KAAS00002G F41-416Z PET Enh
KAAS00002G F41-416Z PET Enh
1-G ENGLISH
CONTENTS
1. DESCRIPTION ...........................................................6-G
2. HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 6 - G
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . …7 - G
3.1. OPTIONAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . …. . . . . . . . . . . . . . . . . . . . . . . . 8 - G
4. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 8 - G
4.1. PIPE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . . 8 - G
4.2. COMPRESSED AIR CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . 9 - G
ENGLISH 2-G
Safety rules
1. Failure to observe the basic rules of accident prevention and safety is one of the main causes of accidents when using
and servicing industrial machinery.
2. Before performing any operation on the machine you must carefully read this manual, the safety rules below and
the information given on the warning notices affixed to the machine. Do not allow unauthorised personnel to use,
adjust or repair the machine.
3. In the design and manufacture of the machine and the writing of the instructions manual, all attempts have been made
to eliminate or reduce the hazards for those who install, use or repair the machine. If you come across any further
potential hazard conditions, please inform the manufacturer, who will take measures to remedy the problem.
4. When required, all persons working on the machine must wear protective clothing (helmets, safety footwear, gloves,
earplugs or anti-noise headsets, safety goggles etc.) in accordance with international workplace safety standards.
5. Only persons with adequate technical training, who have a complete working knowledge of the machine, who have
the necessary physical and psychological requirements for working safely on the machine and who have fully read
the supplied documentation are allowed to operate the machine and perform routine maintenance tasks on it.
6. Set up stands or platforms (in accordance with binding safety regulations) when installing parts that cannot be reached
from ground level.
7. When interfacing with other machinery, keep strictly to the instructions given by the manufacturers of
the other machines.
8. Check that the safety systems (guards, microswitches, sensors) are in perfect working order before starting work.
If anything is out of order, have it repaired. It is strictly forbidden to remove safety devices, tamper with the
electrical system or any of the mechanisms.
9. This machine must be used exclusively for its intended purpose and must not be used improperly.
10. Do not touch the machine with your hands or any other parts of the body if they are wet or damp.
3-G ENGLISH
4. Install the machine in a place that is protected from aggressive chemical and atmospheric agents.
5. Check that the supply voltage and frequency stated on the machine data plate correspond to those of the
electricity mains and check that the mains circuit is suitably scaled for the machine maximum power input (refer to the
"technical data" table and the wiring diagram).
6. The machine must be connected to an efficient earth connection (as provided for in current
electrical safety standards). This basic requirement must be checked and where any doubt exists, a careful check
of the plant by an expert is to be called for. Electrical safety devices, suitably scaled for the total machine power,
must be installed at the point of connection to the electricity line (see electric circuit diagram).
7. Install a main circuit breaker switch between the electricity line and the machine power supply lead. The main switch
must be in an easily accessible position. The electrical connection must be made by a qualified electrician.
GLOSSARY
CE European Union mark applied to machines that comply with EU directives.
Artificial product (polymer) with a macromolecular structure which, under certain conditions, takes on a
Plastic
plastic consistency and can be moulded with a number of different techniques (see UNI
material
4266 and ASTM D 883 Standards).
ENGLISH 4-G
Refers to procedures or practices which, if not performed correctly, will cause serious
damage to
health, injury or death.
Refers to procedures or practices which, if not performed correctly, may cause serious damage to
health, injury or death.
Refers to procedures or practices which, if not performed correctly, may cause serious damage to the
product.
5-G ENGLISH
1. DESCRIPTION
PIOVAN Vacuum Units are designed for the transport of plastic materials in granular form. The Vacuum Units suck the ma-
terial from the storage point (silo, hopper, etc.), using the air flow generated by the on-board vacuum blower, and send it to
one or more PIOVAN Vacuum Receivers.
All the models have an air intake filter, for protecting the vacuum blower. The filters are self-cleaning and can be used for
filtering the material carrier air in both single and centralised systems.
If the filter is used for cleaning air that carries several different plastic materials, make sure that the dust released by these
materials does not form corrosive, explosive or inflammable mixtures or deposits, which may damage the filter itself.
The following materials must not be used with the vacuum units and carrier air filters:
• plastic materials in fibre, flake or scale form, foodstuffs, corrosive, inflammable, explosive or harmful materials;
• metallic materials or minerals (stones, crushed stone, etc.);
• anything not strictly defined as plastic material.
2. HANDLING
WARNING!
Read the “HANDLING, LIFTING PACKING AND UNPACKING SAFETY RULES" section carefully
before proceeding with the following operations.
The machine can arrive at its destination packed in palletisable cardboard packing, crates, cages, wood-
en pallets and protective plastic sheets. Keep the packing materials to protect the machine if it has to
moved again in the future; if the material is disposed of, observe the binding waste disposal regulations
in the place of installation.
The machine, either packed or unpacked, can be transported easily on a trolley (transpallet) (see Fig. 1).
For moving longer distances, use the means of transport that best preserves the integrity of the pack and the machine.
Vacuum units F41Z, F42Z, F44Z and F48Z can be lifted with ropes of suitable load-bearing capacity and length and with
the correct load factor. The anchor points for the lifting ropes are shown in Fig. 2 and Fig. 3.
Fig. 1
F41 F44
F42 F48
Fig. 2 Fig. 3
ENGLISH 6-G
3. OPERATION
(see Fig. 4, TAB. 7)
The material is sucked in through the suction probe (1) with the vacuum air flow generated by the on-board vacuum blower
(m). The probe can be set to achieve the best possible suction flow, following the instructions in the PIOVAN vacuum re-
ceivers manual.
The material is then carried in the pipes to the vacuum receiver (2) being loaded, where it is stored for use. The air used
for carrying the plastic material is then sent through the inlet (10) to the filter: the dust suspended in the carrier air is filtered
out by the cartridge (12) in the filter. The air comes out through the outlet (9), goes through the cooler 17 (if present), which
lowers the temperature, and is then sent back towards the vacuum blower. From here it is either released into the atmos-
phere or recycled through the system.
The automatic filter cleaning system is activated at set time intervals: in filters CF1, CF2, CF3 the opening of the vacuum
valve (VR) at the end of the suction stage creates a pressure air flow that that cleans the cartridge (12).
WARNING!
During operation the external surface of the filter can reach high temperatures (up
to 80°C
(176°F)). There is therefore a burns hazard if the filter surface is touched accidentally. Set up
safety guards to prevent accidental contact with parts of the filter and never go near the filter
with items that are sensitive to high temperatures (e.g. electricity
cables, electronic components, etc.).
1 m
3
Fig. 4 Fig. 5
7-G ENGLISH
3.1. OPTIONAL ACCESSORIES
(see TAB. 7)
DIFFERENTIAL PRESSURE SWITCH (not available for F41 and F42): device (SP3) that senses the difference in pres-
sure between the filter intake air (10) and outgoing air (9). When this difference exceeds the set level on the device an alarm
is given, signalling that the filter cartridge (12) is clogged and must be cleaned or replaced.
CLOSED CIRCUIT BY-PASS DEVICE: allows the material to be carried in a 'closed circuit', with the discharge of the air
into the atmosphere in the vacuum blower standby phases: the material is carried by air that has already been dehumidified
and which is sent back through the circuit after leaving the blower.
4. INSTALLATION
(see Fig. 7)
WARNING!
Read the “INSTALLATION SAFETY RULES" section carefully before proceeding
with the following operations.
7
6
a b
7
c d
e
Fig. 6
Fig. 7 Fig. 8
ENGLISH 8-G
4.2. COMPRESSED AIR CONNECTION
(see Fig. 9, TAB. 7)
Couple the compressed air supply line to the connector (8) at the top of the filter. The compressed air must be dry and non-
lubricated, at a pressure of 600 ÷ 800 kPa (6 ÷ 8 bar) and a minimum filtration grade of 25µ.
WARNING!
Do not connect other user units to the length of hose between the compressed air supply line
and the vacuum unit.
Fig. 9
5. MAINTENANCE
WARNING!
Read the “ADJUSTING, SERVICING AND TROUBLESHOOTING SAFETY RULES"
section carefully before proceeding with the following operations.
All maintenance jobs must be performed with the machine switched off and disconnected from
the electrical and compressed air power supply lines.
Wait until the machine has cooled down to room temperature before working on internal parts.
Unless it is to be re-used, any material recovered during the cleaning must be sealed off and
disposed of in accordance with binding waste disposal regulations in the country of installation.
Scheduled maintenance must be performed on a regular basis to guarantee the maximum efficiency of the machine.
SCHEDULED MAINTENANCE
Every 300 hours Cleaning filter cartridge CF1, CF2, CF3. Follow the instructions in Para. 5.2. - Page 10.
9-G ENGLISH
5.1. BLOWER MAINTENANCE
The vacuum unit bearings do not require maintenance. The machine works less efficiently when the silencers, (4 - see Fig.
5 - Page 7), filters (CF1, CF2, CF3) or cooler (17 - see TAB. 7) are dirty or clogged up.
WARNING!
Automatic filter cleaning does not substitute the manual cleaning of the filter.
The filter must be cleaned manually at periodic intervals, following the instructions given here,
even in models with self-cleaning filters.
The dust collected as a result of the filter servicing must be sealed in special containers.
The filters must be cleaned once a week if new, clean materials are used. Clean them more frequently if particularly dusty
materials are used.
The filter cleaning must be done in a suitable place, in accordance with the binding regulations in the country where the
machine is installed.
If the filter clogged alarm signal is given (on the vacuum unit operating cycle control unit - see Chap. 3. - Page 7), the filters
must be cleaned.
The filter must be replaced if damaged or if the cleaning is no longer effective.
ENGLISH 10 - G
6. CLEANING PIPE VALVE
6.1. DESCRIPTION
The cleaning pipe valve (VPC) is a device which empties and cleans the plastic materials transportation piping (pipe) at the
end of the material loading phase. It is installed at the beginning of the material's transportation pipe or as near as possible
to the material's storage area. The EC Declaration of Conformity is not necessary for this device.
11 - G ENGLISH
7. PUTTING THE MACHINE OUT OF SERVICE
When the machine's life cycle comes to an end, it must be disconnected from the electrical and pneumatic supply sources
and uninstalled from its work station. The machine must be disposed of in full compliance with the waste disposal laws in
the country where it is installed.
IMPORTANT!: After removing the machine from its work station, affix a permanent notice to it with the message:
“MACHINE TO BE SCRAPPED: DO NOT USE".
8. SPARE PARTS
To reduce machine downtimes caused by worn or broken parts to a minimum, we advise you to keep a reserve stock of all
the spare parts marked * in the spare parts list.
The following details must always be given when ordering spare parts:
1. All the data on the identification plate affixed to the machine (see Fig. 10 - Page 12);
2. The reference number and code number of the requested part (see spare parts tables);
3. A description of the requested part;
4. The quantity requested;
5. The exact address and requested forwarding method.
PIOVAN S.p.A. accepts no responsibility for mistaken consignments resulting from inaccurate or incomplete information.
9. IDENTIFICATION PLATE
t1 t2
t3
t4 t5 t6 t7 t8
Fig. 10
KEY
t1 Name of model.
t2 Serial Number.
t4 Year of manufacture.
ENGLISH 12 - G
TAB. 1 TECHNICAL DATA
WORKING ENVIRONMENT
5 ÷ 40°C
Ambient temperature
(41 ÷ 104°F)
Max 35°C
Average ambient air temperature for a 24 hour work period (Max 95°F)
120°C
Intake air maximum temperature
(248°F)
600 ÷ 800kPa
Compressed air pressure
(6 ÷ 8bar)
Max 800kPa
Water pressure
(Max 8bar)
Max 25°C
Water temperature
(Max 77°F)
TAB. 2 TECHNICAL DATA
F41Z + FZ • F42Z + FZ
Voltage Spare part code Power Max relative vacuum pressure Noise level Max weight
(150mbar)
230V / 3 / 50Hz
21kPa
F42Z 418X004 1.3kW
(210mbar)
66dB(A)* 52kg
400V / 3 / 50Hz
230V / 3 / 50Hz
44kPa
F44/2Z 400V / 3 / 50Hz
418X005 4kW
(440mbar)
70dB(A)** 160kg
230V / 3 / 50Hz
7.5kW 75.5dB(A)** 261kg
46kPa
F412/2Z 400V / 3 / 50Hz
4181867
(460mbar)
230V / 3 / 50Hz
11kW 43kPa 79dB(A)**
F416/2Z 4181868
(430mbar)
272kg
400V / 3 / 50Hz
Data supplied by the constructor according to DIN45635 standard.
TAB. 6: VPC Ø40 - Ø50
8 VPC VPC
> 1m
VPC
VPC
VPC
8
TAB. 7 SPARE PARTS LIST
SP3 22 9 10 11 12 8 13 16 YV VR
14
17
TAB. 8
18
19
20
21
m
TAB. 3
DESCRIPTION
12 Filter cartridge
CF2 8µ 6151230
13 Vacuum gauge 414X008
14 Two-pole plug 4531857
15 Black cap 628X029
16 VR Box 6411640
A
Project: 960A436 A
Order:
B B
A l i m e n t a z i o n e : 400V/50Hz ; 380V/60Hz ; 460V/60Hz/3F
S u p p l y :
Contents:
C i r c u i t i a u s i l i a r i : 230VAC ; 24VDC
A u x i l i a r y c i r c u i t :
P o t e n z a i n s t a l l a t a : Max. 13,5kW
C I n s t a l l e d p o w e r : C
C o r r e n t e m a s s i m a a s s o r b Max.
i t 31A
a :
M a x i m u m l o a d c u r r e n t :
C o r r e n t e d i s p u n t o : Max. 241A
P e a k c u r r e n t :
D D
P r o t e z i o n e c o n s i g l i a t a : Max. 50A aM
R e c o m m e n d e d p r o t e c t i o n :
M a x . s e z i o n e c a v o a l i m e 16mm²
n t a z i o n e :
M a x i m u m s e c t i o n s u p p l y c a b l e :
E E
F F
a Data 19.03.04 Loc. Inst.
b Disegn. L.A. Descr. pag. Dis. N. 960A436 Pag. 0
c Segue Pag. 1
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1 2 3 4 5 6 7 8
X1
LINE FROM DRYER
PE
L3 1L3 13/r
1 3 5
2 4 6
A A
L2 1L2
L1 1L1
13/r
FU0 QS1
Max. 50A aM
1 3 5 1 1 3 7
QM10 FU1 FU2 KA10
CLIENTE 2A 1A /2.E5
CUSTOMER / PIOVAN 2 2 11
QM10 I> I> I>
P I O V A N 13 14 2 4 6
B /1.C6 B
21 22
/2.B3
90
8
12/r
14/r
13/r
13/r
1W10
1U10
1V10
13
1 3 5 QM10
KM10 /1.B2 14
/1.E6
2 4 6
C C
15/r
W10
U10
V10
6 mm² RC10 X1
A1 13
X1 KM10 KA11 HL10
/1.E6 /1.E7 WHITE
480V 230V A2 14
U V W PE X2
D M 460V D
M10
3~ 400V
230V 0V 11/r
24V
12V KM10 KA11
/1.D6 /1.D6
1 2 5
9
3 4 /2.B2 1
0V 0V /1.C3
5 6 6
10
TC10 2
E 7 E
11
3
8
12
4
F F
a Data 19.03.04 Loc. Inst.
b Disegn. L.A. Descr. pag. Dis. N. 960A436 Pag. 1
c Segue Pag. 2
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1 2 3 4 5 6 7 8
3/a XS1
A 2 A
2/a
1
10/a
3
11/a
X1 X1 X1 X1
13
15
4
3
1 5 21
B KA11 QM10 P SQ13 SQ12 B
/1.E6
9 /1.B2 22 ST10 SP10
14
16
X1
4
2
+/a
5
7/a
6
3/a
6/a
C 9 C
9/a
7
5/a
X1 X1 X1 8
5
9
X1
13
YV14 YV13 YV12
HL11 KA10
RED /2.E5
PE
14
PE
PE
D PE D
PE
PE
/a
10
KA10 PE
/2.D5
5
9
1
6
10
CLOSED FILTER 2
E P E T S Y S T E M SUCTION CIRCUIT CLEANING 7 E
11
3
/1.B6
VACUUM VACUUM 8
12
G E N E R A L SELECTION SELECTION 4
SUCTION VALVE VALVE
M U L T I - S T A T I O N
(EMERG. OFF) (EMERG. ON)
F F
a Data 19.03.04 Loc. Inst.
b Disegn. L.A. Descr. pag. Dis. N. 960A436 Pag. 2
c Segue Pag. 3
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ICO LOADING BLOWER Revisione REV.4 * 11.01.05 * S.Z. Tot. Pag. 9
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1 2 3 4 5 6 7 8
A 1) PE (PG7) A
XS1 2) M10 (M25x1.5)
3)
2 6 7 4) ST10 (PG9)
40
G/V 4mm² 5) SP10 (PG9)
GROUND FRAME
TERMINAL M6 6) YV13 (PG9)
7) YV14 (PG9)
85
L=200mm 1 4 5
65
75 90 130 40
B B
QS1 FU2
90
HL10
KA10
KA11
FU1
QM10
C QS1 C
HL11 PE
400
350
400
X1 TC10
KM10 PE
D D
XS1
=
E E
F F
a Data 19.03.04 Loc. Inst.
b Disegn. L.A. Descr. pag. Dis. N. 960A436 Pag. 3
c Segue Pag. 4
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A A
T E R M I N A L S T R I P
X 1
B B
10
11
NUMBER OF CONDUCTOR
+
3
9
10
13
14
15
16
1
8
9
2
6
7
C C
ST10 SP10 YV14 YV13 YV12 SQ13 SQ12
D D
E E
F F
a Data 19.03.04 Loc. Inst.
b Disegn. L.A. Descr. pag. Dis. N. 960A436 Pag. 4
c Segue Pag. 5
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b Disegn. L.A. Descr. pag. Dis. N. 960A436 Pag. 5
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b Disegn. L.A. Descr. pag. Dis. N. 960A436 Pag. 6
c Segue Pag. 7
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D D
NOTA : (*1) CODICI PARTI RICAMBIO DA RICERCARE NELLA SEZIONE MECCANICA DEL MANUALE.
SPARE PARTS CODES TO BE FOUND IN THE MECHANICAL SECTION OF THE MANUAL.
DIE ERSATZTEILCODENUMMER SIEHE MECHANISCHER TEIL DER BETRIEBSANLEITUNG.
CODE DE LA PIECE DE RECHANGE A RECHERGER DANS LA PARTIE MECANIQUE DE CE LIVRET D'INSTRUCTION.
LOS CODIGOS PIEZAS DE REPUESTO TIENEN QUE BUSCARSE EN LA SECCION MECANICA DEL MANUAL.
OS CODIGOS DAS PECAS SOBRESSALENTES DEVEM SER PROCURADOS NA SECAO MECANICA DO MANUAL.
E E
F F
a Data 19.03.04 Loc. Inst.
b Disegn. L.A. Descr. pag. Dis. N. 960A436 Pag. 8
c Segue Pag.
Rev. Modifica Data Nome Verif. U F F I C I O T E C NProg.
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1 2 3 4 5 6 7 8
A
Project: 960A506 A
Order:
B B
Alimentazione : 400V/50Hz ; 380V/60Hz ; 460V/60Hz/3F
Supply:
Contents:
Auxiliary circuit :
Potenza installata : Max. 13,5kW
C Installed power : C
Peak current :
D D
Protezione consigliata : Max. 50A aM
Recommended protection :
Max. sezione cavo alimentazione : Flex cable : 16mm²
Rigid cable : 35mm²
Maximum section supply cable : Bus bar :/
E E
F F
a Data 18.05.07 Loc. Inst.
b Disegn. S.S. Descr. pag. Dis. N. 960A506 Pag. 0
c Segue Pag. 1
Rev. Modifica Data Nome Verif. UFFICIO TECNICO Prog. LOADING BLOWER Revisione REV.0 * 18.05.07 * S.S. Tot. Pag. 7
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
PE
L3 1L3 17/r
2 4 6
5
A A
L2 1L2
3
L1 1L1
1
FU0
QS1
max.50A aM 12 14
1 3 5
QM10 1 1 KA10
CLIENTE FU1 FU2 /2.E5
CUSTOMER / PIOVAN 2A aM 1A 11
QM10 I> I> I> 2 2
PIOVAN 13 14 2 4 6
B /2.B5 B
21 22
1W10
1V10
1U10
16/r
18/r
1 3 5
KM10
/1.E6
2 4 6
C C
15/r
W10
U10
V10
6mm² RC10 X1
A1 A1
14/r
KM10 KA11 HL10
/1.E6 /1.E7
480V 230V A2 A2 WHITE
U V W PE X2
D 460V D
M10 M
3~ 400V
230V 0V 19/r
24V
12V KM10 KA11
/1.D6 /1.D6
1 2 14
11
3 4 12
0V 0V /1.C3 /2.B5
5 6
TC10
E E
F F
a Data 18.05.07 Loc. Inst.
b Disegn. S.S. Descr. pag. Dis. N. 960A506 Pag. 1
c Segue Pag. 2
Rev. Modifica Data Nome Verif. UFFICIO TECNICO Prog. LOADING BLOWER Revisione REV.0 * 18.05.07 * S.S. Tot. Pag. 7
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1 2 3 4 5 6 7 8
4/a
XS1 4
3/a
A XS1 3 A
5/a
XS1 5
X1
5
12 14
KA11
/1.E6
11
X1 P
3
SP10
B B
13/a
PE
X1
1
13
QM10
/1.B2 14
BT10 1/a
XS1 1
2/a
C 2 C
XS1
6/a
XS1 6
9/a
XS1 9
7/a
XS1 7
X1 X1 X1 8/a
6
7
9
XS1 8
D D
YV14 YV13 YV12 A1
KA10
/2.E5
V14 V13 V12 A2
PE
PE
PE
10
10
10
F F
a Data 18.05.07 Loc. Inst.
b Disegn. S.S. Descr. pag. Dis. N. 960A506 Pag. 2
c Segue Pag. 3
Rev. Modifica Data Nome Verif. UFFICIO TECNICO Prog. LOADING BLOWER Revisione REV.0 * 18.05.07 * S.S. Tot. Pag. 7
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A 1) PE (PG7) A
2) M10 (M25x1.5)
3)
4) BT10 (PG9)
G/V 4mm²
GROUND FRAME 6 7 5) SP10 (PG9)
TERMINAL M6 XS1 2 6) YV13 (PG9)
L=200mm 1 4 5 7) YV14 (PG9)
B B
300
75
X1
FU2
KA10
KA11
QS1
85
HL10
TC10
PE
10
QS1
9
4
/
C C
380
80
10
10
KM10
7
1
QM10
FU1
X1
PE
BT10 / YV13
D D
XS1
SP10 YV14 YV12
LINE PG29
E E
F F
a Data 18.05.07 Loc. Inst.
b Disegn. S.S. Descr. pag. Dis. N. 960A506 Pag. 3
c Segue Pag. Legend1
Rev. Modifica Data Nome Verif. UFFICIO TECNICO Prog. LOADING BLOWER Revisione REV.0 * 18.05.07 * S.S. Tot. Pag. 7
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
E E
F F
a Data 18.05.07 Loc. Inst.
b Disegn. S.S. Descr. pag. Dis. N. 960A506 Pag. Legend3
c Segue Pag.
Rev. Modifica Data Nome Verif. UFFICIO TECNICO Prog. LOADING BLOWER Revisione REV.0 * 18.05.07 * S.S. Tot. Pag. 7
1 2 3 4 5 6 7 8