Download
Share
Print this page
  1. Manuals
  2. Brands
  3. Elsema Manuals
  4. Remote Control
  5. ProWay StockFlow
  6. Service manual

Elsema ProWay StockFlow Service Manual

Pneumatic equipment
Hide thumbs

Advertisement

Quick Links

Download this manual
Pneumatic equipment
Maintenance and Service Manual
VERSION 1.2
PLEASE READ CAREFULLY PRIOR TO INITIAL OPERATION
www.proway.com.au
PH: 1300 655 383

Advertisement

loading
Need help?

Need help?

Do you have a question about the ProWay StockFlow and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Elsema ProWay StockFlow

Summary of Contents for Elsema ProWay StockFlow

  • Page 1 Pneumatic equipment Maintenance and Service Manual VERSION 1.2 PLEASE READ CAREFULLY PRIOR TO INITIAL OPERATION www.proway.com.au PH: 1300 655 383...
  • Page 2 Pneumatic equipment Maintenance and service manual Thank you for purchasing ProWay StockFlow Pneumatic Equipment The following document outlines key safety and operation instructions. Please be sure to read this document carefully before operation and that new staff are adequately inducted for safe use of all pneumatic equipment prior to use.
  • Page 3 Pneumatic equipment Maintenance and service manual CONTENTS SAFETY AND PRECAUTION WARNINGS INSTALLATION MAINTENANCE / REPAIR OPERATION FAULT IDENTIFICATION FLOW CHART SERVICE PHOTO GUIDE PARTS INDEX MAINTENANCE CHECKLIST AND LOG WARRANTY INFORMATION NOTES www.proway.com.au...

  • Page 4: Safety And Precaution Warnings

    Pneumatic equipment Maintenance and service manual SAFETY AND PRECAUTION WARNINGS General Precautions Safety instructions are intended to prevent hazardous situations and/or equipment damage. Safety instructions contained in this document apply to tasks that must be adhered to. It is important that these safety concerns are always followed. Failure to do so could result in personal injury and/or damage to the unit or other equipment.

  • Page 5: Installation

    Pneumatic equipment Maintenance and service manual INSTALLATION Installation – Electrical and Pneumatic WARNING: Risk of electric shock. Failure to observe may result in personal injury, death or equipment damage. WARNING: Air pressure has the potential to cause injury, do not perform maintenance duties until air supply is isolated, vented, and is safe to carry out work.

  • Page 6: Maintenance / Repair

    Pneumatic equipment Maintenance and service manual MAINTENANCE / REPAIR MAINTENANCE Allow only qualified personnel to perform the procedures set out in this document. Wear appropriate protective clothing and equipment when carrying out maintenance or repairs. WARNING: Ensure that electrical power is fully isolated from the unit. Even when only the circuit breaker is switched OFF the unit is still electrically energized.
  • Page 7 Pneumatic equipment Maintenance and service manual MAINTENANCE / REPAIR COMPRESSED AIR SUPPLY It is essential that within a compressed air system that minimum condensation accumulates, and no excessive amount of oil is delivered to the system by the compressor. Small amounts of contaminants, however, will reach the control system. These can be minimised by air service equipment.
  • Page 8 Pneumatic equipment Maintenance and service manual MAINTENANCE / REPAIR PNEUMATIC COMPONENTS FAILURE PROCEDURE If failure of a pneumatic component is suspected, the following checks should be made to determine the cause of the fault. Ensure that the air supply is sufficient. Check for kinks and blockages in the air lines, both inside and outside the system, that are associated with the suspect component(s).
  • Page 9 OPERATION Intended Use ProWay StockFlow Pneumatic equipment is designed and intended to be used for the purpose of livestock processing and husbandry using best practice stock management. Applications not in accordance with the intended product use or which have been modified from the original installation are considered outside the intended use and may void product warranty.
  • Page 10 Pneumatic equipment Maintenance and service manual The following flow charts can be used as a logical checking process to identify a fault in your ProWay Pneumatic system should one occur. ISSUE: INDIVIDUAL GATE FAILURE NOTE Individual gate not working properly If viewing this guide on a tablet, PC or phone, the individual icons can be...
  • Page 11 Is the LED light on the 240V/12V Check compressor power supply? instruction manual Is the LED light on the Elsema 240V/12V card? power could be faulty No light Change battery Does the transmitter light come on when pressed?
  • Page 12 Pneumatic equipment Maintenance and service manual Presence of pressure in gauge Pressure can be read from the pressure scale of the regulator The desired pressure should be shown 6 Bar Pressure can be adjusted by regulator knob Pressure gauge shown in red box IMPORTANT ENSURE OPERATOR, PERSONNEL AND LIVESTOCK...
  • Page 13 Pneumatic equipment Maintenance and service manual Is shut-off valve opened? Shut-off valve is shown as red box. It is part of filter regulator assembly and usually located near the control box. It should be in opened position, which is along the pipe direction. If shut-off valve is closed, open it by turning the knob in clockwise.
  • Page 14 Pneumatic equipment Maintenance and service manual Is compressor on? Ensure the compressor is turned on. If your compressor is not or will not run, refer to your compressor operation manual. For electric compressors ensure is properly connected to an adequate power supply.
  • Page 15 Pneumatic equipment Maintenance and service manual Is compressor outlet valve opened The compressor outlet valve should be opened position as shown in the photo. (Valve knob along the pipe line). If the valve is not open turn the tap to the correct position.
  • Page 16 Pneumatic equipment Maintenance and service manual Is there pressure in the reservoir? Pressure can be read from digital screen and/or pressure scale from reservoir. If you just turn on the compressor after draining the reservoir or from an empty reservoir, pressure in reservoir may be low or empty.
  • Page 17 Pneumatic equipment Maintenance and service manual Is the furthest solenoid working? Test manual override function. Solenoid valve To check this, air should be on. Once you press the manual Manual override button override button on the solenoid valve, cylinder (gate) will be moving to the opposite position.
  • Page 18 Pneumatic equipment Maintenance and service manual Is control box connected to a power supply? WARNING: Before re-connecting power, ensure air supply has been turned off and people/livestock are clear of all moving components. Connect the power supply as per the original installation. For 12V systems connect: Red alligator clip to positive •...
  • Page 19 Pneumatic equipment Maintenance and service manual Is 12V battery charged? Some 12V batteries have an indicator which shows the state of the battery. This battery indicator shows green which means the battery has charge. You can check voltage in the battery by using a multimeter.
  • Page 20 Pneumatic equipment Maintenance and service manual Is 240V mains power on? Make sure that 240V switch and 240V power supply are on. If the power supply is turned off, turn the power on. Power and mains supply on IMPORTANT ENSURE OPERATOR, PERSONNEL AND LIVESTOCK ARE NOT IN PROXIMITY TO MOVING PARTS...
  • Page 21 Maintenance and service manual Is LED light on Elsema card? When 12V battery has power, LED light on Elsema card should be lit. If there is no light on Elsema card check polarity of battery. (Red is + and Black is -) IMPORTANT...
  • Page 22 (Red is + and Black is -) Step 2.) Check 12V across input terminals of Elsema card with a multimeter. If 12V are not shown, tighten the wires fitted into socket and make sure +/- plug is properly inserted into Elsema card.
  • Page 23 Pneumatic equipment Maintenance and service manual Is LED light on 240V/12V power supply? There should be a green light on the power supply. If there is no light on 240V/12V DC power supply even though main 240V is on, the power supply could be faulty.
  • Page 24 Pneumatic equipment Maintenance and service manual Does red light turn on when transmitter button is pressed? Light should be on when a button is pressed as shown in the photo. If no light is showing at the top of the transmitter, replace battery with a new 9V battery.
  • Page 25 Pneumatic equipment Maintenance and service manual Do lights turn on the Elsema card when transmitter button is pressed? Light on the Elsema card should be lit when a button on a transmitter is pressed as shown in the photo. If it is a new transmitter, it may need to be synced to the Elsema card.
  • Page 26 Pneumatic equipment Maintenance and service manual Sync the new transmitter with the receiver card There are two common types of transmitters used for ProWay pneumatic equipment. Depending on your equipment you will have one of the below: MCT 915 (See page 29) 433 GIGALINK (See page 28) IMPORTANT ENSURE OPERATOR,...
  • Page 27 (Elsema card) TEST come on. If no resolution refer back If lights on the Elsema card are still not visible when buttons are to page 10 & 11 | Flowchart pressed, please contact ProWay on: 1300 655 383 www.proway.com.au...
  • Page 28 Down Down Down Down Down (Transmitter) (Receiver) If lights on the Elsema card are still not visible IMPORTANT when buttons are pressed, please contact ProWay on: 1300 655 383 ENSURE OPERATOR, PERSONNEL AND LIVESTOCK ARE NOT IN PROXIMITY TO MOVING PARTS...
  • Page 29 PERSONNEL AND LIVESTOCK ARE NOT IN PROXIMITY TO MOVING PARTS * If there is still no light visible on the Elsema card when TEST the transmitter buttons are pushed, there may be a fault with the receiver or bad connection. Contact ProWay If no resolution refer back to page 10 &...
  • Page 30 Pneumatic equipment Maintenance and service manual Do other PCL/Relay lights come on as buttons are pushed? Light on PLC after input Light on PLC after input Ice Cube Latching relay change state LED and Flag If there is no light visible on the relay when IMPORTANT the transmitter buttons are pushed, there may be a fault with the receiver or bad...
  • Page 31 Pneumatic equipment Maintenance and service manual Do individual solenoids operate when buttons are pushed? When the button for the gate is pressed on the transmitter, check that the small LED is turning on at the solenoid. There should be a clicking sound at the solenoid.
  • Page 32 Pneumatic equipment Maintenance and service manual Single solenoid not working * These are general schematic and control box picture which may not be applicable to your system To check that solenoid gets a signal from the control box (relays), a multimeter is required. For example, the schematic shows that when CH-1 (Button1) is closed(pressed), Draft gate-1 gets a signal while R4 and R6(Relay4 and 6) on.
  • Page 33 Pneumatic equipment Maintenance and service manual Most of the solenoids not working If there is no operation on any solenoid, then likely cause is a fault with the negative (-) terminated bar. Please check the wires fitted into socket properly and tight up the bridge shown in the picture.
  • Page 34 Pneumatic equipment Maintenance and service manual Does manual override button work? To check this, air must be on. Solenoid valve Once you press the manual override button on the solenoid valve, cylinder (gate) will be Manual override button moving to the opposite position. Therefore, please take every WARNING PRESSING THE MANUAL OVERRIDE BUTTON...
  • Page 35 Pneumatic equipment Maintenance and service manual Gate operating slowly: Adjusting speed controller * This is general schematic which may not be applicable to yours. When the gate is opening too slow or too fast, you can adjust the speed controller. In the above schematic, it shows that air goes from port 1 to 2, and then leaves port 4 to 5 in normal position.
  • Page 36 Pneumatic equipment Maintenance and service manual Individual gate malfunction - Possible Issues Inspect the air hoses that they are not kinked or Case 1. folded which may stop the air flow. Faulty Air Hose If not solved yet. Go to next Case The internal components of the valve may be stuck.
  • Page 37 Pneumatic equipment Maintenance and service manual Individual gate malfunction - Possible Issues Carry out the following steps to determine if there is another problem which is causing the gate not Case 3. to operate Mechanically seized 1) Turn off the air supply 2) Bleed air from system (Operate gates using transmitter until the gate no longer moves) 3) Disconnect the airlines between the valve and...
  • Page 38 Pneumatic equipment Maintenance and service manual Individual gate malfunction - Possible Issues In some cases, where large amounts of water get into the compressed air system the water may Case 4. migrate through the air lines and “pool” in the low Solenoid valve spots.
  • Page 39 Pneumatic equipment Maintenance and service manual Individual gate malfunction - Possible Issues Usually on each of the solenoid valves, there are exhaust silencers. Over time these may become Case 5. blocked with atmospheric dust which can cake on the Plugged exhaust silencer and restrict the air flow.
  • Page 40 Pneumatic equipment Maintenance and service manual Make sure coil (solenoid) is correctly fastened If there is a gap between solenoid and holder as shown in the picture, tight the nut to sit coil (solenoid) properly on the holder. If the solenoid does not make a clicking sound, it could be faulty (Internally seized). Please contact ProWay on: 1300 655 383 IMPORTANT ENSURE OPERATOR,...
  • Page 41 Pneumatic equipment Maintenance and service manual Use coil (solenoid) from a gate which is operating on a spare Carry out the following steps to determine if there is another problem which is causing the gate not to operate. 1) Unscrew bolts to dismount valve from cylinder if there is not enough space for solenoid to be removed 2) Tilt valve to give space for solenoid...
  • Page 42 Pneumatic equipment Maintenance and service manual COMMON PARTS INDEX For replacement parts and materials, please note any visible part codes and take a photo of the faulty component. Pneumatic Cylinder Converts compressed air into linear mechanical force and motion. Consists of a movable element such as a piston and a piston rod, plunger or ram, operating within a cylindrical bore.
  • Page 43 Spare and replacement transmitters can be supplied for multiple users. Receiver card ProWay use Elsema receivers for wireless pneumatic systems as they are Versatile and easy to install, these receivers are designed to stand the test of time. In most cases wireless pneumatic equipment will run via a single receiver.
  • Page 44 Pneumatic equipment Maintenance and service manual AIR COMPRESSOR MAINTENANCE CHECKLIST ProWay advise to refer to your air compressor manual for best maintenance guidelines, however the following checklist offers generic maintenance advice for 240V compressors. Air Compressor Maintenance Checklists For best long term maintenance and to ensure your entire system is working correctly it is best to setup a maintenance schedule for your compressor.
  • Page 45 Pneumatic equipment Maintenance and service manual EXAMPLE SERVICE & MAINTENANCE LOG Maintenance for normal operating conditions Date: Previous service date: Estimated plant and equipment hrs: Operator/technician: Property Name: SERVICE ACTION / COMMENT Compressor Check replace compressor oil and filters Inspect moisture drain and drain reservoir as required Check compressor belts for tension and condition Check power supply for compressor and system Pneumatic System...
  • Page 46 Pneumatic equipment Maintenance and service manual PRODUCT WARRANTY ProWay Livestock Equipment and facilities are covered by a 12-month warranty against workmanship and/or materials from date of practical completion. For standalone products which are delivered in working condition, the warranty period commences from date of delivery. Scheduled maintenance of ProWay products and facilities is recommended and will ensure many years of safe and efficient stock handling.
  • Page 47 Pneumatic equipment Maintenance and service manual Notes www.proway.com.au...
  • Page 48 The choice of livestock professionals Head Office: 19 Bomen Rd. Bomen NSW, 2650 Regionally based designers servicing clients across Australia Phone: 1300 655 383 Phone (international): +612 6932 4000) Fax: 02 6931 8410 Email: information@proway.com.au www.proway.com.au...