DEC PTS 50 Installation, Operating And Maintenance Manual

Powder transfer system

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INSTALLATION, OPERATING AND MAINTENANCE

MANUAL

POWDER TRANSFER SYSTEM

PTS 50 - 400

Dietrich Engineering Consultants sa

Z. I. Larges Pièces A · Chemin du Dévent · P. O. Box 9 · 1024 Ecublens · Switzerland

Tel +41 21/694 20 40 · Fax +41 21/694 20 59 · info@dec-group.ch

MAN-PTS-GB, Revision 9, BSC, 15-FEB-2017

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Page 1 Dietrich Engineering Consultants sa Z. I. Larges Pièces A · Chemin du Dévent · P. O. Box 9 · 1024 Ecublens · Switzerland Tel +41 21/694 20 40 · Fax +41 21/694 20 59 · info@dec-group.ch MAN-PTS-GB, Revision 9, BSC, 15-FEB-2017...
Page 2 2/46 MAN-PTS-GB, Revision 9, BSC, 15-FEB-2017...
Page 3: Table Of Contents
TABLE OF CONTENTS Safety ................................ 6 Symbols ............................6 Operators and maintenance personnel ................... 6 Risk analysis ............................. 6 Powder characteristics ......................... 7 Inspection ............................7 Residual risks ............................ 7 General description ..........................8 Warranty ............................8 Application ............................. 8 Patents .............................
Page 4 Transport and lifting ........................18 Storage ............................18 Assembly, connections and first commissioning ................20 Mechanical assembly......................... 20 Installation ............................. 20 Commissioning ..........................23 5.3.1 Safety check ..........................24 5.3.2 Adjustments ..........................24 Daily start-up ..........................25 Operation, Maintenance and Repair ....................26 Normal operation ........................
Page 5 Manufacturer documentation....................46 5/46 MAN-PTS-GB, Revision 9, BSC, 15-FEB-2017...
Page 6: Safety
SAFETY For safe handling of the system, it is imperative that you strictly follow these instructions. Pay particular attention to the instructions marked with the following symbols. Please also note the safety instructions from the vendor documentation. SYMBOLS The following symbols and instructions are used for safety instructions. They warn of possible personal injury or property damage, and give advice to facilitate working with the system.
Page 7: Powder Characteristics
This instruction manual refers only to the operation and use of the PTS system. Specific risks related to the powders are not part of this manual and must be treated separately. Dec takes no responsibility in the case of accidents resulting from incorrect handling of the products to be transferred.
Page 8: General Description
GENERAL DESCRIPTION The PTS technology, developed and patented by Dec, is a proven technology which allows the transfer and dosing of powder. Due to its unique concept, it is possible to solve various and complex problems in industrial applications and pilot plants. This manual describes mainly the standard models used in industrial applications.
Page 9 The PTS consists of a cylindrical chamber with a tangential inlet and a filtration membrane at the top. The system is equipped with 4 pneumatic valves (inlet valve V1, outlet valve V2, vacuum valve V3, and pressure valve V4) connected to a pneumatic or electro-pneumatic control cabinet.
Page 10: Major Advantages
• GMP compliant design, ATEX compliant CHOICE OF PTS PTS models (PTS 50 to PTS 400) are standard installations designed for industrial applications. Other models are also available, depending on the problem to solve. Furthermore, it is also possible to transfer almost continuously by using two PTS chambers which work alternately or to provide a second input for an additional product.
Page 11: Options
OPTIONS 2.7.1 PTS MOBILE The portable PTS allows the operator to charge multiple processes, giving maximum benefit for the investment. It provides all the benefits of the static system but is also easily dismantled for repositioning anywhere in the production unit. The control panel and vacuum pump remain permanently mounted on the trolley, while the PTS can easily be installed on the process equipment to be charged.
Page 12 Liquid separator The liquid separator is integrated in the cover of the PTS System. Pressure and vacuum valves are mounted on a separated tee directly connected to the cover. The device consists of one main separation chamber with a float in stainless steel. The system comprises a flange at the bottom and a cap at the top.
Page 13 Bypass with manual ball valve (Option) Product inlet Spraying device (optional) Connection for spraying device, closed with a plug Connection with mounted spraying device Spraying device The PTS body is equipped with a connection for the installation of a spraying device, which can be removed after each cleaning.
Page 14: Technical Data
TECHNICAL DATA This chapter describes the technical data of the system. Other models are also available according to your specific needs. If you have ordered a special model, see the corresponding technical data in the appendix to this manual. 2.8.1 DIMENSIONS The detailed dimensions and materials of the system can be found in the drawings and part lists of the technical documentation.
Page 15: Construction And Operation
CONSTRUCTION AND OPERATION The chamber is the main part of the PTS technology. The PTS filter is located in the upper part of the chamber, between the body and the cover. The system consists of 4 valves which are connected to a control system. The valve "product inlet" V1 and the valve "product outlet" V2 are directly mounted on the chamber.
Page 16 VACUUM PRESSURE PUMP After a predetermined time, the inlet valve V1 opens. The product is sucked into the chamber with the vacuum Valve closed created by the vacuum pump. Valve open POWDER VACUUM PRESSURE After a given time, when sufficient PUMP powder has been filled into the PTS chamber, inlet valve V1 closes (the filling...
Page 17 In most cases, a new suction cycle will immediately restart. However, it may be necessary for certain processes to introduce a waiting time between each cycle in order to regulate the transfer capacity. During this waiting time, all valves remain closed. The logic described above corresponds to the standard operation of the PTS.
Page 18: Transport And Storage
A general drawing of all components of the system can be also found in the technical documentation. Missing or damaged parts must be immediately notified to Dec. Please document these defects immediately by taking pictures and accurate records.
Page 19 Risk of damage to components! The storage must be done in an enclosed area, dry, temperate, protected from frost and light. Avoid moisture, high temperatures and dirt. Depending on the time and the conditions of storage, a special packaging may be necessary. In all cases, you must check with the manufacturer by describing the conditions and the time of storage.
Page 20: Assembly, Connections And First Commissioning
ASSEMBLY, CONNECTIONS AND FIRST COMMISSIONING Risk of damage to components! Assembly, connections and first commissioning should be performed by qualified personnel with relevant experience. Errors could lead to dangerous situations and result in considerable material damage. According to the ATEX 137 guideline and the regulations on safe operation, the operator must ensure a safe working environment.
Page 21 Risk of damage to components! Make sure that the valve is correctly positioned and centered and that it can open/close freely. In case of incorrect installation, the valve and the PTS chamber can be damaged and the valve can get wedged. Install the filter gasket in the recess of the upper part of the PTS chamber;...
Page 22 (earthing through screw connections already made). Earthing of the butterfly valve (delivered by DEC but not mounted on the PTS). Measure the electrical continuity to monitor and validate the entire earthing of the PTS system and all equipment adjacent to the PTS system;...
Page 23: Commissioning
Make sure that a pressure reducer (pressure range < 3 bar) is installed in the line for the supply of compressed gas to discharge the PTS. In case the process pressure can be higher than the PTS operating pressure (as indicated in the technical specifications) an appropriate pressure release valve has to be installed.
Page 24: Safety Check
5.3.1 SAFETY CHECK 1) Verify that all parts of the PTS installation are correctly earthed (cf. chap. 6.2, pt. 8); 2) Make sure that the PTS filter is correctly installed (cf. chap. 6.2, pt. 4); 3) Check that all screws and connections are tight; 4) Check the pneumatic connection: Open the compressed air supply to the control panel;...
Page 25: Daily Start-Up
A discharge time which is too low can provoke operating problems. Adjust this timer at a value superior to 5 s. 3) Adjust the discharge time in a way that, at the opening of valve V2, the entire powder quantity in the PTS chamber is discharged without excessive dust creation. The typical range is around 0,8 –...
Page 26: Operation, Maintenance And Repair
OPERATION, MAINTENANCE AND REPAIR NORMAL OPERATION During normal operation, the system does not require any particular maintenance. A visual check must be completed at regular intervals depending on the frequency of operation and the type of powders transferred. These controls can be done directly by the operators (check of the vacuum safety filter, the PTS filter, etc.).
Page 27: Maintenance
Risk of damage to components! Before disconnecting the system, ensure the control panel is shut down, i.e. the compressed air and/or electricity is cut. MAINTENANCE To avoid injury risks from maintenance and repairs performed incorrectly, you must respect the following points. Risk of accident! Ensure that no energy source may accidentally or inadvertently move the equipment which could endanger users during maintenance works.
Page 28: Repairs
The PTS requires only limited maintenance due to its sturdy and reliable design. Standard maintenance consists mainly of inspecting and cleaning the parts which are in contact with the product (PTS chamber, valves, PTS filter, safety filter and vacuum pump) at regular intervals.
Page 29: Cleaning
CLEANING HAND CLEANING Risk of accident! A risk of dust creation and injury exists when opening the cover if the PTS chamber is still under pressure. Before opening the cover, ensure that the system is shut down and the chamber is not under vacuum or pressure (vent the unit beforehand). 1) Close the compressed air supply to the control panel;...
Page 30: Cleaning In Place (Cip)
CLEANING IN PLACE (CIP) The complete unit should be cleaned entirely prior to opening and drying the system. The following cleaning sequences must be strictly followed. Operate the PTS System for a few cycles without sucking in any powder being able to empty the suction hose and flush the PTS body from the remaining traces of powder Danger of explosion! CIP with solvents requires some precautions:...
Page 31: Drying
DRYING The complete unit must be dried prior to start a new conveying. Some parts should also be exchanged. The selector switch must be reset to “transfer”. The following drying sequences should be strictly followed: 1) Operate the PTS during a predetermined period of time being able to empty the line from the remaining liquid (approx.
Page 32 10) Remove the used filter membrane; 11) Assemble the filter membrane inside the filter body on the grid. The felted side of the filter membrane has to be installed towards the filter grid, the opposite side of the membrane, the smooth part (marked with a red point), comes in contact with the product;...
Page 33: Filter Assembly
FILTER ASSEMBLY 7.5.1 OPTION WITH 1 O-RING AND SCREW  Place the grid (6) in the housing (7).  Place the filter membrane (5) with the red dot above the grid (6).  Place the O-Ring (4) with the cover (3) on the filter membrane (5).
Page 34: Option With 1 O-Ring And Groove
7.5.2 OPTION WITH 1 O-RING AND GROOVE  Place the grid (5) in the housing (6).  Place the filter membrane (4) with the red dot above (5).  Place the O-Ring (3) with the cover (2) on the filter membrane (4). ...
Page 35: Option With 3 O-Rings And Groove For Triclamp Version
7.5.3 OPTION WITH 3 O-RINGS AND GROOVE FOR TRICLAMP VERSION  Place the grid (5) in the housing (6).  Place the filter membrane (4) with the red dot above the grid (5).  Place the O-Ring (3) with the cover (2) on the filter membrane (4).
Page 36: Operating Problems And Their Solutions
OPERATING PROBLEMS AND THEIR SOLUTIONS The PTS is a very simple and reliable system. However, in case of operating problems, refer to the following table, which summarizes some typical problems which might occur including their solutions. Please contact the manufacturer, in case the problem cannot be solved. N°...
Page 37 N° Problem Probable cause Solution Incorrect use of the suction Insert the suction lance directly lance. into the product and move it around. Partial blockage of the hose with Eliminate all lumps prior to powder lumps. initiating the powder transfer. Install a lump breaker.
Page 38 N° Problem Probable cause Solution No transfer takes place. Wrong connections between the Correct the pneumatic valves and the control panel. connections according to the instructions in the manual. Pneumatic control panel Check the pneumatic control defective. panel, see point 8. The supply of compressed air to Increase the pressure and the the control panel is insufficient.
Page 39 N° Problem Probable cause Solution and away from the product. Consult the manual for instructions. The lifetime of the PTS filter has Replace the PTS filter. been reached. The PTS filter is damaged Replace the filter. Avoid (punctured or torn). getting the filter in contact with pointed objects and don't clean it with liquids.
Page 40 N° Problem Probable cause Solution The pressure valve does not Check if the valve works and open. replace it if necessary. The supply of pressure is Check the capacity of the insufficient. pressure supply, see point 10. The powder outlet valve does not Make sure the valve is open.
Page 41 N° Problem Probable cause Solution The butterfly valve at the powder Install a ball valve with full inlet provokes a restriction. bore at the powder inlet. No more suction from the The PTS has been wrongly Check the pneumatic PTS. connected to the control panel.
Page 42 N° Problem Probable cause Solution The external signal "Operation Verify the logic of the control authorization" is not activate panel. (option on the control panel). The emergency stop is activated Deactivate the emergency (option on the control panel). stop. The vacuum pump Check the direction of the Modify the electrical switches off (refer to the...
Page 43 N° Problem Probable cause Solution 11 The PTS filter is plugged up. The discharge pressure is too Verify the pressure supply, see weak or the supply of pressure is point 10. too low. The filter is wet. Avoid cleaning the filter with a liquid.
Page 44 N° Problem Probable cause Solution The valve is incorrectly Correct the pneumatic connected to the control panel. connections according to the A valve works incorrectly instructions in the manual. (stays open/shut or closes The butterfly valve is incorrectly Verify the centering of the incompletely or only with installed.
Page 45 N° Problem Probable cause Solution The filter of the vacuum pump is Make the filter tight or replace not tight. A valve of the PTS is no longer Replace the valve or the tight. sleeve of the valve. 45/46 MAN-PTS-GB, Revision 9, BSC, 15-FEB-2017...
Page 46: Appendix
APPENDIX ADDITIONAL DATA If you have ordered a PTS in a special execution, you will find in the technical documentation of the installation, the diagrams and the technical data corresponding to your system. LIST OF SPARE PARTS Please refer to the list of spare parts available in the technical documentation or to the general equipment list of your installation in order to obtain the reference numbers of the various components.

This manual is also suitable for:

Pts 400