boiler in question. All burner adjustments must be made in accordance with boiler manufacturers instructions.these must include the checking of flue gas temperatures, average water temperature and CO 2 or O 2 concentration. To adjust the combustion device, start by increasing the air volume and the nozzle assembly somewhat.when the burner starts it is burning with excess air and smoke number 0. Reduce the nozzle assembly adjustment until soot occurs, and then increase the adjustment to make the soot disappear again. Then the volume of air is reduced until soot occurs and increased again to reach a combustion free of soot. By this procedure an optimum adjustment is obtained. If larger nozzles are used the preadjustment of both the air volume and the nozzle assembly must be increased. A whistling sound may be heard which can be eliminated or reduced as follows: Increase the nozzle assembly adjustment somewhat. The CO 2 -content and consequently the air volume will then be reduced. CONDENSATION IN CHIMNEY A modern burner works with less excess air and often also with smaller nozzles than older models. This increases the efficiency but also the risk of condensation in the chimney. The risk increases if the area of the chimney flue is too large. The temperature of the flue gases should exceed 60 C measured 0,5 metres from the chimney top. Measures to raise the temperature: Insulate the chimney in cold attics Install a tube in the chimney Install a draught regulator (dilutes the flue gases during operation and dries them up during standstill) Increase the oil quantity Raise the flue gas temperature by removing turbulators, if any, in the boiler. PUMP ADJUSTMENT See separate description. MAINTENANCE The boiler/burner should be examined regularly for any signs of malfunction or oil leakage. OIL SUPPLY The oil line should be dimensioned in accordance with the pump manufacturer s instruction. In the suction line to the burner a filter should be mounted to prevent any particles in the oil from reaching the burner. If the installation consists of several burners each one should have its own suction line from the tank or a circulation system should be used. The temperature in the oil line should be kept as constant as possible. Avoid exposing the line to excessive cold which may cause blockages of paraffin deposits. The oil pipe and electric cable should be fitted so that the burner can be placed on the floor for inspection of the combustion device

59 GENERAL INSTRUCTIONS ADJUSTMENT OF NOZZLE ASSEMBLY Adjust the nozzle assembly with the adjustment screw D to the desired position. D AIR ADJUSTMENT First stage: Set the operating switch (S2) on low capacity (I). Loosen the screw (A) and turn the damper to the position wanted. Tighten the screw (A) again. Second stage: Set the operating switch (S2) on high capacity (II). Screw the knurled ring (B) in (reduce) or out (increase). The position of the damper can be read on the damper scale (C). Check the air adjustment by making a flue gas analysis. B A C

60 MAINTENANCE OF OIL BURNER Warning: Before doing any service switch off power at the main switch and cut off the oil supply. SERVICE OF BURNER HEAD NOTE! For maintenance of the brake plate, nozzles, electrodes etc, when using a long design of the burner tube, you have to remove the nozzle assembly from the connecting pipe and move the assembly backwards in the fan housing (from the boiler)

61 ELECTRIC EQUIPMENT OIL BURNER CONTROL: LMO B2B/LOA44 WIRING DIAGRAM LIST OF COMPONENTS A1 Oil burner control B1 Photoresistor F1 Operating fuse F2 Fuse F3 Fuse H1 Lamp, low capacity H2 Lamp, high capacity K1 Thermal overload protection M1 Burner motor S1 Operating switch S2 Operating switch, high/low capacity S3 Control thermostat S4 Temperature limiter S5 Micro switch for hinged door S6 Control thermostat, high/low capacity S7 Main switch S20 Main switch T1 Ignition transformer X1 Connection terminal board X2 Earth terminal X3 Plug-in contact "Euro", burner X4 Plug-in contact "Euro", boiler X5 Plug-in contact "Euro", high/low burner X6 Plug-in contact "Euro", high/low boiler X7 Plug-in contact "Euro" 3-phase, burner X8 Plug-in contact "Euro", 3-phase, boiler Y0 Solenoid valve start Y1 Solenoid valve 1 Y2 Solenoid valve 2 If S6 is missing connection between T6 and T8. Mains connection and fuse in accordance with local regulations. 3N~50/60Hz 400 V

62 ELECTRIC EQUIPMENT OIL BURNER CONTROL: LMO B2B FUNCTION 1. Switch on operating switch and twin thermostat The burner motor starts, an ignition spark is formed, the prepurge goes on till the prepurge period expires and the solenoid valve 1 opens (2). 2. Solenoid valve 1 opens Oil mist is formed and ignited. The photocell indicates a flame. 3. The safety time expires a. If no flame is established before this time limit the control cuts out. b. If for some reasons the flame disappears after this time limit, the burner will make an attempt to re-start. 4. Full load thermostat ON The burner is in operating position and can now change between high and low capacity Operating position If the burner operation is interrupted by means of the main switch or the thermostat, a new start takes place when the conditions in accordance with point 1 are fulfilled. The oil burner control cuts out A red lamp in the control is lit. Press the reset button and the burner re-starts. TECHNICAL DATA Pre-ignition time: 25 s Pre-purge time: 25 s Post-ignition time: 5 s Safety lock-out time: 5 s Reaction time on flame failure: max. 1 s Ambient temperature: from - 20 to +60 C Min. current with flame established: 30 µ A Max. photo current at start: 5,5 µ A Enclosure: IP 40 CONTROL OF PHOTO CURRENT Current through photo unit is measured with a d.c. ammeter (a moving coil instrument connected in series with the photo unit)

63 INSTRUCTIONS PUMP TYPE DANFOSS RSA 125 TECHNICAL DATA Viscosity range: 1,3-18,0 mm 2 /s Pressure range: 12,0-21,0 bar Oil temperature: -10 to +70 C COMPONENTS 1.Pressure gauge port G 1/8" 2.Nozzle port G 1/8" 3.Suction line G 1/4" 4.Suction line G 1/4" 5.Return line G 1/4" 6.Return line R 1/4" 7.By-pass plug 8.Pressure adjustment, 5 mm allen key SUCTION LINE TABLES The suction line tables consist of theoretically calculated values where the pipe dimensions and oil velocity have been matched so that turbulences will not occur. Such turbulences will result in increased pressure losses and in acoustic noise in the pipe system. In addition to drawn copper piping a pipe system usually comprises 4 elbows, a non-return valve, a cut-off valve and an external oil filter. The sum of these individual resistances is so insignificant that they can be disregarded. The tables do not include any lengths exceeding 100 m as experience shows that longer lengths are not needed. The tables apply to a standard fuel oil of normal commercial quality according to current standards. On commissioning with an empty tube system the oil pump should not be run without oil for more than 5 min. (a condition is that the pump is being lubricated during operation). The tables state the total suction line length in metres at a viscosity of 6,0 mm 2 /s. PURGING On 1-pipe systems it is necessary to purge the pump. On 2-pipe systems purging is automatic through the return line. H 1-pipe system Height Pipe diameter H ø10mm ø12mm ø15mm ø20mm m m m m m With an overlying tank a 1-pipesystem is not recommended Two-pipe system Height Pipe diameter H ø10mm ø12mm ø15mm ø20mm m m m m m 4, , , , , , , , H 1-pipe system Height Pipe diameter H ø10mm ø12mm ø15mm ø20mm m m m m m With an underlying tank a 1-pipesystem is not recommended Two-pipe system Height Pipe diameter H ø10mm ø12mm ø15mm ø20mm m m m m m , , , , , , , ,

64 FUNCTION DANFOSS RSA When the pump is started oil is drawn through the suction port "S" via filter "H" to the suction side of the gearwheel set "C". From here the gearwheel set pumps the oil to the pressure side and at the same time the oil becomes pressurized. The oil is led to cut-off and regulating valve "V" which opens when the set pressure is reached. The pressure is controlled and kept constant by regulating valve "V". At the same time the gearwheel set "C" distributes the oil through nozzle port "P" and pump return side "R" via the shaft seal "F". The quantity of oil supplied to nozzle port "P" is determined by the pressure set on regulating valve "V" and the nozzle/resistance in the nozzle line. In 2-pipe-systems excess oil is led back to the oil tank. In 1-pipe-systems the by-pass plug "A" must be removed to give free flow back to the suction side via return line "G" with return port "R" closed. When the pump is stopped, the pump S R output drops and produces a drop in the oil pressure. The spring in the regulating valve presses the regulating piston forward until it seals in port "P". This cuts off the oil flow to the nozzle and ensures that the nozzle line is effectively shut off. If the pump is overloaded, i.e. more oil is demanded than the gearwheel is able to pump under the given conditions, the oil pressure falls below the set value because the piston of the regulating valve moves towards its closed position and partially or wholly cuts off the return oil via port "O". This can be remedied by - reducing the pump pressure - reducing the capacity, i.e. smaller nozzle or greater resistance - changing to a pump with higher capacity MOUNTING/DISMOUNTING BY- PASS PLUG In a 2-pipe-system excess oil is led back direct to the oil tank. In a 1-pipesystem the by-pass plug must be removed so that there is a free passage back to the suction side through the return line with the return port closed. One pipe system EXCHANGE OF FILTER Two pipe system

65 FUNCTION FOR DANFOSS RSA 1. Nozzle 1 2. Nozzle 2 3. Nozzle 3 4. Solenoid valve Nozzle 1 5. Solenoid valve Nozzle 2 6. Solenoid valve Nozzle 3 and adjustment of air Stage 2 7. Oil pump 8. Air adjustment Stage 2 N.B. Nozzle 1+2= 1 st Stage Nozzle 1+2+3= 2 nd Stage

66 NOZZLE TABLE Pump pressure bar Gph kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h 1,00 3, , , , , , , , ,10 4, , , , , , , , ,20 4, , , , , , , , ,25 4, , , , , , , , ,35 5, , , , , , , , ,50 5, , , , , , , , ,65 6, , , , , , , , ,75 6, , , , , , , , ,00 7, , , , , , , , ,25 8, , , , , , , , ,50 9, , , , , , , , ,75 10, , , , , , , , ,00 11, , , , , , , , ,50 13, , , , , , , , ,00 14, , , , , , , , ,50 16, , , , , , , , ,00 18, , , , , , , , ,50 20, , , , , , , , ,00 22, , , , , , , , ,50 24, , , , , , , , ,00 26, , , , , , , , ,50 27, , , , , , , , ,00 29, , , , , , , , ,50 31, , , , , , , , ,00 33, , , , , , , , ,50 35, , , , , , , , ,00 37, , , , , , , , ,00 40, , , , , , , , ,00 44, , , , , , , , ,00 52, , , , , , , , ,00 59, , , , , , , , ,00 67, , , , , , , , ,00 74, , , , , , , , ,00 81, , , , , , , , ,00 89, , , , , , , , ,00 96, , , , , , , , The table applies to oil with a viscosity of 4,4 mm 2 /s (cst) with density 830 kg/m

67 Situation FAULT LOCATION BURNER FAILS TO START Possible causes Remedies Motor runs Flame instabillity Burner pre-purges Flame occurs Burner locks out Motor runs Burner pre-purges No flame occurs Burner locks out Incorrect head settings Low oil pressure Excess air Photocell not seeing light Photocell failed Control faulty False light No spark No oil Check nozzle to burner head dimension and electrode position Check oil pressure Adjust air damper Check that photocell is clean and unobstructed Confirm with new photocell Confirm with new control. (NB. it is advisable to change the photocell if also changing control) Check that photocell is not seeing ambient light Check that H.T. leads are sound and are not arcing other than at electrode gap Check oil supply to burner - check that pump is not airlocked Check operation of magnetic valve BURNER FAILS TO START AFTER NORMAL OPERATION Burner fails to start Lamp not lit Fuse has blown Appliance thermostat has not reset Appliance overheat device has operated Control relay or photocell defective Check or replace fuse if necessary. Check reason for failure Adjust thermostat Reset overheat device. Find reason for its operation and rectify Check by replacement Motor runs Burner runs to lockout No oil being delivered Excessive flue draught is preventing flame establishment No spark Check that tank, oil lines, fire valve, pump and nozzle are all in good order Rectify condition Check ignition transformer. Check electrode gap and porecelains DELAYED IGNITION, BURNERS STARTS VIOLENTLY Burner pulsates on start-up only with hot flue Excessive draught Recommission burner Burner pulsates on start-up Nozzle partly blocked Replace nozzle Oil pressure too low Check and recommission Flue blocked or damaged Check and rectify Fan slipping on shaft Check and retighten Pump coupling loose or worn Check and replace Burner starts violently Delayed ignition Check the electrode adjustment, see diagram Check electrodes for damage Check H.T. leads for damage and disconnection