operating manual multi-cooler simpson

OPERATING INSTRUCTIONS - SIMPSON MULTI-COOLER ___________________________________________________________________

___________________________________________________________________ Simpson Technologies GmbH www.simpsongroup.com Sennweidstrasse 43 Phone ++41 41 711 15 55 CH-6312 Zug/Switzerland Fax ++41 41 711 13 87 j:\winwdat\tech_doc\BA\2002274\MC150E00108 - 1 - 12.08.10

Table of contents Customer : Fundiciones Garbi S.A.

B de Muntsaratz 33 Crta Abdadiano-Elorrio Aprdo. De Correos 4 ES-48220 ABADINO-BIZKAIA Machine Type : Multi-Cooler MC - 150 Machine No. : CHMC150-108 These operating instructions cannot fullfil their purpose, if they are put into a cupboard. The instructions should always be available for the people who work with the cooler. For this reason we are sending you several copies. If you have any requests or orders for spare parts, we kindly ask you to state the above-mentioned machine number. This will allow us to serve you more efficiently. We cannot accept any claims for compensation for damages caused by incorrect manipulations by the user. It is prohibited to copy these instructions or to make them accessible to other people without our consent, according to the regulations of copyright.



0 Table of contents

1 Description of Multi-Cooler

2 Acceptance Certificate

3 Accident prevention

4 Erection

5 Commissioning

6 Operation

7 Maintenance and lubrication

8 Trouble shooting

9 Disassembling for transport

10 Spare parts

11 Drawings

12 Commercial parts


___________________________________________________________________ Simpson Technologies GmbH www.simpsongroup.com Sennweidstrasse 43 Phone ++41 41 711 15 55 CH-6312 Zug/Switzerland Fax ++41 41 711 13 87 K:\WINWDAT\Tech_doc\BA\MC150\CHMC150-108\MC150E01108.doc - 3 - 12.08.10

1. DESCRIPTION OF MULTI-COOLER

1.1. Theory of Operation Hot Sand - what is it ? A system sand returned to the muller for reconditioning with a temperature of 71 C or greater is considered to be excessively hot sand. A return sand in the temperature range of 49 C to 71 C is hot enough to demonstrate inconsistent properties during mixing and is very difficult to control. Studies have shown that hot sand can affect virtually every major operation within the foundry production line. To best understand the full impact of this problem requires a careful study of what causes hot sand, what happens in a foundry with hot system sand, and what benefits can be expected by controlling sand temperatures to 49 C or below. Where does hot sand come from ? In a regenerative green sand system the composition of the sand mixture is formulated to meet the requirements of the moulding method and type of casting to be manufactured. The typical system sand consists of varying percentages of sand, clay, organic additives, and water. The system muller and moulding machine processes this mixture into a finished mould. To form a casting, molten metal is then introduced to the mould, and in the process, extensive damage occurs to the mould material (the green sand mixture).The damage that occurs (heat is the primary concern for the purposes of this discussion) will vary according to the location of the material in the mould. As molten metal is poured into the mould, the sand grains expand in size by more than 10%. During this time of expansion, some of the sand grains will experience thermal shock and crack apart. The effect of this shock is the most severe at the mould/metal interface and diminishes as you move away from the mould face. As the sand grains at the mould/metal interface are maintained at a high temperature for a period of time, they can go through a physical modification. The clay additives in the green sand mould lose their combined water and structure. At this point the clay has lost its plasticity and cannot be regained by water addition. Calcium bentonite is destroyed at a temperature of 455 C and sodium bentonite at 620 C. The water in the mould evaporates as the temperature in the sand mixture exceeds 100 C, until all the free water has evaporated. Some of the water that has evaporated is carried through the mould with hot air and condenses in a layer behind the mould face. As a result of this overall process, the green sand mould now consists of many layers of sand with properties ranging from the very hot, hard, and brittle mould face to the relatively cool, wet, and plastic layer at the mould back. The sand will now experience shakeout and re-enter the sand system segregated in surges of sand with vastly different properties.



Perhaps the most important consideration and most often ignored physical law governing the cooling of foundry sand has to do with the rate at which heat will flow out of sand grains. The rate of heat flow is limited by the thermal conductivity of the material through which the heat must flow (in this case, silica), and by the temperature differential existing between the sand grain center and its surface. No one should make the mistake of believing that because sand grains are small heat removal can be accomplished almost instantaneously, if the method of heat removal is extremely efficient. The subject of heat flow in sand grains is too lengthy and complex a problem for a full discussion here. At best it would be an empirical solution based on the assumption that sand grains can be considered spheres of silica, and a host of other simplifications. Let it suffice to say that many technicians have run high-speed cooling tests on sand to achieve a temperature of, say, 38 C on discharge from his cooling device, only to find the temperture of the sand had risen to 48 C or 49 C a minute or so afterward. What happened was that the thermocouple or thermometer could only measure the cumulative effect of a multitude of sand grain surfaces. The insides of the grains were still hot and it took more time for heat to flow out of the grains to the gain surfaces. To reduce the temperature, the heat must be transferred from the sand grains to another media. The media chosen must be disposable without creating atmospheric pollution and must be readily available at low cost. Air and water vapors fulfill these requirements provided both are free of solids when discarded. To achieve heat transfer it is required that both the air and water come in physical contact with as many sand grain surfaces as is practical. The water and air must be intimately mixed with the sand grains and the contact time must be extended to allow sufficient time for heat flow from the center of the sand grain to its surface where the heat exchange takes place. As the water surrounds the sand grain surface, heat is transferred to the liquid film, raising the film temperature to the surface temperature of the sand grain. As the water film temperature rises the molecular activity of the liquid increases causing some of the water molecules to achieve a vapor state. In so doing a higher level of energy is inducted in the vapor water molecule than existed as a liquid bound molecule. This phenomena results in a vapor pressure development. Whenever a liquid (water) is evaporated, assuming constant pressure (isobaric), heat must be supplied from some source. In this case the sand grain surfaces are the source. The higher the temperature the higher the vapor pressure of the water. If the surface temperature of the sand grain is high enough (above 100 C) the water boils because the vapor pressure then exceeds the pressure of air pressure of air atmosphere above or about it. Below 100 C temperature the rate of evaporation is reduced, but continued evaporation at a slower pace does occur. This makes sand cooling below 100 C possible. It should be noted that the lower the temperature of the heat source the slower the heat removal process becomes. Examination of a vapor pressure curve clearly shows the difficulty of cooling below 52 C by the water evaportive process under normal atmospheric temperatures and pressures.



Besides this basic explanation of heat generation, a sand system can also gain heat from rapid sand system turnover, low sand to metal ratios, or simply high ambient temperatures. Sand cooling and the laws of physics. The total amount of heat to be removed from the foundry sand is a function of several factors: A) The hot sand temperature initially; B) The desired temperature of the cooled sand; C) The thermal capacity of the sand; D) The total weight of the sand to be cooled. Whatever method of cooling is selected, remember: The cooling of foundry sand by evaporative means must, and does, follow the laws of physics. These are the inescapable laws that all evaporative cooling units must obey. It is universally agreed in the foundry industry that using water evaporation for cooling of foundry sand is still the most economical method yet devised. One pound of water forms one pound of water vapor. For each pound of water evaporated, approximately 1000 BTU of heat are removed from the sand. To calculate the total heat which must be lost to achieve the desired cooling, the following formula may be used: Q = (T1-T2)(c)(m) Where: Q = Heat expressed in British Thermal Units (BTU) T1 = Initial Sand Temperature (F) T2 = Final Sand Temperture (F) c = Thermal Capacity (BTU/lb./F) approximately 0.19 for silica sand m = Mass in pounds (lb) For example, to cool 1 ton of sand/minute from 300 C to 100 C requires the removal from the sand of (300-100)(0.19)(2000)=76,000 BTU per minute or roughly the evaporation of 76,000 BTU/1,000 BTU/lb. = 76.0 lb. of water per minute.



It is not enough that the water vapor be formed, it must also be removed from the environment so further vapor will form. To do this it is necessary to flush the vapor from between the sand grains. This is accomplished by the use of air. By mechanically fluidizing the sand mass with continuously changing air, the water vapor being formed is flushed away with the fluidizing air. The lower the moisture content of the fluidizing air, the more effective the cooling process since the air molecules themselves are capable of heat absorption as their temperature rises. Low temperature, low relative humidity fluidizing air will more effectively cool the sand in the same exposure or treatment time. Air alone, at the quantities usable, will not be sufficient coolant except under very long sand to air exposure times. The Multi-Cooler achieves maximum Q (kJ) removal in the least space and at the least cost, under reproducible and controllable conditions.

1.2. Description Simpson Multi-Cooler The Simpson Multi-Cooler is a continuously working sand cooler for foundries. With the help of air and water the used, hot sand is being cooled down to temperatures acceptable for foundry applications and at the same time water is added until the sand reaches a determinated humidity Due to its working principle the Simpson Multi-Cooler not only cools, but also homogenizes the sand to a high degree, thus facilitating the subsequent mixing of the sand. Before the exhaust air reaches the filter it passes through a cylone. The residues contained in the cyclone have to be brought to the discharge belt in order to put the still usable fines back into the sand system. Mixing Section - Two counter-rotational heads support a total of eight plows (mixing blades) four plows to each head. The purposes of the plows are multiple. They must move the sand from the charge point to the discharge point. During the movement toward discharge the sand is actively agitated to cause wetting of the sand grains as the water is distributed. Since the incoming sand is of non-uniform temperature and moisture content, it is essential that the sand does not have a straight line conveyance to discharge. The counter rotating plows will constantly back-blend, averaging the sand condition. The plows must constantly move the sand furthest removed from the cooling air supply into contact with the incoming air (entering from the walls of the container). The plows must keep the sand loose so the incoming air can fluidize the mass and penetrate between the sand grains to flush away water vapor. Air System - The cooling air supply is obtained from a separate motor driven fan. The air is introduced into a plenum chamber behind the vessel's inner wall. As the ever-changing sand sweeps over the panel surfaces, the air purges the sand of the moisture vapor.



As the warm, moisture-laden air leaves the sand, it moves toward the top of the dust hood covering the cooler. Upward air flow is maintained because the top is exhausted to produce a slight negative pressure within the hood. The exhaust air capacity must always exceed the inlet air by a factor large enough to handle the heat expanded air plus the generated water vapor. Adjustable atmosphere dampers are engineered into the system to correctly balance the supply air with the exhaust air. After the warm, moist air leaves the hood of the cooler, any solid particles coarser than 120 mesh (approx. 125 microns) are removed by an air exhaust chamber (sand trap or cyclone) generally located directly over the dust hood and/or discharge area. The discharge of the captured solids is continuous back into the sand system. After the cyclone, the air and water vapor are directed to a dust collector before exhausted to the atmosphere. Discharge Door - A self-adjusting door keeps the discharge rate equal to the sand feed rate and keeps the discharge sand properties within specified levels. The discharge door is actuated by an actuator which modulates between open and closed. This modulation is established by a sensing loadmeter connected to the Multi-Cooler's drive motor. It is readily adjustable to maintain a set percentage of the connected horsepower. This control also maintains a desired volumetric sand level in the Multi-Cooler. Moisture Control - A variable addition of water input will be called for dependent on the rate of sand feed and the temperature of the incoming sand. It is most important that the moisture content of the sand be maintained at a level which will assure sufficient water for cooling with some measure of residual moisture in the sand at discharge. The controller furnished with the Multi-Cooler is of the electrical conductivity type. It is a simple device which opens a water solenoid valve in one, or all, of three water addition manifolds when the water content of the sand falls below a selected level. It regulates the water valve as long as the correct water content is established and maintained. Normally, moisture is 1.5% to 3% at discharge.

___________________________________________________________________ Simpson Technologies GmbH www.simpsongroup.com Sennweidstrasse 43 Phone ++41 41 711 15 55 CH-6312 Zug/Switzerland Fax ++41 41 711 13 87 J:\WINWDAT\TECH_DOC\BA\MC150E02108 -8-

2. C E R T I F I C A T E O F I N S P E C T I O N Customer: Fundiciones Garbi S.A.

B de Muntsaratz 33 Crta Abdadiano-Elorrio Aprdo. De Correos 4 ES-48220 ABADINO-BIZKAIA Type of machine: SIMPSON Multi-Cooler MC-150 No.: CHMC150-108 Verifications made: 1. Mech. perfection: According to the specifications and drawings o.k. 2. Weld seams: According to the drawings and the relevant DIN Standards o.k. 3. Painting: One shop and one finishing coat with RAL 6002 (leaf green) o.k. Drive guard RAL 1023 (traffic yellow) 4. El. equipment: All functions simulated with success at manufacturer's place o.k. 5. Completeness: According to the Bill of Material o.k. Remarks: Inspection o.k. Inspection partly o.k. For divergences pls. refer to separate report attached Inspection not o.k. For defects pls. refer to separate report attached Delay for elimination of defects: ............................................................... The guidelines for tests and verifications made in order to establish this certificate of inspection are outlined in the Simpson Check List for fabrication control. Place and date: Inspector(s): ................................................ ............................................................ Subcontractor: ...........................................................

___________________________________________________________________ Simpson Technologies GmbH www.simpsongroup.com Sennweidstrasse 43 Phone ++41 41 711 15 55 CH-6312 Zug/Switzerland Fax ++41 41 711 13 87 J:\WINWDAT\TECH_DOC\BA\MC150E02108 -9-

EG Declaration of conformity

Pursuant EG-Machine Directive 98/37/EG, Appendix II, sub. A

Manufacturer: SIMPSON TECHNOLOGIES GmbH, Sennweidstrasse 43 6312 Steinhausen/ Zug-Switzerland herewith declare, that the following machine: Model: SIMPSON MULTI COOLER Type: MC-150 Serielnumber: CHMC150-108 is designed and produced in accordance to EG-Directive 98/37/EG. The following harmonised standards are applied: EN ISO 12100-1 2004 Safety of machinery Basic concepts, general principles for design,

Part 1: Basic terminology, methodology

EN ISO 12100-2 2004 Safety of machinery Basic concepts, general principles for design,

Part 2: Technical principles and specifications EN ISO 14121-1 2007 Safety of machinery Risk assessment,

Part 1: Principles

Zug, 15.06.2010.. city, date signiture Name and function of the signatory: Christian Lemke, Engineering manager Simpson Technologies GmbH, Steinhausen, Zug



3. ACCIDENT PREVENTION Before operating and/or performing any maintenance or repair on any Simpson Technologies Corporation designed and/or manufactured equipment, it is required that all personnel have read and understood the entire operation and service manual. If any questions exist, you must contact your supervisor or Simpson Technologies Corporation before taking any action. If properly operated and maintained your Simpson Technologies Corporation supplied equipment can provide many years of faithful and safe operation. Please follow all recommended safety, operating, and maintenance instructions. Note further that the introduction of any non-Simpson Technologies Corporation manufactured and/or approved parts to the equipment may create a hazardous situation. Never alter the equipment without prior consultation with Simpson Technologies Corporation.

3.1. Lockout: Tagout System Procedures Prior to any maintenance (routine or otherwise) or repair of equipment, a safety procedure should be established and maintained. This procedure should include the training of personnel, identification and labeling of all equipment which is interlocked mechanically, electrically, through hydraulics, pneumatics, levers, gravity or otherwise, and listing of established lockout procedure on each piece of equipment. This listing should be permanently attached to the machinery in a prominent area. The form at the end of this section should be used as an example of a listing that might be utilized. This form could be copied, the information filled/completed, and then sealed in a clear plastic laminent before being attached to the equipment.

3.2. Operation Never enter the machine while it is operating. Never operate this equipment in an application other than originally intended or in any manner that exceeds the original design parameters.

3.3. Maintenance and Repair - Z.M.S. Any lubrication, cleaning or repairing may only be carried out when the machine is not running. Any calibration, rewiring or programming changes may only be carried out when equipment is not running. Cleaning doors, peepholes and protection devices should not be opened or displaced while machines or motors are running.



Whenever performing any type of maintenance or repair, whether in the form of cleaning, inspection, adjustment, mechanical or electrical maintenance, the equipment must be rendered into Zero Mechanical State (ZMS). ZMS can be accomplished by:

3.3.1. Notify others, such as machine operators, supervisors, or workers in hidden areas, that the machine will go into ZMS. 3.3.2. Identify all energy sources, such as electrical circuits, motors, hydraulic, pneumatic, or gravity systems. 3.3.3. Neutralize all energy by turning off all electrical power, blocking movable parts, venting air pressure, bleeding hydraulic lines, etc. 3.3.4. Lock out all power in the off position and secure by attaching locks to all switch boxes, valves, or controls and tagging them with warning signs. Check again to be sure others who are nearby are aware the machine is in ZMS. Test machine by pushing buttons, operating valves, testing electrical circuits, etc. to make sure that no part of the machine could move unexpectedly. "LOCK OUT and TRY OUT". 3.3.5. After termination of any calibration, rewiring or programming changes, do not forget to affix again or close doors and other protection devices. 3.3.6. Before the machines are put into operation again after cleaning, repair and similar work has been completed, ensure that no-one is still in the danger area. If possible, use acoustic and visual signals to announce that the machines are about to be put into operation again.

Note: For all Simpson Multi-Coolers, a dusthood is included as part of the equipment. The dusthood is not only an integral part of the Multi-Cooler, but also serves as a safety device covering the top of the equipment and must be in place when operating.

For further instructions concerning the security read also the instructions under register 12: Commercial Parts.



3.4. LOCKOUT: TAGOUT SYSTEM CAUTION: Servicing or maintenance is not permitted unless this equipment is isolated from all hazardous energy sources. This is the exclusive reponsibility of designated "Authorized Employees" (**see listing at bottom) who must follow the complete "Lockout/Tagout Procedure" as published by the company. This sheet is limited and abbreviated. It must not be considered a substitute for the company's complete procedure:

3.5. LOCKOUT: TAGOUT DATA SHEET For Equipment No. CHMC150-208 Equipment Description: _______________________________________________________________________________ _______________________________________________________________________________ HAZARDOUS ENERGY

ISOLATING DEVICES

CONTROL DEVICES (Check)

Type

Magnitude

Type

Location

I.D. No.

Lock

Tag

Both

Additional Measures (See Below)

* ADDITIONAL SAFETY MEASURES (Refer to Table Above): _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ ** AUTHORIZED EMPLOYEES. Only the following are authorized to undertake the Lockout/Tagout Procedure on this equipment:


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4. Erection The SIMPSON Multi-Cooler has to be mounted and levelled according to the Foundation Plan (see Register 11) on a levelled ground floor or steel structure platform. We recommend to prepare proper steel plates according to fig. 1 to allow an easy fine adjustment with the adjusting screws provided. Place these plates according to the dimensions on the Foundation Plan. fig. 1 Preparing the cooling chambers for mounting.

4.1. Fix the sealing tape delivered on the flange of one cooling chamber half. Watch carefully that on both pressure chamber openings the tape overlaps to make sure to have the flange endlessly sealed. This protects you from loosing air after both cooling chamber halves are mounted together.

4.2. Mounting of the cooling chamber halves. Place one cooling chamber half on the foundation spots prepared. Warning: To move the cooling chamber halves please only use the suspensions provided (see fig. 2). After you placed one cooling chamber half move the other carefully until the flanges of both chamber halves are together. Make sure the leading bolts move into the matching hole. Connect the chamber halves with the corresponding screws. fig. 2

Hilti shear connector

suspensions



4.3. Levelling of the cooling chamber. Use a bubble level on the cooler chamber bottom to level the cooling chamber. With the help of the adjusting screws on all cooler supports shift the distance in-between cooler supports and foundation. The mounting material required to fix the cooler on the foundation is not delivered by us. We recommend to use (HILTI) anchoring screws and nuts, if you mount the machine on a concrete foundation. If the machine is placed on a steel structure, just take ordinary screws, washers and nuts.

4.4. Drive system. 4.4.1. Mounting of the tension rails and motor

Place the tension rails in the right position according to the foundation plan (see Register 11). Then mount the motor on the rails and improve the alignment between Start-up coupling and V-belt sheave. If the alignment is O.K. the tension rails has to be fixed with anchor bolts to the ground. 4.4.2 Mounting of the V-belts Move the Motor on the tension rails completely in a front position close to the cooler, then mount the V-belts on Start-up coupling and V-belt sheave and tensioning the V-belts according to the disciption in Register 5, Item 5.2

4.5. Preparing the crossheads for mounting of the intermediate shaft. By turning the gear box inlet shafts you are able to move the crossheads into the correct position as shown under Register 5, Item 5.3.1.

4.6. Mounting of the intermediate shaft.

To mount the intermediate shaft and the 2 lamella packages, use the instruction and maintenance manual of the steel coupling to be found under Register 12.3.

4.7. Checking the gear boxes.

On both gear boxes you have to replace the oil filling screw by the special deaeration screws (see thereto also instructions in the SEW Manual, Register 12.4.). Make sure that the oil level is visible in the corresponding oil viewing glass. If not, fill it up before you mount the deaeration screw. Check all fixing screws in-between gear box flange and support flange as well as support flange and cooling chamber bottom flange. Make sure they are all tightened. Also control the torque support fixed on the gear box and on one cooler support leg.



4.8. Mounting of the cover hood. Fix the sealing tape on top of the cooling chamber flange. Make sure to have the endings overlapping so that no gap remains there. When placing the tape make sure that you do not cover the thread holes, which are provided to mount the cover hood. Also fix on 1 cover hood half the sealing tape on the vertical flange, which belongs to the second cover hood half. Place both cover hood halves on the cooling chamber. To lift the cover hood halves use only the suspensions provided (see fig. 3). Now mount the cover hood with the attached screws and washers. fig. 3

4.9. Mounting of the suction hood. Fix sealing tape on top flange of the cover hood. Make sure that you do not cover the thread holes to fix the suction hood. Lift the suction hood on the suspensions provided and place it on the cover hood. Fasten the attached screws.

4.10. Mounting of the suction flap. Fix sealing tape on both flanges of the suction flap. Place the flap on top of the suction hood and fasten it with the attached screws, washers and nuts.

suspensions



4.11. Assembly of outlet door. For better understanding please open Drawing No. 250-1509d in Register 11. 4.11.1. Mounting of the actuator Pos.10.

Attention: The supports Pos. 13, 14 are secured with tape. The bearing pins Pos. 11 are just loosely put into the actuator housing. If one of the supports Pos. 13, 14 with bearing pin Pos. 11 gets pulled out of the housing, hydraulic oil would disappear. Please be careful when removing the tape and push both supports Pos. 13, 14 in direction of the housing. Now fix both supports Pos. 13, 14 on the holder plate provided, Pos. 10, using the corresponding screws. Do not tighten the screws yet. 4.11.2. Connection between actuator and outlet door Remove now the pin Pos. 12 mounted on the outlet door Pos. 6. Move the cylinder end Pos. 16 in-between the supports provided on the outlet door. Push the lever on the opposite side of the actuator drive motor in direction of the control box on an angle of approx. 20. With this manipulation you unclutch the drive motor of the actuator. If the lever cannot be moved, turn the handwheel about 30. Now the lever should be movable until it hooks on. Now you can move the cylinder with the handwheel till the end of the cyclinder matches the holes in the supports of the outlet door. Fix now the pin removed, Pos. 12, with the splints Pos. 44. Then verify that the cylinder is parallel in-between the guiding rails of the outlet door. If so, tighten the screws on the supports Pos. 13, 14.



4.12. Mounting of the aerator The blower has to be positioned according to Foundation and general Layout Plan (Register 11). 4.12.1 Mounting of the radial fan Check whether the shock absorbers (fig. 4) are mounted on the blower supports. If not, screw them on the supports as shown on fig. 4. For mounting of the compensator be aware that both flanges be taped with sealing tape. Now screw one flange to the flange of the blower. Push the blower in direction of the inlet cooling chamber flange to the foreseen foundation place. Before fixing the blower to your foundation make sure that the elastic compensator is not under tension. Now screw the loose flange of the elastic compensator to the cooling chamber flange. At the end fix the radial fan to the ground with anchor bolts or screws depending on the floor . fig. 4 4.12.2 Mounting of the blower flap

Use sealing tape on both flanges before you screw the blower flap flange to the blower housing flange. Please make sure that now hole is covered with sealing tape. 4.12.3 Mounting of the silencer (optional) Now mount the silencer by setting the flange on the blower flap and screw them together. Check whether the protection grid is mounted on the open inlet side of the noise damper. If not, screw it on this location.

shock absorber

hex nut

flange



4.13. Mounting of the watering pipes. As shown in water piping drawing in Register 11, the three water pipes coming out of the water cabinet have to be fixed together with the corresponding ones installed in the cooler hood. Before you screw them together take the sealing rings placed inside the water dosing cabinet and place them in-between the fittings. To open the cabinet use the key attached to the hand valve.

4.14. Compressed air connections. Prepare piping to connect the magnetic valves to the main air stream (see Drawing in Register 11). For this connection it is possible to use hydraulic tubes or a flexible hose for compressed air.

4.15. Mounting of the sand indication flap. This flap has to be mounted on the feeding belt conveyor to the Multi-Cooler (see Drawing No.998-3500 in Register 11). To assemble the flap proceed according to the instructions under Register 5, Item 5.10.

4.16. Protection grids. The protection grids have to be mounted according to drawing layout drawing. The protection housing has to cover the drive clutch and the V-belts in a way that nobody can get access to it. Now the housing can be screwed on the cooling chamber support and to the ground floor. The protection grid has to be fixed on the opposite side of the protection housing using the foreseen threads in the cooling chamber supports. Note: As we estimate that the machine is placed on a closed floor there are no protection covers for cases where you would allow access from the floor side. Please secure such a situation with your owen built cover.

4.17. Installation of measuring transmitter Install the measuring transmitter according to Register 5, Item 5.14. The hoses have to be shortened so that they fit to the counter part. Warning: When cutting the hose make sure that you do not cut the insulation of the long electric cable inside the hose. Before fixing the hoses, the electric cables have to be pulled through the counter part and through the electrode. Now you can fix the pipe slips on all hoses. For the electric installation proceed according to the relevant manual Micomp UNI G91 in the electrical documentation.

4.18. Electrical installation. For the installation of the electrical connections in-between cooler control cabinet and sand cooler proceed with the instructions given in the electrical documentations.


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5. COMMISSIONING

5.1. Checks-up before comissining Before commissioning the machine, the following checks have to be carried out thoroughly: - Check the terminal points when laying the cables. - Check the links in the motor terminal box. - Check the earth connection. - Adjust the thermoblock to the nominal current of the motor. - Check the oil level in reducer (see instructions in manifacturer's service manual.) - Check the tension of the V-belt. - Adjust or check the plows according to the drawing. - Check the discharge door. - Check hood and cooling chambers (all screws tightened). - Test liquid and air supply on density. - Check that there are no tools left in the cooler. - Mount all protective devices like V-belt protection etc. After all these points have been thoroughly checked, the cooler can be put into operation. Direction of rotation of the cooler. - Check rotation of blower and cooler drive. - Check function of suction flap and blower flap.

CW = Clockwise CCW = Counter clockwise

CW CCWSand inlet

Sand outlet



5.2. Drive The Multi Cooler is powered by an electric drive motor and mounted on slide rail separately from the machine. Power transmission is from the drive motor by an adjustable start-up clutch and connected to the Multi Cooler by high transmission V-belts to the intermediate shaft. From the Multi Cooler V-belt pulley the transmission is split to both reducer by an aligned steel coupling. At the steel coupling, the revolution will be controlled by a speed sensing switch. This switch shut down the drive motor if there is any failure with the drive system. Important: The torque moment of the start-up clutch will preset by factory according to motor power Caution: During replacement of V-belts or steel coupling always check the right postion

of the plows, to avoid any collision. (see item 5.5.1)

5.3. V-belt drive The V-belt drive on this MULTI-COOLER uses high performance narrow V-belts. Common V-belts do not fit into the sheave grooves. Due to their smaller profiles, these V-belts have a higher flexibility and may not feel tensioned sufficiently. Observe the following points : - Never put new V-belts into sheave grooves nor bring them from one groove to the next, instead loosen motor on slide rails and shove it forward. - Tension of V-belts correctly according to following data. - After the V-belts are tensioned, check that motor shaft and drive shaft to reducer are parallel and the two sheaves are aligned with the straight edge. - Within the first 50 hours of operation, check the specified tension several times and retension if necessary. Periodical checks are necessary. - When one or more belts have become worn and are to be replaced, best practice is to replace the entire set with matched belts of the same type as originally furnished. Still usable belts can be assembled to one set. The proper tension can be checked easily. At the centre of the span between the two sheaves, apply the force P (see table) to one belt resulting in the deflection f (see table). For the particular drive of the MULTI-COOLER, the following data are applied:

P = ~70 N/V-belt fig.2 f = 20 mm X/1 = X/2

X

X/2X/1

fp



5.4. Installation and operation instruction for Steel-coupling 5.4.1. General announcement The arrengement of the coupling flanges is variable. 5.4.2. Assembly Attention to the plow arrengement, that everything is in the right position according to item 5.5.1. Start mounting with one plate pack between flange and bushing, use only the enclosed bolts and nuts. The second plate pack will be arranged inversely see annex Steel-coupling register 12.3. 5.4.3. Alignment Steel-coupling compensate deviation in position of the connecting axles. During alignement of the shafts, the offset in radial and axial direction has to be kept to a minimum. To fulfill this intention align the shafts by ruler in radial direction and by feeler in axial direction. By using a gauge the results can improved considerably. By using lineal and feeler multiple points at the circumference has to be checked By using a gauge the coupling has to be turned in 360 Picture A in fig. 3 shows the alignement by gauge. Picture B in fig. 3 shows the alignement ba ruler and feeler. Before start-up improve the alignement and fitting of the bolts again. fig.3 A B



5.5. Adjustment of plows The plows of the MULTI-COOLER fulfill two important tasks: - Movement of the mixing sand to obtain an optimum cooling effect and homogenized cold sand. - Transport of the sand to be cooled from the inlet chamber to the outlet chamber and back till the cold sand leaves the cooler. The plows are the parts mostly exposed to wear-out. In case of a crust of sand sticking to the bottom, it is necessarey to adjust the plows towards the bottom. The serviceable life of the plows depends mainly on the correct adjustment of same, because deposits of material on the base plate increase wear-out. Foundry sands show different tendencies of adherence. Mixtures of sand of coarse granularity and greater consistency adhere less, while fine, hot sand mixtures with little consistency stick to the base plate. To increase their serviceable life the plow edges, which are mostly exposed to wear- out, are equipped with welded hardmetal plates. These plates are sensitive to hits, and therefore the plows have to be handled with care. When mounting the plows they have to be to adjusted until a free space of approx. 10 to 15 mm remains between bottom and 3 to 5 mm remains hub. The adjustment of the plows has to be controlled frequently. Caution: Make sure that the plows in the right position to avoid any collision. (see item 5.5.1) Before activate the Multi-Cooler always turn the cooler manually until one revolution has been completed.



5.5.1. Adjustments of plows When assembling make sure that the intermediate shaft between the gears gets mounted after the crossheads, with the plows set in the direction shown on the sketch below.

CCW CW45



5.6. Discharge device The mixture is discharged through an outlet gate situated in the wall of the cooling chamber. The outlet gate is installed at one of the side walls of the cooling chamber. It runs on roller bearings. It is moved up and down by a lifting drive which is load-controlled. The control drive is fitted completely with a three-phase AC-motor and torque switches which restrict the lifiting power to a predetermined power thus preventing the spindle from blocking. W A R N I N G : The torque is adjusted in the factory. It must not be manipulated. The opening of the door which is load-controlled according to the drive is adjusted to the throughput quantity during the initiation. The maximum control angle of the door is secured by a lower and an upper limiting switch.

5.7. Installation Discharge Device 5.7.1. Electrical Connections The connection at the actuator has to be made corresponding to the local regulations and the connection diagram inside the switch box. The connection for the motor is made in accordance with the connection diagram inside the motor terminal box, resp. according to the pin accommodation plan in case of plug connection. Thereby tension and frequency have to be compared with the technical data sheet resp. with the data on the rating plate of the motor. 5.7.2. Operation Device for manual displacement. The handwheel is uncoupled during motor operation and must only be used when the motor is not running. Before moving the wheel the lever opposite the motor has to be pushed for approx. 20 degrees in the direction of the switch box (pls. see label with information). If there is a resistance the handwheel has to be turned for approx. 30 degrees. The lever then locks and the motor is uncoupled. Upon starting the motor it is automatically coupled to motor operation again. The lever jumps back. A manual switch over from manual operation to motor operation is not possible. First start. To check the correct sense of rotation of the actuator drive, place first the door in a half open position. Then press the button to open the door in automatic cycle to check whether the door is opening or closing. If it does not work the way as indicated on the button you just change the wiring of the to actuator motor.



5.7.3. Maintenance.

Every three months the actuator has to be checked for loss of lube. Only if there are large leakages you have to refill it until the cause of the leakage can be eliminated. CAUTION! In order to prevent overfilling, fill only with door completely open. 5.7.4. Door actuator limit switch adjustment Lowermost switch : end actuating direction I Medium switch : end actuating direction II Above positioned switch : discharge position For adjustment of the tripping cams use the holes to move the segments to the right position (Fig.5). To fullfill a switching operation, the actuator has to move from the outer circle to the inner circle. (fig.5). One pair of tripping cams actuate one switch. fig.5 5.7.5 Adjustment of the mechanical position indicator A positioning of the indicator could be easy align by continuously variable rotating of the pointer sheave. The right position of the pointer (end actuating direction I or II) can be verified by the vision panel in the actuator cover. fig.6

I

II



5.7.6 Schematic diagram to actuator fig.7

Remark: Rotating direction I = Motor right hand rotating for OPEN Rotating direction II = Motor left hand rotating for CLOSED (Line of sight: motor fan)

123

678

202122

242526

161718

111213

303132

Torgue switch for actuating direction I OPEN

Stroke switch for actuating direction I OPEN Signal switch I OPEN Signal switch II CLOSED Stroke switch for actuating direction II CLOSED Torgue switch for actuating direction II CLOSED Variable resistor I



5.8. Aerator 5.8.1. Installation. The Aerator must be, as much as possible, protected from dirt and humidity and be firmly fixed and aligned on a base of iron or concrete. 5.8.2. Mounting of drive parts on shafts: Rolling and plain bearings suffer with shocks and vibrations, i.e.: a) the ventilator wheel should be installed with a matching mounting tool by using the thread at the end of the shaft, b) when mounting the bearings avoid tilting. 5.8.3. Set into operation: The ventilator may only be put into operation in the direction in which the arrow on the casing points.

5.9. Function of the blower flap When starting the blower the flap is closed, to allow an easier start of the blower. The flap will also be closed, if no sand is fed into the cooler.

5.10. Function of the exhaust air flap This flap is interlocked with the blower flap to open and close. This is done to ensure that no fines are sucked out unnecessarily during a period in which sand stays for a longer time inside the cooler.



5.11. Damper Function: The damper is needed to allow a constant minus pressure inside of the cooler dust hood. Mounting: The flap is to be fixed so that the point of rotation of the pendulum flap stays in the upper part of the centre of the flap. In this position the damper can be fixed within the foreseen opening flange at the dust hood. Use screws. If no exhaust air is used by the cooler the pendulum flap stays vertical. The flap can only be tilted to the inside of the cooler hood. Adjustment: With counter-weights on the lever the minus pressure can be adjusted. Maintenance: Check weekly for free movement, if necessary remove sand and dust behind the flap



5.12. Sand flap Function: The sand flap indicates, whether there is sand on the belt feeder to the cooler, or not. Mounting: Both supports (Pos. 1+2) have to be screwed firmly to the support. The flap Pos. 3) is fixed with screws. The shaft has to be shortened on both sides to 5 mm. The flap itself does not touch the belt. The flap (Pos. 3) has to be shortened so that a gap of approx. 5 mm exists between flap and belt. Adjustment: When the flap is in a vertical position Pos. 5 is mounted to cover the proximity switch (Pos. 10). Maintenance: Check proximity switch weekly and clean the sensor surface.

310550

4

2

3

10

15,20 18

23,2515,20,

51

12,17



5.13. Measuring Contacter

Control screen INFORMATION MACHINE

The Measurment Contactor is part of the control screen Information Machine. For operating instructions and technical devices for measuring contactor, please refer to electrical documentation.



5.14. Measuring Transmitter to Moisture control system

Pos. 7tube

Pos. 6fexible tube counterpart

175

9

A

item 4

measuring transmitter

cover hood

item 4hex screw

cable

Pos. 7apipe slips

vertical shaft

item 5protective cap

Pos. 8tube to electrode

A

hose stem



5.15. Moisture control Moisture control is done by a moisture meter (Michenfelder), which makes sure that, according to the value measured, the solenoid valves in the water control box supply the respective quantity of water to the sand, which has to be cooled. The exact measuring band depends on the quality of sand and the final moisture degree desired. This will be adjusted by one of our specialists while putting the system into operation. The exact moisture content of the sand can only be adjusted when under normal operational conditions sand is fed continuously over a few hours. In order to add water the following steps must be fulfilled: a) Sand must be fed through a mechanical valve. This process is signalized by a control lamp in the door of the switch box. b) The measuring value must have gone over the contact mark "min." of the Sand level. (Measuring contactors in the device are installed at the door of the control box.). CAUTION! 4 x 1,5 shielded cables are to be used for the electrodes. 1 x 1.5 shielded cables are to

be used for the temperature adjuster. In any case the leads of the electrodes and temperature probes are to be installed in a separately cable tray.



5.16. Mounting and function controls 5.16.1. Fixation to the ground.

Are the tension rails of the motor and the feet of the machine firmly screwed to the ground ? 5.16.2. Steel coupling and lamella packages.

Are the V-belts fitted on the pulley ? The two reducer are joined by means of the Steel-coupling. Are the lamella packages fixed to the coupling and the corresponding bolts inserted and fastened with screws ? Above the Steel-coupling a support with an initiator is mounted. Make sure that the distance between Steel-coupling and cam of 10 mm is observed. 5.16.3. Checks to be made on the 2 reducer.

Can you see the oil level through the oil level indicating glass ? On top of both reducer there is a screw for aeration. Are these screws inserted ? If not, the aeration screws have to be fixed. 5.16.4. Check of water and air conduits.

Are all three water conduits, which lead from the water cabinet up to the hood, firmly screwed on ? Make sure that the hand valve on the water cabinet for the water supply to the cooler is closed. Are air conduits from the water cabinet to the valves of both flaps installed ? 5.16.5. Check of V-belts.

Are the V-belts properly fitted with the correct pretension ? Is the drive motor firmly screwed on the tension rails ? 5.16.6. Checks inside the cooler.

Water nozzles are placed on the sand inlet side of the cooler. These nozzles have to be adjusted to point between vertical shaft and cooler wall. Now the hand valve for water on the water cabinet has to be opened. No water must flow through the nozzles via the hood into the cooler, since the three solenoid valves are closed currentless. Should water flow into the cooler despite of that, check the solenoid valves. 5.16.7. Check of measuring transmitters.

A measuring transmitter is mounted on each cover hood half. Are the cables of the measuring transmitters with the probes fixed to the plow arms ? Is the hose from the measuring transmitter tightly attached to the vertical shaft with a hose-clip ?



5.16.8. Check of plow arms.

Make sure that the plow arms on both vertical shafts do not touch each other in the center of the cooler. For this check a second person is needed, who turns the V-belt pulley until the vertical shaft has made one entire revolution of 360. When doing this check pay special attention to the sense of rotation and keep it in mind. Turn the V-belt pulley so that the sand is pushed by the plows ahead of them. Check with the grease pump whether the vertical shafts are filled with grease. The grease has to emerge below the crosshead, between felt ring and vertical shaft.

5.17. Tests with auxiliary current. Set the SIMPSON Multi-Cooler in operation mode Manual 5.17.1. Check of the position of the flaps.

Do the four initiators on the blower- and exhaust flaps indicate the correct positions (open and closed) ? The button on the 5/2-directional valve has to be set on position 1. At the same time the following diodes should illuminate on the input card in the control cabinet. For the blower flap: E10.0 Flap open E10.1 Flap closed For the exhaust flap: E10.2 Flap open E10.3 Flap closed. 5.17.2. Checks on the discharge door.

Set the mode of operation switch for the outlet door to "manual". Open the outlet door by pushing the relevant button until the indicating lamp shows that the door is open. Check at the Multi-Cooler whether the door is really open. If the drive did not move the door into the desired position, change the drive wiring as the motor runs in the oposite direction. Close the outlet door by pushing the relevant button until the indicating lamp shows that the door is closed. Check at the Multi-Cooler whether the door is really closed. If the drive did not move the door into the desired position, change the drive wiring as the motor runs in the oposite direction. 5.17.3. Check of Sense of rotation of the motors.

The wheel of the blower motor transports air into the cooler. Verification of the sense of rotation only needs a short switching on resp. switching off of the drive motor. If the wheel moves in the wrong direction change the wiring.



5.17.4. Monitoring of speed (r.p.m.).

With an empty machine, i.e. drive motor is working without sand inside the cooler, following adjustments have to be made on the monitoring equipment of the speed (r.p.m.). Time for bridging-over start shall be set to 15 sec. Turn the potentiometer for impulse counting on the rotational speed control sensor until the two diodes indicates a green light while the drive is running. Is the setting (frequence) too low, you will receive the failure message "revolutions cooler" on the front plate of the control cabinet. Make sure that this is not the case. 5.17.5. Check of sand flap.

Is the plate of the sand flap in a vertical position, you will receive the failure message "No sand". In a vertical position the sand flap does not face the initiator. Only when the flap is tilted by the sand flow, the initiator will be covered and the message "Sand supply on" appears in the input card. The diode E9.0 is illuminated. 5.17.6. Check of water piping Below the cooler bottom is a panel containing the water control valves. In the inlet side of the cooler cover hood is the piping with water nozzles mounted. Check all for leakage. 5.17.7. Check of water valves.

To check the water valves open the maintenance doors on the cover hood. Open the main tap of the water conduit to the water cabinet. Check on the pressure reducer that there is water inside the conduit. This is the case if a certain water pressure is shown on the corresponding pressure gauge (manometer). Should the pressure surpass 4,5 bar, reduce it by turning the hand wheel on the pressure reducer. Now verify inside the cooler whether water enters or not. In case of no water running into the cooler open the hand valve in the water cabinet by half turn. Check again that no water runs into the cooler. Should there be water coming out of one or more of the water nozzles inside the cooler, it is necessary to check the solenoid valves inside the water cabinet, since one of them must be leaking. To find out whether the correct valves control the correct group of nozzles, watch the corresponding nozzles for fine, coarse and additional water inside the cooler. To operate the 3 water walves make following input: ? ? F4 F1, now are the keys F1, F2 and F3 are used for fine, coarse and additional water walves, to spray water into the cooler. Should the sequence of fine, coarse and additional water be incorrect, change the connection of the magnetic coils on the solenoid valves, so that the correct valves for fine, coarse and addtional water are controlled. Please see also diagram drawing in register 11 and refer to Electrical instructions chapter 9 Michenfelder moisture control system MICOMP UNI type G-91 page 8.



5.17.8. Check of limit switches. The doors of the hood are closed. The limit switch is checked with running drive motor. When opening the door of the hood, the drive motor should stop. 5.17.9. Check of humidity control unit. For checks and tests please see electrical documentation/ operating instructions, Register 9. When all checks have been executed a test run of the cooler can be made. Thereto the preselection switch of the operating mode ist set on "hand". To start the machine, all interlock signals must be present. Now you can start the machine as described under set into operation "Automatic". You will be guided by blinking keys to start first the blower motor and then the drive motor.


___________________________________________________________________ Simpson Technologies GmbH www.simpsongroup.com Sennweidstrasse 43 Phone ++41 41 711 15 55 CH-6312 Steinhausen/Switzerland Fax ++41 41 711 13 87 j:\winwdat\tech_doc\BA\2002274\MC150E06108 - 37 - 12.08.10

6. OPERATION

6.1. Safety circuit / Main switch The Sequence Safety Circuit / Main Switch is available for each Operation Mode Manual, Automatic 1 and Automatic 2.

1. Prerequisite Safety Circuit Emergency Stop OFF Cooler Doors Closed

2. Main switch "ON" Indicator Reset Button PNOZ Relais (E-Stop) is flashing

3. Reset Button PNOZ Relais (E-Stop) push Indicator Reset Button PNOZ Relais (E-Stop) is solid Indicator Control System ON is flashing

4. Main Contactor and Safety Circuit is on Indicator Reset Button PNOZ Relais (E-Stop) is off Indicator Control System ON is solid



6.2. MAIN SETTINGS Adjust following Main Settings corresponding Specification HMI 7.1 Main:

1. Operating Mode

6.3. SETUP Adjust following Setups corresponding Specification HMI 7.1 Setup:

1. Language Settings 2. Local Remote (only for Service) 3. Water Valve Setup

6.4. PARAMETERS GENERAL Adjust following Groups of Parameters corresponding Specification HMI 8.1 Configuration:

1. Configuration Machine 2. Parameter Machine 3. Parameter Process

6.5. PARAMETERS SAND REGULATION Adjust following Parameters for Sandregulation corresponding Specification HMI 8.4 Sand Regulation:

1. Parameters PID 2. Parameters Regulation 3. Parameters Scaling Equipement 4. Setpoint Sandlevel



6.6. OPERATION MODE MANUAL 1. The Prerequisite Safety Circuit / Main Switch corresponding Pos 6.1 is OK 2. Activate the Machine-Elements corresponding Specification HMI 8.2 Maintenance:

Maintenance Drives Blower ON / OFF Cooler ON / OFF Infeed Belt ON / OFF (Option) Discharge Belt ON / OFF (Option) Cyclon ON / OFF (Option) Saand Discharge OPEN / CLOSE Hydraulic Pump ON / OFF (Option)

Maintenance Valves Blower Flap OPEN / CLOSE Suction Flap OPEN / CLOSE Clutch OPEN / CLOSE (Option) Water Additional OPEN / CLOSE Water Coarse OPEN / CLOSE Water Fine OPEN / CLOSE

Maintenance Equipement Inspection ENABLE / DISABLE (Option) Humidity Control ENABLE / DISABLE Bentonit Control ENABLE / DISABLE (Option)

Local Mode Start Stop Cooler Start only for Service Stop only for Service



6.7. OPERATION MODE AUTOMATIC 1 1. The Prerequisite Safety Circuit / Main Switch corresponding Pos 6.1 is OK 2. The Prerequisite from External must be OK:

Suction System on Operation Discharge Belt on Operation Cyclon on Operation

3. START Multi-Cooler Local or Remote The Multi-Cooler is sequentially set into operation

Suction Flap OPEN Blower Drive ON Cooler Drive ON Blower Flap OPEN Cooling Air Control ON Sand Discharge Control ON Infeed Belt ON (External Signal)

Remarks:

Water addition kann only be effected, when following two points are fulfilled: a) The cooler is charged with sand b) The set sand level is reached

Check if the quantity of outgoing air is larger than the quantity of incoming air (see also position of pressure compensation flap)

Adjustment of sand level resp. sand outlet door in relation to nominal current consumption of drive motor. (Step by step control unit and measuring contactor see documentation of electrical controls.)

Adjustment of water addition by means of push button on the humidity control device, to obtain the required water content of the sand (see documentation of electrical controls).



4. STOP Multi-Cooler Local or Remote The Multi-Cooler is sequentially stopped

Infeed Belt OFF (External Signal) Emptying prodecure of Cooler is started Emptying prodecure of Cooler is finished Blower Flap CLOSE Cooler Drive OFF Blower Drive OFF Suction Flap CLOSE Cooling Air Control OFF Sand Discharge Control OFF

6.8. OPERATION MODE AUTOMATIC 2 1. The Prerequisite Safety Circuit / Main Switch corresponding Pos 6.1 is OK 2. The Prerequisite from External must be OK:

Suction System on Operation Discharge Belt on Operation Cyclon on Operation

3. START Multi-Cooler Local or Remote The Multi-Cooler is sequentially set into operation similary Automatic 1 Exepted the Sand Discharge Drive is OPEN / CLOSE manualy



7. MAINTENANCE AND LUBRICATION A machine working in an unfavourable environment can perform its function efficiently and at lowest possible cost only by virtue of a preventive maintenance program. A machine in contact with highly abrasive particles with binders and water is operating in such an environment. Its mixing components are constantly subject to gradual destruction by corrosion and erosion while its driving means must work continuously under hostile conditions. In addition, the machine must start and stop automatically under load. To suit production requirements the operation must continue for extended periods without shut-downs for maintenance. The Simpson Multi-Cooler is designed to be capable of operating efficiently and dependably in such an unfavourable environment. Experience has shown that it is. The design recognizes the need for periodic replacement of certain components particularly subject to extreme conditions. Provision for easily replacing these parts has been built into the machine. No machine, however, can operate in such conditions without a certain minimal, routine planned maintenance.

7.1. Preventive Maintenance It is recommended that a preventive maintenance program be set up in order to achieve maximum satisfaction from your Simpson machine. This program should include: Inspection of Machine Maintenance Records Adherence to Simpson Technologies Corporation's Maintenance Recommendations. Planned, scheduled, and performed maintenance based on the above factors. At the end of this section are sheets that list recommended inspections and procedures at specified frequencies. It is suggested that these sheets, modified to suit your maintenance experience, be reproduced for your preventive maintenance program. Maintenance procedures for the commercial components are described in the manufacturer's own maintenance manual. (See Section 12). Inspection of the equipment should be of two types: 1) Casual inspection by operators of the equipment, and 2) Planned inspections of specific components by maintenance personnel. Casual inspection may be defined as the reporting of any unusual noise, vibrations, or observed phenomena in the machine to the interested authorities. The frequency of maintenance for specific machine components in a given plant can only be determined through the compilation of records of maintenance performed under the given conditions. For example, plows wear faster in some plants than others due to variation in the abrasive quantities of the materials mixed. Maintenance experience under your operation conditions should be used to modify the maintence schedules recommended since the recommended schedules are based on an average of many plants and industries.



SAFETY. Before doing any maintenance work on the Multi-Cooler make certain that the starting equipment is locked-out. Review Section 3.

7.1.1. Wearplates Wearplates and walls should be cleaned of sand build-up daily and a parting oil or kerosene type release agent sprayed on the surfaces to retard rust and promote the easy movement of material throughout the mixer. 7.1.2. Plows The plows in the Multi-Cooler fulfill two important tasks: Moving of the mix to obtain optimum cooling action. Transport of the sand to be cooled from the inlet chamber to the discharge chamber and eventually to the discharge opening. The mixing plows are considered as being the main wearing part. If a layer of material should build up on the floor, the plows are too high and must be adjusted. Foundry sands have various sticking characteristics; some are self-cleaning, others are not. So, e.g., coarse sand mixtures of less humidity stick less on the base plate than fine, hot sand mixtures with less consistency. Service time of the plows is mainly determined by correct plow setting, since residues of material accumulated on the base plate foster wear and tear. When installing the plows, see to it that they are set with a minimum play to the base plate or the hub. Plow setting must often be checked. Since wear and tear does not occur uniformly, the best possible setting must be chosen. The plows, which are particularly prone to wear and tear, have been equipped with wear resistant hard facing to increase service life. This facing is not resistant to shocks and must, therefore, be treated with care.

7.2. Planned Maintenance. 7.2.1. Vertical Shaft Assembly The Vertical Shaft Assembly consists of a turret, vertical shaft supported by two taper roller bearings, lower seal assembly, and a crosshead that incorporates the upper seal assembly. The vertical shaft is connected to bedplate mouted reducers by means of a pin type coupling; or to the floor mount reducers by means of a grid type coupling. Lubrication of the vertical shaft bearings is made through the turret and relieved through the upper seal.



Prior to performing any inspection of the equipment it must be put into a Z.M.S. Follow the procedures for Z.M.S. in the Safety Chapter (Chapter 3).

A weekly inspection of the crosshead seal should be made, making sure that it is intact and that grease is observed between it and the turret after several pumps from a grease gun are made. A monthly inspection should be made of the end float in the vertical shaft. The endplay should be measured and recorded. To measure the vertical motion, a magnetic based dial indicator should be attached to the outside diameter of the turret with the indicator head in contact with the underside of the crorsshead. Pressure is then applied upwards to the underside of the crosshead by means of a jack or other suitable means. If motion in excess of 0.3 mm is measured, adjustment should be made. 7.2.1.1. Adjustment of Vertical Shaft The Cooler must be put into a Z.M.S. (Zero Mechanical State) condition by following the procedures in the Safety Chapter (Chapter 3). Remove crosshead cap. This will expose the vertical shaft adjusting nuts. These should be adjusted until a vertical endplay of 0,2 mm is measured and then firmly locked. Discretion should be used as to the maximum amount of endplay that is removed by adjustment before components are replaced. A record should be kept of any adjustment made. As you will see by studying the Turret Assembly drawing that is provided, here are several points where endplay can occur. Make sure that the rotating crossheads and the plows are in their proper relationship. If the mixing plows are not in the proper phase, mixing becomes concentrated in one half of the Multi-Cooler, which results in poor mixing and overworking one side of the unit. Watch for proper positioning of the crossheads whenever the couplings on the drive shaft have been uncoupled otherwise it is possible for two crossheads to collide and cause damage. 7.2.2. Crosshead The crosshead is mounted on the vertical shaft and rests on the upper bearing and thrust washer. The plow brackets and plow straps are bolted to the crosshead. Check bolts to see if brackets and straps are secure. 7.2.3. Starting Clutch The use of the starting clutch permits the starting and stopping under full load. Maintenance is mainly limited to an occasional check of complete oil filling of the hydraulics and inspection of wear of friction layers and bumpers.



7.2.4. Oil Filling Act according to the instructions given under Reg. 12, Annex 2 "Amolix starting clutch" 7.2.5. V-Belts V-belts should be checked for proper tension to avoid slippage and should be inspected for possible deterioration and wear. V-belts, when correctly installed, require minimum attention and maintenance. Coating with wax or similar products is damaging the belts and should under no circumstances be done. Belts furnished are matched sets to assure maximum performance. When replacements are necessary, be sure to use only V-belts of the same type as originally furnished and check always belt bottoming in sheave grooves. Make sure to replace always the complete set. 7.2.6. Sheaves The belt sheaves should be inspected for wear to the sidewalls. Belts should not be allowed to "bottom" or slip in the grooves thus resulting in a short wear life. Sheaves should also be checked for proper alignment. 7.2.7. Gear/Reducer Follow the instructions given in the attached manual from SEW regarding the check of the oil quality. Gear oil should be changed at least every 5'000 h. Make sure the proper grade of oil is used and refilled to the correct level at least once a week if necessary. For the type of oil see "Lubrication List" and fill to the correct oil level. 7.2.8. Motor Listen for any unusual sounds, possibly bearing failure. Grease at the recommended intervals. Check the condition of the cooling fan at the end bell of the motor. Make sure hold-down bolts are tightened. 7.2.9. Moisture control Checks necessary for an exact functioning of the water dosing device (see also MICHENFELDER-documentation under the documentation for electrical controls. 7.2.10. In general the electric and electronic components are maintenance-free. So, should any problems with the water dosing arise, the first step would be to ckeck all mechanical components, e.g. electrodes, temperature probes, solenoids, measuring transmitters and the periphery. 7.2.10.1. Clean the two revolving electrodes with a steel brush. Remove encrusted sand residues by hand or with a spatula every day. In case of any irregularities, always first check the electrodes for any cleaning wool, threds or similar object sticking to them. 7.2.10.2. Check the measuring transmitter ohmically once a month. To do so, proceed as follows: Put the cooler into operation. Do not fill it with material. Switch the water dosing device off. Disconnect it at the conduit box of the cooler and carry out the check as described in the operating



instructions of the Michenfelder-Control. The resistance must be constant and not higher than 5 Ohms. In case of irregularities the measuring transmitter has to be replaced. 7.2.10.3. The appliance itself may be checked anytime with its built-in measuring device. 7.2.10.4. Once a week, the 3 water valves must be checked. Therefor refer to Electrical manuals chapter 9 (Michenfelder moisture controls page 8) Make sure on the spot if water actually flows out of the respective nozzles. When the valves are turned off no follow-on water should be coming out of them. 7.2.10.5. The temperature probe which are placed in the exhaust hood has to be cleaned daily by hand and visually inspected. 7.2.11. Discharge device. Every three months the actuator has to be checked for loss of lube. Only if there are large leaks it is necessary to refill until the cause of leakage can be eliminated. 7.2.12. Damper. Check once a week for accumulation of dirt. Behind the pressure compensation flap there is a protective cover, which serves to prevent direct contact with the inside of the cooler and the plows. 7.2.13. Sand flap. The initiator has to be checked and cleaned once a month.



7.3. LUBRICATION POINTS

7

89

2

3

1

4

10

11

6



7.4. LUBRICATION LIST OILING OR QUANTITY LUBRICATIONS DESIGNATION LUBRICANT other PER POINT INTERVAL CHANGE POINT Typs NR. QUANT. _________________________________________________________________________________________________________________

1 2 VERTICALSHAFT GREASE KP 2 K 50 Gramm W -

2 2 GEAR/REDUCER SYNTH OIL see 100 L - 5000 H Mobil Glygoyle 30 Register 11.4

3 1 ACTUATOR SYNTH.OIL see 1,35 L - 2000 H Mobil Glygoyle 30 Register 11.6

4 1 LUBRICATOR OIL DIN 51502 0,045 L Inspection - N 3 E M ISO VG 3

6 2 BLOWER FLAP GREASE KP 2 K - Y -

7 2 EXHAUST FLAP GREASE KP 2 K - Y -

8 1 AMOLIX CLUTCH Hydr. OIL 0,225 L Inspection Mobilfluid 125 ISO VG 32 M

9 1 DRIVE MOTOR GREASE KP 2 K 100g - 12500 H

10 1 BLOWER MOTOR GREASE KP 2 K 60g - 800

operating manual multi-cooler simpson

Documents

hot system sand

sand mixture

return sand

sand temperatures

theory of operation

typical system sand

description of multicooler

multicooler mc