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LINXIS DIOSNA HK300 Original Operating Manual

Elevator tipper
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Original Operating manual
1-034-001-BL_en
Elevator Tipper HK300 600 1000

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  • Page 1 Original Operating manual 1-034-001-BL_en Elevator Tipper HK300 600 1000...

  • Page 2: Table Of Contents

    Contents CONTENTS PRODUCT INFORMATION......................... 1 ......................... 1 ENERAL INFORMATION ......................... 2 AFETY ADVICES AND SYMBOLS ........................3 ANUFACTURERS DRESS ........................3 ARRANTY AND LIABILITY .......................... 4 DESIGNATION OF YPES ........................4 ERSION ADMINISTRATION SAFETY ..............................5 ....................... 5 NTENDED USE OF THE MACHINE ........................
  • Page 3 Contents ............................55 HUTDOWN ......................55 INAL SHUTDOWN AND DISPOSAL TROUBLESHOOTING ..........................57 Operating manual | Elevator Tipper HK300 600 1000...

  • Page 4: Product Information

    Product information PRODUCT INFORMATION 1.1 GENERAL INFORMATION These Operating manual are a part of the product and include all the information necessary for the set-up, start-up, the operation, maintenance, repair and disposal of the described machine. O T I C E These Operating manual must be accessible at all times in a complete and legible condition.

  • Page 5: Safety Advices And Symbols

    Product information 1.2 SAFETY ADVICES AND SYMBOLS A N G E R Ignoring the warning will lead to dangerous situations that will result in death or severe injury. A R N I N G Ignoring the warning will lead to dangerous situations that will result in severe injury.

  • Page 6: Manufacturers Adress

    Product information 1.3 MANUFACTURERS ADRESS DIOSNA Dierks & Söhne GmbH D – 49009 Osnabrück, Postfach 1980 D – 49086 Osnabrück, Am Tie 23 Phone: +49 (541) 33104 – 0 Fax: +49 (541) 33104 – 10 E-Mail: info@diosna.de Web: www.diosna.com 1.4 WARRANTY AND LIABILITY Generally, our „General Terms and Conditions“...

  • Page 7: Designation Of Types

    Product information 1.5 DESIGNATION OF TYPES DESIGNATION OF TYPES HK300 600 1000 NNNNN-XXXX DIOSNA elevator tipper Elevator tipper HK(V) type Type number 1000 1200 NNNNN 00049 Machine type number HK 170 00913/00914 HK 224 00918/00919 HKV 224 00034 HK 300 00044 HK 600 00120...

  • Page 8: Safety

    Safety SAFETY 2.1 INTENDED USE OF THE MACHINE The machine / plant is only intended to be used for food manufacture in the following industrial fields and research institutes: a. Food industry (incl. craft businesses) b. Technical / scientific universities With the exception of radiological, biotechnical, purely toxic, military and pyrotechnical technological and scientific areas.

  • Page 9: Atex - Zone Concept

    Safety 2.3 ATEX – ZONE CONCEPT The machine delivered is a system of electrical and non-electrical devices and components that is envisaged for use in or in conjunction with potentially explosive areas of the zone concept. The conception of the machine was executed corresponding to the safety requirements of the European guideline 2014/34/EU ("ATEX-Guideline").
  • Page 10 Safety Hazard area Danger Movement area of the lifting platform Risk of crushing, impact Movement area of the scraper (optional) Disc, wheels and chains Risk of crushing, tearing and cutting Guide rails and drive mechanism Risk of crushing and tearing Zone of tipping mixture Danger due to mixture falling Zone of bowl drive / tong...

  • Page 11: Warning Signs On The Machine

    Safety 2.6 WARNING SIGNS ON THE MACHINE 2.6.1 GENERAL WARNINGS A N G E R Danger of electric shock! Risks due to electric voltage. Keep the switchgear and control cabinets closed. Disconnect from the mains before working on electrical equipment. A R N I N G Entanglement hazard due to moving machine parts! Danger of crushing or tearing limbs!
  • Page 12 Safety O T I C E Breakdown caused by water jets or high-pressure cleaners! Electrical components can be damaged or fail. Corrosion can occur inside the machine! Do not use water jets (hose) or high-pressure cleaners for cleaning! 2.6.2 WARNINGS ON THE ELEVATOR TIPPER A N G E R Danger of life-threatening injuries due to falling loads!

  • Page 13: Load Capacity

    Safety LOAD CAPACITY HK600, HK1200 = 1200 kg HK300 = 600 kg HK(V) 224 = 600 kg = 200 kg O T E The elevator tipper only works with closed, safety-based “Elevator tipper release” contact. This contact may only be bypassed if the safety-relevant points have been checked and there are no safety concerns.
  • Page 14 Safety A N G E R Risk of ineffectiveness of the protective equipment. The effectiveness of the light curtain must be checked daily by a competent person. See chapter "Maintenance and service instructions" Safety bow (Only in conjunction with a command device with self-acting reset - dead man control) The safety bow has an emergency stop function.
  • Page 15 Safety hydraulic unit to the set maximum pressure. This effectively prevents unintentional opening of the locking device. T T E N T I O N The type of barrier to the operating range of the lifting platform depends on the design: •...
  • Page 16 Safety 2.7.2 PROTECTIVE DEVICES FOR MACHINE PROTECTION DRIVES The motors are protected by overload relays/ motor protectors. If they respond to overload or defective line power supply, the machine will be operable again after approx. 1 Minute. The cause must be found and eliminated immediately. UPPER HOIST LIMITING When the end position of the tilting position has been reached, the elevator is switched off by a limit switch.

  • Page 17: Responsability Of The Operating Company

    Safety 2.8 RESPONSABILITY OF THE OPERATING COMPANY A N G E R Safety devices such as protective covers, safety switches or grids must not be removed or manipulated. The proper functioning of the protective devices must be ensured by regular checks Considerable danger of injury! The machine must be switched off immediately if any defects are noted.
  • Page 18 Safety 2.8.1 OPERATOR The machine may only be used by persons instructed in DIOSNA applications or personnel additionally trained by DIOSNA. They must also have read and understood the Operating Instructions as well as all other instructions. A R N I N G Children may not use the machine.

  • Page 19: User Groups

    Safety O T E Observe the applicable legal regulations of the country in which the machine is operated when young people are employed. 2.8.2 OVERVIEW OF USER GROUPS USER GROUPS Personal Qualification Operator Appropriate instruction in the areas of: • Functional sequences of the machine •...
  • Page 20 Safety Work on pneumatic Special knowledge and experience in handling pneumatics. equipment Work on hydraulic Special knowledge and experience in handling hydraulics. equipment Work on electrical Electrical engineer equipment Instruction, the work may be carried out under the supervision and supervision of a qualified electrician according to the electrotechnical rules.
  • Page 21 Safety 2.8.4 EXAMPLES OF TRAINING TOPICS General Safety • Accident prevention regulations • General legal regulations • General safety regulations • Measures in cases of emergency • Special aspects upon contact with chemical substances (in the pharmaceutical industry) • Safety devices in the periphery of the machine / system •...

  • Page 22: Machine Overview

    Machine overview MACHINE OVERVIEW 3.1 TECHNICAL SPECIFICATION DIOSNA ELEVATOR TIPPER HK300 600 1000 FRAMING Framing for installation on floor, fixing with anchor bolts, vertically welded on floor plates. LIFTING PLATFORM Lifting platform for the collection of the bowls, locking of bowl by 1 hydraulic cylinder with clamp, lifting platform with 4 laterally installed guide rollers and connection for chain fixing.
  • Page 23 Machine overview 3.1.1 SAFETY CAGE Safety cage with gate, made from stainless steel, to be lifted and lowered manually, electrically secured. ALTERNATIVE motorized gate ALTERNATIVE Safety bow O T E Safety bow only in conjunction with a 'deadman control' SAFETY EQUIPMENT The Elevator Tipper has to be prepared that an unintended opening of the clamps is not possible.

  • Page 24: Air Supply

    Machine overview The contacts are provided with a bridge when the elevator is delivered. If necessary, the bridges can be removed. O T E Optional equipment AIR SUPPLY Maintenance unit with main pneumatic valve for pressureless switching of the pneumatic components, pressure switch for monitoring 'Compressed air available'.

  • Page 25: Performance Data

    Machine overview 3.2.2 PERFORMANCE DATA Lifting drive * HK 300 HK 600 HK 1000 Design Power [kW] Speed (50 Hz) [1/min] 10,5 Lifting speed ** [m/min] **) The driving speed can differ accordingly to order specification Bowl drive * HK 300 HK 600 HK 1000 Design...

  • Page 26: Dimensions Elevator Tipper Mach.-Ser. -No. See Typeplate

    Machine overview 3.4 DIMENSIONS ELEVATOR TIPPER MACH.-SER. -NO. SEE TYPEPLATE Figure 3-1 | Dimensions Elevator tipper HK 300 (without safety cage) Operating manual | Elevator Tipper HK300 600 1000...
  • Page 27 Machine overview Figure 3-2 | Dimensions Elevator tipper HK 600 (without safety cage) Operating manual | Elevator Tipper HK300 600 1000...
  • Page 28 Machine overview Figure 3-3 | Dimensions Elevator tipper HK 1000 (with safety cage on both sides) Operating manual | Elevator Tipper HK300 600 1000...

  • Page 29: Transport And Setting Up

    Transport and setting up TRANSPORT AND SETTING UP 4.1 UNLOADING AND TRANSPORT The machine or the individual parts of the system are shipped partially disassembled. The packaging is based on the agreed shipping method (truck, container or wooden crate). All packages should be unloaded using a suitable lifting tool - a mobile crane or forklift with sufficient load capacity is recommended.
  • Page 30 Transport and setting up T T E N T I O N The elevator HK300 600 1000 must be transported with a pallet truck only horinzontally. A R N I N G Observe the lifting capacity of the hoists! (see technical data section for the weight of the machines) Risk of serious injuries due to falling loads! Do not step under a lifted load!

  • Page 31: Setting Up

    Transport and setting up 4.2 SETTING UP 4.2.1 GENERAL INFORMATION Place the machine or individual parts of the plant on a stable, and sufficiently loadable floor. After alignment and connection of the machine, all covering plates are remounted. A R N I N G During the erection of the machine, or plant components, make sure that crushing and shearing is avoided.
  • Page 32 Transport and setting up 4.2.2 ERECTING THE ELEVATOR HK300 600 1000 The elevator tipper is to be supported against a fixed wall with squared timber (see sketch) prior to erection. The squared timber is to be joined together (nailed). To erect the elevator tipper, forklift trucks, cranes or other suitable lifting gear is to be used depending on availability.
  • Page 33 Transport and setting up 4.2.4 ATTACHMENT WITH HILTI HVU SYSTEM (CHEMICAL DOWELS) The machine is to be set up at the intended location. Drill the holes through the attachment drill holes in the base plate using a suitable drilling machine. Place chemical dowel in the drilled hole.

  • Page 34: Connecting

    Transport and setting up 4.3 CONNECTING Connect all tubes and electrical connections accordingly to he delivered drawings and diagrams. Please refer to the chapter for technical data for the ratings of the fuses to be installed by the customer. The permanent connection must only be installed by a qualified electrician in conformity with EN 60204, DIN VDE 0100, or equivalent connecting conditions.

  • Page 35: Setting Into Operation

    Setting into operation SETTING INTO OPERATION 5.1 BEFORE SETTING INTO OPERATION Before commissioning, all plant components must be erected and installed in compliance with the plans delivered. DIOSNA recommends commissioning only with the assistance of the DIOSNA specialist staff. 5.2 SETTING INTO OPERATION 5.2.1 FUNTIONAL TEST •...

  • Page 36: Emergency Stop Button

    Setting into operation • LOWER HOIST LIMITING The lowering movement must be stopped by the limit switch before the mechanical end stop is reached. • BOWL RECEPTABLE The limit switch must switch before reaching the end position O T E With the option of bowl with rod holder, the bowl is protected against falling out by means of a mechanical stop.

  • Page 37: Restart After Stopping

    Setting into operation After assembling the elevator at the customer site, a safety matrix has to be filled out and signed (see electrical circuit diagram). On the basis of this assessment, the bridge can be used for the safety-related contact "Enable Elevator"...

  • Page 38: Operation

    Operation OPERATION 6.1 DESCRIPTION OF THE MACHINE / SYSTEM'S FUNCTIONS ELEVATOR TIPPER HK300 600 1000 Figure 6-1 | Funktional principle of the elevator tipper (Example partly with special equipment) Component Function Lifting platform The lifting platform (1) is pulled upwards by means of roller chains (4) via guide rails or tracks (2) with the locked bowl (3) and Guide rails / tracks is tilted in the upper end position.

  • Page 39: Push-Button Control With Itimern (Execution D)

    Operation 6.2 PUSH-BUTTON CONTROL WITH ITIMERN (EXECUTION D) 6.2.1 DESIGN OF THE CONTROL Figure 6-2 | Push button controlHK300 600 1000 Pos. Function Pos. Function Pos. Function Push button "Lift" Push button "Stop" Push button "Lower" Main-Switch EMERGENCY-OFF button 6.2.2 OPERATING OF THE CONTROL PUSH BUTTON "LIFT"...

  • Page 40: Main Switch

    Operation EMERGENCY-STOP BUTTON Pressing the [EMERGENCY STOP] button or opening the safety bow will shut down the running machine. The machine can be put into operation again after the [EMERGENCY STOP] button has been reset and the safety bow has been closed. MAIN-SWITCH The machine is switched on and off.

  • Page 41: Cleaning

    Cleaning CLEANING 7.1 GENERAL ASPECTS OF HYGIENE RISK A machine does not primarily cause a hygienic risk. Only a certain product in connection with the machine can cause a hygiene risk. Only food processing causes a hygiene risk. Food include products that are more or less sensible. Therefore, it seems to be purposeful to select the product as parameter for the basic risk.

  • Page 42: Cleaning Of The Machine

    Cleaning However, depending on the product sensitivity, additional measures can be required, e.g. treating of the machine with a procedure that kills microorganisms. In the individual case, these methods must be coordinated with DIOSNA. A U T I O N If not cleaned or only insuffiently cleaned, this will pose a high hygiene risk.
  • Page 43 Cleaning O T I C E Remove adhering product residues from the bowl edge, also during production. Especially dried product residues cause increased wearing of the cover edge. After cleaning with water, dry the machine to reduce the risk of corrosion. This particularly applies prior to longer downtimes.

  • Page 44: Machine Areas That Are Difficult To Access

    Cleaning 7.3 MACHINE AREAS THAT ARE DIFFICULT TO ACCESS Due to design necessities, some positions exist that need increased cleaning attention and therefore, they cannot be integrated in the daily cleaning process. Only a SPECIALIST is allowed to remove the covering plates (see chapter "User"). Please find the instructions for removing the covering plates in the spare part drawings that come with the machine.
  • Page 45 Cleaning O T I C E Observe the instructions in the manufacturer's supplementary sheet! C a u t i o n ! The machines must not be cleaned with water jets. Higher pressure can cause damage to the electrical components and bearings. They are allowed to be cleaned with water hose up to a maximum pressure of 10 bar and a temperature of up to 50°C.

  • Page 46: Servicing And Maintenance Instructions

    Servicing and maintenance instructions SERVICING AND MAINTENANCE INSTRUCTIONS 8.1 GENERAL INFORMATION The life cycle of the machine is not subject to certain limits, provided the use is authorized, regular maintenance is carried out according to this manual and fault causes are removed immediately.
  • Page 47 Servicing and maintenance instructions A R N I N G All maintenance work on the machine may only be performed with the main switch turned off and secured or with the mains plug disconnected. Danger of electric shock due to electric current! The machine must be switched off and secured against being switched back on unexpectedly/accidentally.
  • Page 48 Servicing and maintenance instructions A U T I O N Shut off the flow and return lines on-site and disassemble and bleed the cleaning agent supply line when carrying out maintenance or repair work. Personal protective clothing should be worn (facial and body protection, protective gloves, etc.).

  • Page 49: Maintenance Plan Elevator Tipper Hk300 600 1000

    Servicing and maintenance instructions 8.3 MAINTENANCE PLAN ELEVATOR TIPPER HK300 600 1000 O T I C E The maintenance intervals presume normal ambient conditions. Shorter maintenance intervals are required under extreme operating conditions, e.g. high humidity, aggressive environmental conditions and wide temperature fluctuation.

  • Page 50: Maintenance Of The Hydraulic System

    Servicing and maintenance instructions Maintenance point Works to be done Chain Check chain wear Measure chain wear over 20 links (Roller chain according to DIN8187, pitch 25,4 Permissible wear 3% Nominal dimension: 508 mm Limit: 523 mm (best to use a chain gauge) Lifting drive see the manufacturer's operating instructions Hydraulic-Hose-Reel...

  • Page 51: Check The Hydraulic Oil Level

    Servicing and maintenance instructions O T I C E Dirt or liquids entering the hydraulic system can lead to faults; in that case, secure function of the hydraulic system or its components cannot be ensured. Maintain upmost cleanness when working on the hydraulic system! 8.4.2 CHECK THE HYDRAULIC OIL LEVEL •...

  • Page 52: Daily Check Of The (Optional) Light Curtain

    Servicing and maintenance instructions • Document the analyzed data. Ensure to drain the used up oil completely at an oil change; therefore pay attention to the piping and the oil consumers. If necessary, vent hydraulic system. 8.5 DAILY CHECK OF THE (OPTIONAL) LIGHT CURTAIN 8.5.1 SAFETY ADVICES A N G E R Hazard due to lack of effectiveness of the protective device...
  • Page 53 Servicing and maintenance instructions A N G E R Hazard due to lack of effectiveness of the protective device Persons and parts of the body to be protected may not be recognized in case of nonobservance. • Only use the included test rod with the diameter specified on the type label of the safety light curtain.
  • Page 54 Servicing and maintenance instructions (3) Then, guide the test rod along the edges of the area to be protected as indicated by the arrows, see figure below. (4) Watch the OSSD LED on the receiver during the check. The OSSD LED on the receiver should continuously light up red.
  • Page 55 Servicing and maintenance instructions 8.5.3 MAINTENANCE OF THE (OPTIONAL) LIGHT CURTAIN The safety light curtain is maintenance-free. Depending on the ambient conditions, regular cleaning is required. D A N G E R Risk of ineffectiveness of the protective device Persons and parts of the body to be protected are not recognized in case of non-observance.

  • Page 56: Lubricants

    Servicing and maintenance instructions 8.6 LUBRICANTS 8.6.1 GENERAL Properly selected lubricants contribute significantly to achieving a good work performance as well as a longer service life of the machine and help to eliminate downtimes. The lubricants listed have proven successful and are selected based on the prevailing working conditions at the lubrication points.

  • Page 57: Web-Links To The Suppliers Documentations

    Servicing and maintenance instructions 8.7 WEB-LINKS TO THE SUPPLIERS DOCUMENTATIONS LIFTING MOTOR FROM BAUER http://www.bauergears.com/products/Geared-Motors/BK-Series DRIVE MOTORS FROM SEW http://www.sew-eurodrive.de/support/documentation_result.php?gruppen_id=A11 http://www.sew-eurodrive.de/support/documentation_result.php?gruppen_id=A21 HYDRAULIC UNIT https://www.boschrexroth.com/en/xc/products/product-groups/industrial- hydraulics/power-units/power-units-3# LIGHT CURTAIN FROM SICK Light curtain deTec4 Core https://www.sick.com/gb/en/product-portfolio/opto-electronic-protective-devices/safety- light-curtains/detec4-core/c/g269851 MAINTENANCE UNIT AND PNEUMATIC COMPONENTS FROM FESTO https://www.festo.com/cat/de_de/data/doc_engb/PDF/EN/LFR-D-MPA_EN.PDF Operating manual | Elevator Tipper HK300 600 1000...

  • Page 58: Final Shutdown And Disposal

    Final shutdown and disposal FINAL SHUTDOWN AND DISPOSAL 9.1 SHUTDOWN Decommissioning as follows: 1. Lower the lifting platform 2. Switch off main switch 3. Switch off supply media. A U T I O N For longer downtimes, suitable measures are to be taken for corrosion protection.
  • Page 59 Final shutdown and disposal A U T I O N Electrical and electronic waste Devices with this logo on their packaging or on the device itself must be disposed of separately. These devices may not be disposed of via the usual domestic waste. You are responsible to ensure that each electrical and electronic piece of waste will be disposed of via the competent organizations, e.g.

  • Page 60: Troubleshooting

    Troubleshooting 10 TROUBLESHOOTING A N G E R Trouble-shooting that requires removal of the protective devices or cover panels using tools may only be performed by specialists. GENERAL FAULTS Fault Reason Remedy Main fuse has triggered Check,
 measure voltage,
 replace if necessary Control fuses Switch on,
...
  • Page 61 Troubleshooting ELEVATOR TIPPER TYPE HK300 600 1000 Malfunction Cause Remedy Safety bow not Close safety bow closed Gate of the safety gate not depends on Close gate closed the design elevator The protective area of the light Leave safety area curtain is accessed Hopper is not emptied...

This manual is also suitable for:

Diosna hk600Diosna hk1000

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