Chapter IV Installation
Warning——Safety for workers and machine:
1、Please select the level of the ground for installation , the installation site should not have ground vibration , electromagnetic interference, etc.
2、Before lifting, please check the firmness of the rings , be careful when lifting.
4.1 Preparation work before installation
We suggest that make adjustment of the installation site as required below before machine installation in order to avoid problems.
4.1.1 Requirement of installation location
Requirement of site and environment
1.The machine must be installed on a level surface. If additional support brackets are installed, they should be located according to the position of machine feet and fixed by set screws. No ground shaking should occur at installation site.
2.Installation should be made in well-ventilated places rather than places of low or high temperature, or with high humidity or many particulate matters.
3.Prevent it from interference of strong electromagnetism on site or in the vicinity, such as electric welding, high frequency transmitters etc.
4.Color sorter must have good grounding to avoid static electric. The material inlet and outlet that connect to the machine should make of metal and be well grounded, same as the dust sucking pipe.
5.All the welding work at the site should be finished before installing the machine.
Requirement of light
Don’t expose the machine to sunlight or light emitted from lighting equipment. But enough light for machine operation and maintenance is required.
Requirement of maintenance space
There should be enough space around the machine in order to facilitate the operation and the maintenance or inspection (for details please refer to the diagram4-3 of the top view of the machine installation), especially in front and rear. It is very important to leave enough space for replacing lamps as well as maintaining the components in the electric box. In terms of receptacle, sufficient space should be left to ensure disassembling of receptacles of accepted and rejected material. At the same time, special attention should be paid on leaving sufficient space to meet the maintenance requirements of ejectors.
Note----Enough space for unpacking and assembling machine and for lifting device operation is required temporarily.
4.1.2 Requirement of electric installation
1.A qualified electrician should ensure right connection of all air supply and power supply, and to make sure the machine is well earthed;
2.Basic grounding (in the location of power supply inlet) should be high-quality and pure electric grounding;
3.All parts of main machine should be grounded separately or by connecting to machine frame, The material inlet and outlet ,dust sucking pipes should be metallic and grounded separated from the main machine.
4.All conductors and devices nearby should be well grounded.
5.Grounded connection should never use live conductor(such as grounding zero line).
4.1.3 Requirement of machine power supply
1. Rated voltage supply range: 180~240V, 50Hz, single phase.
Absolute range: 180~265V,47~53Hz.
Voltage surge should between180~265V, otherwise machine would get damaged.
Power source be steady without spark.
2.Power consumption:
RS4: 1.8 kW(including heating system 0.8kW);
RS6: 2.9 kW(including heating system 1.2kW);
RS8: 3.5 kW(including heating system 1.6kW);
RS10: 4.2 kW(including heating system 2.0kW).
● Unstable voltage prevention
In order to make sure color sorter stable use, preventive measures below are suggested;
1.Install a high-quality AC power regulator which meet the power requirement of machine running between power supply and color sorter.
2. For the security of electricity providing and reliability of machine operation, high quality grounding connection is required. Grounding resistance should be as low as possible and should be less than 0.1 ohm. Every machine or machine group must have dedicated groundings.
● In order to make good grounding, following conditions are required:
1. Install effective grounding pole, and well connect grounding pole and ground wire.
2. Use low resistance grounding wire, and well connect grounding and machine.
3. All parts of machine should be well ground as well as AC regulator.
4. Grounding cable should be isolated from Zero line of power supply.
4.1.4 Requirement of compressed air
● Requirement of air pressure
1.The air inlet of the machine should be kept between 0.4-0.8 Mpa. It will affect the sorting accuracy if it is too low ,or it will damage the machine if it is too high.
2.Working air pressure during machine running must be between 0.25~0.3 MPa, lower than 0.25 would affect the sorting accuracy, higher than 0.4 will do damage to ejectors.
● Requirement of air supply location
About the distance between air supply device and color sorter, theoretically the closer the better, but consider the real environment and other reasons, please refer to instructions in chapter 4.8 as suggested.
4. 2 Unpacking and inspection and lifting
Warning----For human and machine safety consideration, please strictly follow the precautions bellow:
1.Lifting work should be carried out by professionals, others not involved should leave the site.
2.Make sure that vibrators and hopper have been taken off from the machine before lifting, it is prohibited to lift the machine with vibrator and hopper on
3.The machine weights 1950kg (RS8 weights 1600kg,RS6 weights 1250kg,RS4 weights 900kg), please use lifting equipment that could bear this weight.
After receiving the machine, unpack it carefully to avoid unnecessary damage to the components, check all the spare parts according to packing list.
Main machine hoisting steps, please follow Diagram 4-1:
Warning----please use the lifting tackle supplied with the machine, otherwise it might cause human injury or machine damage; customer should take all the responsibilities if using other lifting tackle.
1.Lifting the machine by lifting equipment, replace the four screws at the bottom of the machine by hoof joints.
2.Move and locate the machine to the working site. Arrange the hoof joints to the height that you need. You can use the leveling gauge to adjust the levelness of the machine and lock down each hoof joint.
3.Remove the lifting tackle and keep it properly for usage next time.
Diagram 4-1 Lifting Work
4.3 Installation Diagram
Note:
1. Please locate the machine on solid platform, and fix 4 hoof joints of the machine onto it as well, lock all hoof joints to make sure the machine is level and stable.
2. No vibration on the ground and no electromagnetic interference on installation site.
3. Protect the chutes and touch panel from sparks of welding when installing the machine.
Take re-sorting as an example to introduce installation of the machine. The material inlet and outlet pipes arrangement are as shown in diagram 4-2 (just for reference).
The diagram shows that the material is supplied from the inlet hopper and feeder then flow down into the machine for primary sorting, the accepts where from is the end product. Then the rejects resulted from primary sorting shall be conveyed to the secondary sorting inlet by lifting device for re-sorting. The accepts from the secondary sorting and middle material from primary sorting will be either put together into the raw material or returned by the lifting device for primary sorting again. The rejects from resorting is waste.
Diagram 4-2 Installation
The machine must be placed on solid platform with guardrails (the distance between the platform and the ground is about 1.8m) or on hard foundation, and it must be leveled up. The levelness of the machine shall be adjusted to 2/1000 mm or less by a leveling instrument. A passage way shall be reserved around the machine for operation, inspection and maintenance. The top feeding inlet shall be matched with : Top view of the installation and material inlet and outlet assemble for reference.
4.4 Vibrator installation
Warning----for human and machine safety:
1.Do not put any parts of one's body (such as fingers or palm, etc) between machine and vibrators during installation.
2.Vibrator components are very heavy, and if falling down it will cause human injury or machine damage, be careful when lifting.
Vibrators installation detailed steps:
1. Open the vibrator box to take out the vibrators, as shown in diagram 4-4.
2. Install the vibrators in upper ledge of the rack in return. Make sure the springs at the lower part of the vibrators insert into the groove of the upper ledge of the rack to fix the position, as shown in diagram 4-4.
3. Put air plugs on each vibrator into the groove and connect the grounding wire with the machine rack, as shown in diagram 4-5.
4.5 Hopper installation
Customer needs to prepare a hopper according to the hopper diagram below ( RS10 ).
Please use suitable lifting device to lift the hopper and level with the inlet of the machine when installing. Use a bracket to support the hopper or hang it on a beam of the room. Do not overlay it on the machine.
Notice---- For human and machine safety consideration, please use suitable
4.6 Receptacle
Pipes of receptacle should be installed according to holes diagram shown in Diagram 4-7.
4.7 Installation of Dust Pipe
The user must prepare the dust pipeline to avoid too much dust accumulated in the closed machine body as it may affect the sorting accuracy. Connect the dust absorption hole with air system or air blower at customer's site by Φ100mm metal pipe, and make sure it is well earthed. Shown in Diagram 4-8.
4.8 Installation of Air Supply
Warning——For consideration of human and machine safety, one must ensure that air supply being cut off when connecting or disconnecting pipes or their spare parts.
The user must adopt an oil-less and waterless air compressor matched with a water diversion filter. The joints between the air passage elements shall be linked with Dg25mm galvanized pipes or another higher grade pipes. It’s advised that the air compressor be installed in a separate neighboring room close to the machine (the maximum distance is 20m) so as to reduce noise and secure sufficient supply of air pressure to the color sorter.
Notices for air supply system installation and operation:
●The air filter of the machines is only a complementary of the engineering air filtration system. The air supply should be turn off when linking or cutting the pipes .
● The working temperature range of air compressor and filters is 0C-40C. When indoor temperature is below 0C, in case the filter and pipelines gets frozen, the operator shall air dry it after turning off the machine and take proper measures to keep it over 0C. Otherwise, the frozen pipeline will block the air and damage the filter components.
● Air compressor shall be put in a place with good ventilation, flat ground, low moisture. Keep the working temperature below 40C. Reserve a 0.8M passage clearance for maintaining purpose. Keep out of direct ray of sunlight. Shelter from the rain.
● The tube between air compressor and air tank should be longer than 3.5m and they two should be installed in different places.
● The preliminary filter system shall keep distance from the air compressor, otherwise it cannot be used to utmost.
● If the pressure gauge of the machine indicates that the air pressure is below 0.1MPA. You should replace the filter of the preliminary filter. Removing without replacement leads to the ruin of the components in the secondary filter system.
● In order to avoid the pipeline vibration, please use 1' high-energy soft pipe line connecting to air compressor (2m) and to sorter (3m).
● Clearance of the blockages in the pipelines shall be done before connecting the pipelines.
Diagram 4-9 is a sample of clean system of compressed air and can be used as a reference of the air passage connection.
1、Air compressor 2、Air tank 3、Air dryer(Optional)4、Main filter 5、Filter for water
Diagram 4-9 Air system
4.9 Electrical installation
Warning----For human and machine safety, please abide by the follow directives strictly:
1. Machine and its accessories must be well earthed to the ground;
2. Machine and its accessories must use standard air switch for power supply, and make sure that this air switch is only used for main machine;
3. Employ professional technician for wiring of all equipment by using standard electric wire.
● Installation of Earth Rod
One must choose high-quality material as earth rod, and keep the surroundings moist. The earth rod resistance should be checked after installation. With time passing by, the earth rod should be changed timely in case it gets rusty.
● Connection between Earth Rod and Earth Cable
The best connecting way is to curl the earth cable to a ring, use nut and bolt to fix, the connecting joint should be Anticorrosion sealed. Copper stranded wire cable is usually used as connecting cable, because of its small resistance. It suggests using 6mmcopper cable.
● Connection with Metallic Parts or Main Machine
Connect earth cable with main machine, UPS or other facilities according to the way mentioned above.
4.9.1 Power Supply for the Main Machine
The capacity of RS10 is 4.2kW(including the heating system 2.0kW),the capacity of RS8 is 3.5kW(including the heating system 1.6kW), the capacity of RS6 is 2.9kW(including the heating system 1.2kW), the capacity of RS4 is 1.8kW(including the heating system 0.8kW). One should prepare cubicle within 4.5M from the machine power supply inlet, the power supply is single-phase AC (50Hz±1%、220V±10%). The machine should be connected with single-phase 20A air switch (220V) directly.
4.9.2 Power Supply of Air Compressor
It is better to install the air compressor at a place near the machine as soon as possible. And the air compressor is to be matched with a three-phase (380V) 50A air switch.
4.9.3 Power Supply of Elevator
To be matched with a three-phase (380V) 10A air switch for one set of elevator.
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