Pneumatic agitator A MAN R

Transcription

1 Pneumatic agitator A MAN R Operation manual MAG00001EN, V05 N

2 Dürr Systems AG Application Technology Carl-Benz-Str Bietigheim-Bissingen Telephone: Internet: Original operation manual MAG00001EN, V05 Transmission and duplication of this document, as well as use and sharing of its contents are not permitted without express written approval. Violations will be liable for compensation for damages. All rights in the event of a patent grant or design registration are reserved. Dürr Systems AG /32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

3 Information about the document This document facilitates safe handling of the product. Read the document before beginning any work. The document must be kept readily accessible and close to the place of use for use in the future. The document must be included if the product is transferred. Always follow specifications such as instructions for use and safety tips. Images are there to help general understanding and can differ from the actual product. Validity range of the document This document describes the products with the following material numbers: N Agitator A MAN R N Agitator A MAN R N Agitator A MAN R N Agitator A MAN R N Agitator A MAN R N Agitator A MAN R N Agitator A MAN R N Agitator A MAN R N Agitator A MAN R Hotline and Contact If you have queries or would like technical information, please contact your dealer or sales partner. 04/2017 Pneumatic agitator A MAN R - MAG00001EN 3/32

4 TABLE OF CONTENTS 1 Product overview Overview Short description Safety Explanation of symbols Intended Use Residual risks Property damage Conduct in the event of a hazardous situation Staff qualification Personal protective equipment Design and Function Agitator Transport, scope of supply and storage Scope of delivery Handling of packaging material Storage Assembly Assembly Connecting Operation Safety recommendations General notes Checks Agitating Cleaning and maintenance Safety recommendations Cleaning Overview Manual cleaning Cleaning container Cleaning bath Maintenance Maintenance schedule Lubrication schedule Lubrication Faults Safety recommendations Behavior during faults Defects table Troubleshooting Replace agitator blade Replace agitator shaft Replace throttle valve Replace pneumatic motor After troubleshooting Disassembly and Disposal Safety recommendations Disassembly Disposal Technical data Dimensions and weight Connections Operating conditions Emissions Operating and auxiliary materials Operating values Type plate Materials used Compressed air Replacement parts, tools and accessories Replacement parts Accessories Order Index /32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

5 Product overview 1 Product overview 1.1 Overview DANGER! High risk situation that can lead to serious injuries or death. Medium risk situation that can lead to serious injuries or death. CAUTION! Low risk situations that can lead to minor injuries. NOTICE! Situations that can lead to material damage. ENVIRONMENT! Situations that can lead to environmental damage. Contains additional information and recommendations. Fig. 1: Overview 1 Handle 2 Pneumatic motor 3 Throttle valve on/off 4 Sound muffler 5 Compressed air supply connection 6 Grounding screw 7 Connecting piece 8 Threaded pin 9 Agitator shaft 10 Agitator blade 1.2 Short description The pneumatic agitator (hereafter called Agitator) is used for agitating, mixing and consistency maintenance of fluid coating materials. 2 Safety 2.1 Explanation of symbols The following notes can appear in this instructions manual. 2.2 Intended Use Use The agitator A MAN R with pneumatic motor is to be used exclusively for agitating, mixing and consistency maintenance of fluid coating materials. The agitator may exclusively be used in original packs and with suitable approved cleaning agents. The agitator may only be operated in the industrial range and within the approved technical data. Ä 10 Technical data The agitator may be used under the following conditions: In explosive areas Ex zones 1 and 2 In non-explosive areas With flammable fluid coating materials of the Explosion group IIA With non-inflammable fluid coating materials Wrong use If the agitator unit is used improperly, there is risk of death. Adhere to the following conditions: Do not process any gaseous or solid materials. Only use the agitator with components approved for operation by Dürr Systems. Only use approved materials. Follow the safety data sheets. Do not attempt to make changes on your own. Only use agitator in a container pointed downwards. 04/2017 Pneumatic agitator A MAN R - MAG00001EN 5/32

6 Safety Do not use agitator in Ex zone 0. EX labeling II II 2G IIA T6 - Device group II: all areas except mining 2G - Device category 2 for gaseous ex-atmosphere IIA - Explosion group T6 - Temperature class 2.3 Residual risks Explosion Sparks, open flames and hot surfaces can cause explosions in explosive atmospheres. Serious injuries and death can be the consequence. Only work on the product after eliminating explosive atmosphere. Do not use sources of ignition and open light. Do not smoke. Ground the product. Flammable materials can cause a fire or an explosion. Ensure that the flashpoint of the cleaning agent is at least 5 K above the ambient temperature. Please note the explosion group of the material and cleaning agent Ensure that forced ventilation and fire protection equipment are in operation. Do not use sources of ignition and open light. Do not smoke. Follow the safety data sheets. Material Contact with hazardous liquids or vapors, can result in serious injury or death. Ensure that the forced ventilation is operational. Follow safety data sheets. Adjust the rotational speed to the material viscosity. Avoid formation of eddies. Reduce rotational speed when removing material Keep the agitator at a safe distance from the wall and the bottom of the container. Wear specified protective equipment. Noise The noise during normal operation may cause severe hearing damage. Wear hearing protection. Do not spend more time then necessary in the work area. Rotary components Clothing or hair can get entangled in the rotary components and if body parts come in contact with them, it can result in serious injuries. To avoid injury: Keep the product at a safe distance from the body. Do not touch rotary components. Wear close-fitting work clothes. If you have long hair, wear a head cover. Wear specified protective equipment. Compressed air Hoses under pressure can tear or burst. If compressed air escapes, it can cause serious injury. Protect compressed air hoses from heat and sharp edges. Do not let the compressed air hose bear the weight of the agitator. Do not use the compressed air hose to pull the throttle valve. Separate the agitator from the compressed air supply after the work is over. Wear specified protective equipment. If hoses under pressure come off loose, the hoses can lash around and cause injuries. Check that the hose connections are seated tightly. Check compressed air hose for damage. Relieve pressure from the hoses after each operation end and before servicing and maintenance work. 2.4 Property damage Material damage due to excessive rotational speed Operating the agitator at excessively high rotational speeds causes eddy currents and mixes air. Air in the material line can cause uneven coating. Adjust the rotational speed to the material viscosity. Reduce rotational speed when removing material 6/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

7 Safety Unprepared material If you do not agitate the material well, the settled material particles remain at the bottom of the container. This can cause imperfect painting results. Agitate the material in the delivery pack before painting or emptying. 2.5 Conduct in the event of a hazardous situation Conduct in case of danger depends on the operator s installation situation. Perform the following activities: Close material supply lines. Secure against reconnection. Depressurize the lines. 2.6 Staff qualification Inadequate qualification If you do not assess risks properly, serious injury or death may result. All activities must be conducted exclusively by people who possess the proper qualifications. This instructions manual is intended for qualified personnel in the industry possessing: Cleaning staff The cleaning personnel is verifiably instructed on the following contents by the operator: Handling cleaning tools Handling cleaning agents Possible dangers at the place of work Electrically instructed person. The electrically instructed person has been instructed and if necessary trained by a qualified electrician. Contents of training: assigned tasks Possible hazards of improper conduct safety devices precautionary measures Mechanic The mechanic is trained specifically for the field of work in which he works. The mechanic has been instructed by the operator and receives regular training. The mechanic has knowledge of regulations and safety measures when working in potentially explosive areas. Furthermore, he has the following knowledge: National Health and Safety Regulations Guidelines and Rules of engineering Applicable accident prevention regulations The mechanic is responsible for the following activities on equipment and components: Assembly Commissioning Servicing Maintenance Disassemble Trained person The trained person is verifiably instructed by the operator. Contents of training: Using the product Handling the coating materials used Possible dangers at the workplace. Dürr Systems offers special product training Ä Hotline and Contact. 2.7 Personal protective equipment When working in explosive areas, the personal protective equipment used must be conductive. Wear the required personal protective equipment when working. Provide the following personal protective equipment: Eye protection Protects eyes from dust, paint drops and particles. Protective gloves Protect the hands from: mechanical forces Thermal forces Chemical effects Protective workwear Tight fitting workwear with low tear strength, tight sleeves and no hanging parts. Respiratory protection device The respiratory protection device protects from hazardous gases, vapors, dust and similar materials and media. The version of the respiratory protection device must be suitable for the media used as well as their usage. Safety boots Protect feet from crushing, falling items and slipping. Use ear protection Protects from auditory damage due to noise. 04/2017 Pneumatic agitator A MAN R - MAG00001EN 7/32

8 Design and Function 3 Design and Function 3.1 Agitator 4 Transport, scope of supply and storage 4.1 Scope of delivery The scope of supply includes the following components: Agitator Flexible grounding lead Ä 11.2 Accessories Inspect delivery on receipt for completeness and integrity. Report defects immediately Ä Hotline and Contact. 4.2 Handling of packaging material ENVIRONMENT! Environmental damage due to wrong disposal Wrongly disposed packaging material may not be re-used or recycled. It harms the environment. Dispose of material no longer required in an environment-friendly manner. Observe local disposal specifications. Fig. 2: Design and operation 1 Handle 2 Pneumatic motor 3 Throttle valve on/off 4 Sound muffler 5 Compressed air supply connection 6 Grounding screw 7 Connecting piece 8 Threaded pin 9 Agitator shaft 10 Agitator blade For agitating material, you can hold the agitator by its handle (1) or mount it in a stand. Use the connection (5) to connect the agitator to compressed air. Connect and disconnect the agitator and adjust the rotational speed of the agitator shaft (9) at the throttle valve (3). The pneumatic motor (2) drives the agitator shaft via the connecting piece (7). The agitator blade (10) is firmly connected to the agitator shaft and rotates synchronously with it. The sound muffler (4) at the outlet of the pneumatic motor reduces the sound emission. 4.3 Storage Requirements for the warehouse: Do not store outdoors. Store in a dry and dust-free place. Do not expose to aggressive media. Protect from solar radiation. Avoid mechanical vibrations. Temperature: 10 C to 40 C Relative humidity: 35 % to 90% Protect agitator shaft and agitator blade from load to avoid bending. 5 Assembly 5.1 Assembly Mount the agitator on a stand. As an option, you can mount the agitator on a stand. The stand is not part of the basic version and can be ordered separately Ä 11.2 Accessories. 8/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

9 Assembly Personnel: Trained person Protective equipment: Safety boots Requirement: Agitator is switched off. Ä 6.4 Agitating Assemble grounding braids Electrostatic charge If the product is not grounded, there will be an electrostatic charge on the product. Electrostatic discharge can cause sparks. In an explosive atmosphere, these sparks can prove to be the cause for an explosion. Serious injuries and death can result. Ground the product carefully. Measure grounding resistance. Fig. 3: Mount the agitator on a stand. 1. Insert the agitator in the clamp (2) of the stand. 2. Tighten the butterfly screw (1). ð Agitator is fastened. 3. Adjust its height on the mast by using the butterfly screw (3). 5.2 Connecting Personnel: Mechanic Protective equipment: Eye protection Protective gloves Safety boots Fig. 4: Grounding 1. Remove screw (1). 2. Remove lock washer (2) and washer (3). 3. Insert lock washer (2) on the screw (1). 4. Insert cable lug (5) of the flexible grounding lead on the screw (1). 5. Insert washer (3) on the screw (1). 6. Tighten screw (1) into the pneumatic motor (4). 7. Connect the terminal of the flexible grounding lead (6) to a secure current conductor. 8. Measure grounding resistance Ä 10.6 Operating values. Container for the material must be grounded. 04/2017 Pneumatic agitator A MAN R - MAG00001EN 9/32

10 Operation Mounting the compressed air hose Fig. 5: Mounting the compressed air hose Materials: Suitable compressed air hose Please note the maximum operating pressure Ä 10.6 Operating values. 1. Pull up compressed air hose on the nozzle (2) of the throttle valve (1). 2. Secure compressed air hose with a hose clamp to prevent slipping. 3. Connect the other end of the compressed air hose to the compressed air supply. 6 Operation 6.1 Safety recommendations Danger of explosion if there are sources of ignition in an explosive atmosphere. Sparks, open flames and hot surfaces can cause explosions in explosive atmospheres. Serious injuries and death can be the consequence. Only perform servicing and maintenance work after eliminating explosive atmosphere. Do not use any sources of ignition and no open light in the work area. Do not smoke. Ground the product. Ground the work piece. Danger of explosion if there are sources of ignition in an explosive atmosphere. If a rotary component of the agitator touches a fixed object, it can generate sparks. Sparks can cause explosions in explosive atmospheres. Serious injuries and death can be the consequence. The agitator may only be used in the delivery pack. Make sure that there are no objects present in the container. Danger from harmful or irritant substances If you come in contact with hazardous liquids or vapors, serious injury or death can be the consequence. Ensure the technical ventilation is operational. Observe the safety data sheets. Wear specified protective clothing. Risk of injury from whipping hoses If hoses under pressure come off loose, the hoses can lash around and cause injuries. Check that the hose connections are seated tightly. Check hoses for damage. Before carrying out any work: Depressurize hoses. Risk of injury due to escaping compressed air Compressed air hoses under pressure can tear or burst. If compressed air escapes, it can cause serious injury. Separate the product from the compressed air supply after the work is over. Danger due to escaping compressed air Compressed air escaping from the sound muffler can contain solid or liquid particles. Particles under pressure can injure the eyes or the skin. Wear specified protective equipment. 10/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

11 Operation Danger due to damaged components If you operate the product with damaged components, serious injury or death may result. Check components at specified intervals for damage. If you detect unusual operating sounds or any other noticeable aspects, put the product out of service. Contact the manufacturer Ä Hotline and Contact. Replace damaged components promptly. 6.2 General notes NOTICE! Contact of rotary components with objects If the rotary agitator touches a fixed object, the agitator shaft can bend or the agitator blade can be damaged. A bent agitator shaft can cause high vibrations in the pneumatic motor. The vibrations can loosen the agitator from the stand and can touch the walls or bottom of the container. Material can squirt out. Contact with objects can reduce the service life of the components. Keep the agitator at a safe distance from the wall and the bottom of the container. Keep the agitator at a safe distance from objects. 6.3 Checks Check for unusual noises during operation. Perform the following checks before beginning the shift: Cleanliness Ensure there are no material residues and other contaminants. Damage and leaks can only be seen on clean components. Check tightness of the connections and lines. Threaded pin on the connecting piece is tightened. Screw on the agitator blade is tightened. A pin is present in the agitator blade. Material temperature Ä 10.3 Operating conditions Operating pressure Ä 10.6 Operating values Flexible grounding leads is correctly connected. Ä 5.2 Connecting Grounding screw is tightened. Ä 5.2 Connecting 6.4 Agitating NOTICE! Unprepared material If you do not agitate the material well, the settled material particles remain at the bottom of the container. This can cause imperfect painting results. Agitate the material before painting or emptying. NOTICE! Unprepared material If you do not agitate the material well, the settled material particles remain at the bottom of the container. This can cause imperfect painting results. Agitate the material before painting or emptying. NOTICE! High rotational speed Operating the agitator at excessively high rotational speeds causes eddy currents and mixesin air. Air in the material line can cause uneven coating. Adjust the rotational speed to the material viscosity. Reduce rotational speed when removing material Fig. 6: Ideal agitating position (without stand) 1 Distance from the wall 25 mm 2 Agitating angle approx Distance from the wall min. 25 mm 4 Distance from the floor min. 25 mm 04/2017 Pneumatic agitator A MAN R - MAG00001EN 11/32

12 Cleaning and maintenance Personnel: Trained person Protective equipment: Eye protection Respiratory protection device Use ear protection Protective gloves Protective workwear Safety boots Requirement: Compressed air supply is switched on. Material is in the container. Agitator and container are grounded. Agitator is correctly mounted Ä 5.1 Assembly. 1. If you use a stand, clamp the agitator vertically. Hold the agitator by the handle and dip it into the container outside the center (1). Switching on Turn the setting screw (1) further to increase the rotational speed. ð Slight movement is visible at the surface. Switching off Fig. 8: Switching off 4. Rotate the setting screw (1) on the throttle valve in the direction of the arrow. ð The more the throttle valve is closed, the slower does the agitator shaft rotate. If the throttle valve is closed completely, the agitator is switched off. 5. Pull out the agitator from the container. 6. Wipe material drops with a cloth. 7 Cleaning and maintenance 7.1 Safety recommendations Do not conduct cleaning and maintenance work in explosive atmosphere. Fig. 7: Switching on 2. Slowly rotate the setting screw (1) on the throttle valve in the direction of the arrow. ð Agitator is switched on. The more the throttle valve is opened, the faster does the agitator shaft rotate. 3. The rotational speed depends on the material viscosity. NOTICE! High rotational speed Operating the agitator at excessively high rotational speeds causes eddy currents and mixes-in air. Air in the material line can cause uneven coating. Adjust the rotational speed to the material viscosity. Reduce rotational speed when removing material Danger of fire and explosion Flammable materials can cause a fire or an explosion. Ensure that the flashpoint of the cleaning agent is at least 5 K above the ambient temperature. Only electrically conductive containers may be used for the cleaning fluid. Containers must be grounded. Pay attention to the explosion group of the material, cleaning and rinsing agent. Ensure that forced ventilation and fire protection equipment are in operation. Do not use any sources of ignition and no open light. Do not smoke. Follow safety data sheets. 12/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

13 Cleaning and maintenance Risk of injury due to escaping material and compressed air Material can escape with high pressure and penetrate the body. The injury can look like a harmless cut wound. Death or serious injuries may result. If there are injuries, seek medical attention immediately. Before working on the product: Disconnect the system with the product from compressed air and material supply. Secure the system against reconnection. Relieve the lines. Risk of injury from unsuitable replacement parts in explosive areas. Replacement parts not compliant with the specifications of the ATEX guidelines can cause explosions in an explosive atmosphere. Serious injuries and death can be the consequence. Use exclusively original replacement parts. Unsuitable tools in hazardous areas. Tools that do not have Ex permission can generate sparks and cause a fire or an explosion. Serious injuries or death can result. If possible, carry out cleaning and maintenance work outside the Ex zones. For activities within the Ex zone, use tools with the corresponding Ex labeling. Danger of explosion if there are sources of ignition in an explosive atmosphere. If metal parts fall into the container, sparks can be generated. Sparks can cause explosions in explosive atmospheres. Serious injuries and death can be the consequence. Perform maintenance work outside the reach of the container. Prevent metal parts from falling into the container. Danger from harmful or irritant substances If you come in contact with hazardous liquids or vapors, serious injury or death can be the consequence. Ensure the technical ventilation is operational. Observe the safety data sheets. Wear specified protective clothing. Components flying about The components in the pneumatic motor are under pressure and can cause serious injuries on dismantling the pneumatic motor. Do not dismantle pneumatic motor. If there is a malfunction or fault in the pneumatic motor, please return it to the reseller. NOTICE! Material damage due to unsuitable cleaning agent Unsuitable cleaning agents can damage the product. Only use suitable cleaning agents approved by the material manufacturer. Observe the safety data sheets. Place heavily soiled components into a cleaning bath. Only place those parts in the cleaning bath, which are suitable for the cleaning bath. Use only electrically conductive containers. Ground the container. Do not use ultrasound baths. 7.2 Cleaning Overview Clean the agitator. Before every change of material After end of operation Depending on the level of contamination, Dürr Systems recommends the following cleaning methods: Manual cleaning for light contamination Cleaning in a cleaning tank, for medium and light contamination Cleaning in a cleaning bath, if heavily contaminated 04/2017 Pneumatic agitator A MAN R - MAG00001EN 13/32

14 Cleaning and maintenance Manual cleaning Clean the following components of the agitator manually for light contamination: Pneumatic motor Agitator shaft Agitator blade Personnel: Cleaning staff Protective equipment: Respiratory protection device Eye protection Protective workwear Protective gloves Safety boots Requirement: Compressed air supply is switched off. Compressed air hose is depressurized. 1. Remove contamination with a cloth or a soft brush Cleaning container Clean the following components of the agitator in a cleaning tank, for medium and light contamination. Agitator shaft Agitator blade Personnel: Cleaning staff Protective equipment: Respiratory protection device Eye protection Use ear protection Protective workwear Protective gloves Safety boots NOTICE! Contact of rotary components with objects If the rotary agitator touches a fixed object, the agitator shaft can bend or the agitator blade can be damaged. A bent agitator shaft can cause high vibrations in the pneumatic motor. The vibrations can loosen the agitator from the stand and can touch the walls or bottom of the container. Material can squirt out. Contact with objects can reduce the service life of the components. Keep the agitator at a safe distance from the wall and the bottom of the container. Keep the agitator at a safe distance from objects. 1. Hold the agitator by the handle. 2. Submerge the agitator blade and agitator shaft up to the connecting piece in the cleaning tank. Switching on Fig. 9: Switching on 3. Slowly rotate the setting screw (1) in the direction of the arrow. 4. Turn the setting screw (1) further to increase the rotational speed. 5. Let it run at medium rotational speed until the contamination comes off. Requirement: Compressed air supply is switched on. Cleaning container is unbreakable, corrosionfree and grounded. NOTICE! Penetration of cleaning agents If cleaning agents penetrates the pneumatic motor, the pneumatic motor can be damaged. Do not submerge pneumatic motor in the cleaning medium. 14/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

15 Cleaning and maintenance Switching off Fig. 10: Switching off 6. Rotate the setting screw (1) in the direction of the arrow. ð Agitator is switched off. 7. Pull out the agitator from the container. 8. Wipe drops with a cloth. 9. Remove loosened contaminants with a cloth or a soft brush. ð If necessary, repeat steps 1 to 9 until agitator is clean. 10. After cleaning, wipe the agitator dry with a cloth Cleaning bath Clean the following components of the agitator in a cleaning bath, if they are heavily contaminated. Agitator shaft Agitator blade Personnel: Cleaning staff Protective equipment: Respiratory protection device Eye protection Protective workwear Protective gloves Safety boots Requirement: Compressed air supply is switched off. Compressed air hose is depressurized. 1. Disassemble agitator blade. Ä 8.4 Troubleshooting 2. Disassemble agitator shaft. Ä Replace agitator shaft NOTICE! Penetration of cleaning agents If cleaning agents penetrates the pneumatic motor, the pneumatic motor can be damaged. Do not submerge pneumatic motor in the cleaning medium. 3. Place components in the cleaning bath. ð The cleaning duration depends on the contamination. 4. Remove components. 5. Remove residual contamination with a cloth or a soft brush. ð If necessary, repeat steps 1 to 4 until agitator is clean. 6. Wipe components dry with a dry clean cloth. 7. Assemble components. Ä 8.4 Troubleshooting 7.3 Maintenance Maintenance schedule Interval Before each use After each use Maintenance work Check grounding Ä 5.2 Connecting. Ensure that the screw on the agitator blade is tightened. Ä Replace agitator blade See that the threaded pin on the connecting piece is tightened. Ä Replace agitator shaft Clean the agitator. Ä 7.2 Cleaning 04/2017 Pneumatic agitator A MAN R - MAG00001EN 15/32

16 Faults Lubrication schedule Interval After 16 operating hours Maintenance work Lubricate pneumatic motor Ä Lubrication Lubrication Lubricate pneumatic motor. If you operate the agitator with oil-free compressed air, the pneumatic motor must be lubricated manually. Personnel: Mechanic Protective equipment: Safety boots 1. Switch off compressed air supply. 2. Depressurize the line. 3. Disconnect the compressed air hose from the compressed air supply. 4. Put in two drops of lubricant in the compressed air hose. Do not fill in the lubricant directly in the pneumatic motor. 5. Connect the compressed air hose to the compressed air supply. 6. Turn on compressed air supply. ð The lubricant is distributed in the pneumatic motor. 8 Faults 8.1 Safety recommendations Danger of fire and explosion Flammable materials can cause a fire or an explosion. Ensure that the flashpoint of the cleaning agent is at least 5 K above the ambient temperature. Only electrically conductive containers may be used for the cleaning fluid. Containers must be grounded. Pay attention to the explosion group of the material, cleaning and rinsing agent. Ensure that forced ventilation and fire protection equipment are in operation. Do not use any sources of ignition and no open light. Do not smoke. Follow safety data sheets. Risk of injury due to escaping material and compressed air Material can escape with high pressure and penetrate the body. The injury can look like a harmless cut wound. Death or serious injuries may result. If there are injuries, seek medical attention immediately. Before working on the product: Disconnect the system with the product from compressed air and material supply. Secure the system against reconnection. Relieve the lines. 16/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

17 Faults Risk of injury from unsuitable replacement parts in explosive areas. Replacement parts not compliant with the specifications of the ATEX guidelines can cause explosions in an explosive atmosphere. Serious injuries and death can be the consequence. Use exclusively original replacement parts. Unsuitable tools in hazardous areas. Tools that do not have Ex permission can generate sparks and cause a fire or an explosion. Serious injuries or death can result. If possible, carry out cleaning and maintenance work outside the Ex zones. For activities within the Ex zone, use tools with the corresponding Ex labeling. Danger of explosion if there are sources of ignition in an explosive atmosphere. If metal parts fall into the container, sparks can be generated. Sparks can cause explosions in explosive atmospheres. Serious injuries and death can be the consequence. Perform maintenance work outside the reach of the container. Prevent metal parts from falling into the container. Danger from harmful or irritant substances If you come in contact with hazardous liquids or vapors, serious injury or death can be the consequence. Ensure the technical ventilation is operational. Observe the safety data sheets. Wear specified protective clothing. Components flying about The components in the pneumatic motor are under pressure and can cause serious injuries on dismantling the pneumatic motor. Do not dismantle pneumatic motor. If there is a malfunction or fault in the pneumatic motor, please return it to the reseller. 8.2 Behavior during faults When faults occur: Switch off the compressed air supply and secure it against unauthorized restarting. Relieve the lines. Follow the defects table to correct the fault. 04/2017 Pneumatic agitator A MAN R - MAG00001EN 17/32

18 Faults 8.3 Defects table Fault description Cause Remedy Pneumatic motor runs slowly or not all. Agitator virates / does not run smoothly. Material sprays out. Material coat is uneven. Compressed air supply is switched off. Compressed air supply is paused. Throttle valve is not open. Turn on compressed air supply. Localize and eliminate compressed air interruption. Turn on the throttle valve slowly. Throttle valve is defective. Replace throttle valve. Ä Replace throttle valve Pneumatic motor has no lubrication/ is running dry. Pneumatic motor is defective. Compressed air hose with cross section less than DN 8 is used. Agitator shaft and/or agitator blade not correctly mounted. Lubricate pneumatic motor. Ä Lubrication Send in pneumatic motor for repairs or replace it. Ä Replace pneumatic motor. Assemble compressed air hose with the required diameter. Ä 10.2 Connections Assemble agitator shaft again. Ä Replace agitator shaft Assembling agitator blade Ä Replace agitator blade Agitator blade damaged or bent. Replace agitator blade. Ä Replace agitator blade Agitator shaft has an imbalance or is damaged. Material is being agitated with too high a rotational speed. Material is being agitated with too high a rotational speed. Replace agitator shaft. Ä Replace agitator shaft Reduce rotational speed. Ä 6.4 Agitating Reduce rotational speed. Ä 6.4 Agitating 8.4 Troubleshooting Replace agitator blade Check components for damage before assembly. If necessary, replace with new components. Fig. 11: Replace agitator blade(s) 18/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

19 Faults Personnel: Mechanic Protective equipment: Protective workwear Protective gloves Safety boots Eye protection Requirement: Compressed air hose is dismounted. Ä 9.2 Disassembly Throttle valve is closed. Disassembly 1. Remove screw (4). 2. Remove agitator blade (3). ð Contaminants can stick agitator blades together. NOTICE! Material damage due to disassembly of the agitator blade Wenn component durch Contamination verklebt sind, können sich in the case of the disassembly des agitator blade die agitator shaft und der agitator blade verbiegen. Knock off agitator blade carefully using a rubber mallet. 3. Pull off pin (2) from the agitator shaft (1). Assembly 1. Insert pin (2) into agitator shaft (1). 2. Insert new agitator blade (3) on the agitator shaft (1). ð The pin (2) rests in the groove of the agitator blade. 3. Thread-in screw (4) and tighten it. ð Agitator blade has been assembled Replace agitator shaft Check components for damage before assembly. If necessary, replace with new components. Fig. 12: Replace agitator shaft Personnel: Mechanic Protective equipment: Protective gloves Safety boots Eye protection Requirement: Compressed air hose is dismounted. Ä 9.2 Disassembly Disassembling 1. Disassemble agitator blade. Ä Replace agitator blade 2. Clamp agitator shaft (1) in a vise with plastic protective jaws. ð The pneumatic motor (4) is clamped in a horizontal position. 3. Unscrew threaded pin (2). 4. Pull off pneumatic motor (4) with the connecting piece (3) from the agitator shaft (1). ð Agitator shaft has been disassembled. NOTICE! Material damage due to disassembly of the agitator shaft If components are stuck due to dirt, that could cause damage to the pneumatic motor and agitator shaft during disassembly of the agitator shaft. Do not hit on pneumatic motor. Knock off agitator shaft carefully using a rubber mallet. 04/2017 Pneumatic agitator A MAN R - MAG00001EN 19/32

20 Faults Assembling 1. Clamp agitator shaft (1) in a vise with plastic protective jaws. ð The pneumatic motor (4) is clamped in a horizontal position. 2. Set pneumatic motor (4) with the connecting piece (3) on the agitator shaft (1). See that the flattended side of the agitator shaft points to the holes for the threaded pin. 3. Screw-in and tighten threaded pin (2). 4. Assemble agitator blade. Ä Replace agitator blade ð Agitator shaft has been assembled Replace throttle valve Check components for damage before assembly. If necessary, replace with new components. Personnel: Mechanic Protective equipment: Protective gloves Safety boots Eye protection Requirement: Compressed air hose is dismounted. Ä 9.2 Disassembly Throttle valve is closed. Disassembling Assembling Fig. 14: Assemble throttle valve Thread seal Loctite 511 NOTICE! Contamination If you use a sealing tape, frayed threads from the sealing tape and damage the product. Only use thread seal. 1. Apply thread seal on the external threads (1) of the throttle valve. 2. Screw in throttle valve. See that a distance of 3 to 5 mm in maintained between nut and motor. ð Adjusting screw points upward. Throttle valve has been assembled Replace pneumatic motor. Check components for damage before assembly. If necessary, replace with new components. Personnel: Mechanic Protective equipment: Protective gloves Safety boots Eye protection Fig. 13: Disassemble throttle valve 1. Unscrew throttle valve (1) in the direction of the arrow, using a wrench. ð Throttle valve is disassembled. 2. Clean external threads. Requirement: Grounding braid and compressed air hose are disassembled. Ä 9.2 Disassembly Throttle valve is closed. 20/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

21 Disassembly and Disposal Requirement: Atmosphere is not explosive. Compressed air supply is switched off. Lines are discharged. Disassemble compressed air hose Fig. 15: Replace pneumatic motor. Disassembling 1. Disassembling agitator shaft Ä Replace agitator shaft Assembly 1. Assemble agitator shaft. Ä Replace agitator shaft 8.5 After troubleshooting Connect compressed air supply Ä 5.2 Connecting If the agitator is used in an EX zone, check grounding for correct connection. Ä 5.2 Connecting Fig. 16: Disassemble compressed air hose Requirement: Compressed air supply is switched off. Lines are discharged. Throttle valve is closed. 1. Open the hose clamp at the throttle valve (1). 2. Pull out the compressed air hose from the nozzle (2). Disassemble grounding braids 9 Disassembly and Disposal 9.1 Safety recommendations Risk of injury due to escaping compressed air Compressed air hoses under pressure can tear or burst. If compressed air escapes, it can cause serious injury. Separate the product from the compressed air supply after the work is over. 9.2 Disassembly Personnel: Electrically instructed person. Mechanic Protective equipment: Eye protection Protective gloves Safety boots Fig. 17: Grounding 1. Remove screw (1). 2. Remove lock washer (2) and washer (3). 3. Remove cable lug (5) of the grounding braid. 4. Separate terminal (6) of the grounding braid from the current conductor. 5. Insert lock washer (2) and plain washer (3) on the screw (1). 6. Thread in the screws (1) again and tighten. ð Lock washer (2) and washer (3) are captive. 04/2017 Pneumatic agitator A MAN R - MAG00001EN 21/32

22 Technical data 9.3 Disposal ENVIRONMENT! Environmental damage caused by improper disposal Improper waste disposal threatens the environment and prevents re-use and recycling. Always dispose of components in accordance with their characteristic. Ä 10.8 Materials used Collect leaked out operating and auxiliary materials completely. Dispose of operating and auxiliary materials according to the disposal provisions in force. In case of doubt, refer to the local disposal authorities. 10 Technical data 10.1 Dimensions and weight Detail Length Width Width Agitator shaft incl. connecting piece Weight Agitator blade diameter 10.2 Connections Detail Compressed air connection Value approx mm approx. 180 mm mm 330, 440, 550, 650 mm above 1.5 kg 75, 100 mm Value DN 8 mm Grounding braids min. 4 mm 2 Cable lug 10 x Operating conditions Detail Surface temperature when operating with protective gloves, max. Surface temperature when operating with heat-resistant protective gloves, max. Value 40 C 85 C Max. material temperature 40 C Ambient temperature 0 C - 40 C Distance of the agitator blade from the wall and the bottom of the container, min Emissions 25 mm Detail Noise level without load, operating pressure max. 7 bar Noise level at 600 RPM, operating pressure max. 4 bar Muffler permeability Value 103 db 80 db 36 microns 10.5 Operating and auxiliary materials Fig. 18: Dimensions Material Material number Thread seal Loctite Lubricant VG l W /32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

23 Technical data 10.6 Operating values Detail Value Protection type IP 65 Operating pressure min. Operating pressure max. Ventilation duration of the pneumatic motor max. Grounding resistance Recommended rotational speed range Power Air consumption 0.5 bar 7 bar 2 s < 2 Ω up to 800 RPM 0.07 kw The characteristic curve shows the relation between the air consumption and the rotational speed of the agitator. EX labelling Maximum surface temperature CE labelling Material number Year of manufacture Serial number 10.8 Materials used All parts in contact with material are made of stainless steel The position numbers of the components refer to the chapter Ä 11.1 Replacement parts. Component Material Agitator blade (11) Screw (12) Threaded pins (9) Connecting piece (8) Agitator shaft (10) Pin (11) Compressed air Compressed air quality Purity classes according to ISO :2010 3:4:X Limitations for purity class X: 25 mg/m 3 Fig. 19: Characteristic curve agitator blade Ø Type plate The type plate is placed on the pneumatic motor and features the following detail: Product name Maximum operating pressure 04/2017 Pneumatic agitator A MAN R - MAG00001EN 23/32

24 Replacement parts, tools and accessories 11 Replacement parts, tools and accessories 11.1 Replacement parts Fig. 20: Exploded view 24/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

25 Replacement parts, tools and accessories Item Description Amou nt Material number 1 Compressed air connection DN 8 Js Throttle valve 1 M Noise muffler G 1/8" 1 M Grounding screw M5 x Locking washer Ø5.3 mm 1 6 Washer 05.3 mm 1 7 Pneumatic motor 1 N Threaded pin M6 x Connecting piece 1 10 Agitator shaft 330 mm, (only in the case of N , N ) 1 M Agitator shaft 369 mm, (only in the case of N ) 1 M Agitator shaft 440 mm, (only in the case of N , N ) 1 M Agitator shaft 550 mm, (only in the case of N , N ) 1 M Agitator shaft 650 mm, (only in the case of N , N ) 1 M Pin 3 x 14 1 Included in M Agitator blade / propeller Ø75 mm, (only in the case of N N ) Agitator blade / propeller Ø100 mm, (only in the case of N N ) 1 M M Agitator blade screws M6 x 8 1 Included in M Accessories Denomination Stand for agitator shaft 330 mm Stands for agitator shaft 440 mm / 550 mm / 650 mm Flexible grounding lead 10 x 5 Screws set for agitator blade (pin (11), screw (13)). Material number N N E M /2017 Pneumatic agitator A MAN R - MAG00001EN 25/32

26 Replacement parts, tools and accessories 11.3 Order Risk of injury from unsuitable replacement parts in explosive areas. Replacement parts not compliant with the specifications of the ATEX guidelines can cause explosions in an explosive atmosphere. Serious injuries and death can be the consequence. Use exclusively original replacement parts. Ordering replacement parts, tools and accessories as well as information on products that are listed without order number. Ä Hotline and Contact 26/32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

27 12 INDEX A Advanced training... 7 Agitating Agitator operation Agitator blade assembly disassembly replace Agitator shaft assembly disassembly replace C Checks Operation Cleaning Cleaning bath Cleaning container manually Compressed air hose assembly disassembly Compressed air quality Connections Contact... 3 D Design... 8 Disposal Handling packaging material... 8 E Emissions Explanation of symbols... 5 Explosion protection EX labeling... 5 F Fault Behavior in the event of faults Faults table Function... 8 G General notes Operation Grounding braids disassembly H Hazards... 6 Hotline... 3 I Information about the document... 3 L Lubricant Lubrication Lubrication schedule M Maintenance schedule Material number... 3 O Operating conditions Order Overview... 5 P Packaging Handling packaging material... 8 Performance values Personal protective equipment... 7 Pneumatic motor assembly disassembly lubrication replace Protective equipment... 7 Electrostatic discharge... 7 Q Qualification... 7 R Replacement parts Risks... 6 S Safety Explanation of symbols... 5 Property damage... 6 Safety instructions Cleaning Disassembly Operation Troubleshooting Safety recommendations Maintenance Scope of Supply... 8 Scope of the document... 3 Sealant Service... 3 Short description... 5 Staff qualification /2017 Pneumatic agitator A MAN R - MAG00001EN 27/32

28 Stand assembly... 8 Storage... 8 T Technical data Compressed air quality Connections Dimensions Emissions materials used Operating conditions Performance values Weight Throttle valve assembly disassembly Replace Training... 7 Type plate U Use... 5 W Wrong use /32 Pneumatic agitator A MAN R - MAG00001EN 04/2017

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32 Dürr Systems AG Application Technology Carl-Benz-Str Bietigheim-Bissingen Original operation manual Transmission and duplication of this document, as well as use and sharing of its contents are not permitted without express written approval. Violations will be liable for compensation for damages. All rights in the event of a patent grant or design registration are reserved. Dürr Systems AG