Operating Instructions and Operating Manual Mobile 3 ... · PDF fileOperating Instructions and...

Operating Instructions and Operating Manual

Mobile 3-Fraction Screening Plant

Model designation:

Type:

Machine serial number:

Project number:

Year of manufacture:


BA-L3-3BA_12_6736_en.docx of 72

N O T E

The operating instructions consist of four manuals:

1. Safety regulations (Chapter 1)

2. Technical data (Chapters 2 to 4)

3. Operating instructions (Chapters 5 to 7)

4. Maintenance instructions (Chapters 8 to 10)

The operating instructions are deemed complete only when all 4 manuals are available.

W A R N I N G

Operation of the machine without having read and under-stood all 4 manuals is strictly prohibited!

Important! – Read thoroughly before use – Keep for later use!

These operating instructions form an integral part of the ma-chine and must be available to operating personnel at all times.

The safety regulations contained therein must be strictly fol-lowed.

These operating instructions must always be handed over when the machine is sold on.


of 72 BA-L3-3BA_12_6736_en.docx

Table of contents

• Safety regulations (separate manual)

1. Safety and dangers

• Technical data (separate manual)

2. Foreword

3. Overview and intended use

4. Function

• Operating Instructions and Operating Manual

5. Transport, installation and commissioning ................. 6

5.1. Scope of delivery ................................................................... 6

5.2. Transport ................................................................................ 7 5.2.1. Delivery (also in case of spare and replacement parts) ....... 7 5.2.2. Intermediate storage ............................................................. 7

5.3. Transport to the installation site (by the customer) .......... 8 5.3.1. Shut-down procedures before transportation ....................... 8 5.3.2. Transport locks ..................................................................... 9 5.3.3. Transport by truck ............................................................... 10 5.3.4. Transport by wheel loader (option) ..................................... 12 5.3.5. Transport by crane .............................................................. 14

5.4. Installation and commissioning ......................................... 15 5.4.1. Commissioning ................................................................... 15 5.4.2. Installation ........................................................................... 16 5.4.3. Commissioning ................................................................... 21 5.4.4. Out of service ...................................................................... 21

5.5. Adjustments on the wind sifter (optional) ........................ 22

5.6. Switchover 3- / 2-fraction screening (option) ................... 24 5.6.1. Switching from 3- to 2-fraction screening ........................... 24 5.6.2. Switching from 2- to 3-fraction screening ........................... 28

6. Operation ..................................................................... 32

6.1. Operating controls .............................................................. 32 6.1.1. Operating controls on the hydraulic system ........................ 32 6.1.2. Operating controls on the wireless remote control (option) 34 6.1.3. Operating controls in the control cabinet ............................ 36



6.2. Operating modes ................................................................. 38 6.2.1. Switching the machine on and off....................................... 39

Installation and setup..................................................... 39 Switching on .................................................................. 40 Switching off .................................................................. 41

6.2.2. Selecting the mode of operation ......................................... 42

6.3. Overview of touch panel ..................................................... 44

6.4. Automatic operation ........................................................... 46 6.4.1. Overview of aggregates ...................................................... 46 6.4.2. Display view ........................................................................ 48 6.4.3. Switching on the wind sifters (option) ................................. 50

6.5. Manual operation ................................................................ 51

6.6. Menu ..................................................................................... 52 6.6.1. Rotary speed adjustment .................................................... 52 6.6.2. Recipes ............................................................................... 54 6.6.3. Settings ............................................................................... 56

Times and remote maintenance .................................... 56 Changing the user ......................................................... 58 Operating hours ............................................................. 59 Language ....................................................................... 60 Manuals ......................................................................... 61

6.6.4. Fault .................................................................................... 62

6.7. Failure of the touch panel .................................................. 63

6.8. Generator ............................................................................. 64 6.8.1. Control module PowerWizard PW 1.1 and 2.1 ................... 64 6.8.2. Control module PowerWizard PW 1.0 and 2.0 ................... 66

6.9. Signal lamp with horn ......................................................... 68

6.10. Power failure ........................................................................ 69

7. Emergency ................................................................... 70

• Maintenance instructions (separate manual)

8. Maintenance / Cleaning

9. Troubleshooting

10. Dismantling / Disposal



5. Transport, installation and commissioning 5.1. Scope of delivery

2

Operating manual

1

3

Technical

documents

Fig. 5-1 Scope of delivery

The scope of delivery includes:

1 mobile screening plant MULTISTAR L3

2 Operating instructions

3 Technical documentation

N O T E

Details of the scope of delivery can be found in the order confirmation.



5.2. Transport Although Komptech GmbH has carefully packed and inspected the System and machinery prior to shipment, possible damage during transport cannot be totally discounted.

5.2.1. Delivery (also in case of spare and replacement parts) Goods in inspection: • Check that the shipment is complete as listed in the deliv-

ery note!

Signs of damage • Check the delivery for damage (visual inspection)!

In the case of complaints

If the delivery has been damaged during transport:

• Immediately contact the last forwarding company! • Maintain the spare and replacement part packing (so that

it can be examined by the freight company or for returning the equipment)

Packing for return shipment of spare and replacement parts

If possible, use the original packaging and original packaging materials.

Should these be no longer available:

• Call in a professional packaging company. • Place the spare or replacement part on a pallet (its design

must be suitable to the weight). • Please contact Komptech GmbH if questions arise re-

garding the packing or the transport securing devices. 5.2.2. Intermediate storage

Freight packaging used for spare and replacement parts is de-signed with a service life with delivery of up to 3 months.

Storage conditions

In a closed and dry room with a room temperature of -10 to +35 °C



5.3. Transport to the installation site (by the customer) 5.3.1. Shut-down procedures before transportation

D A N G E R

The following shut-down procedure must be strictly ad-hered to (by specialists only) prior to performing cleaning, service, maintenance or repair work.

1. Always run the plant empty before shutting it down.

2. De-energize the plant.

• Switch the main switch on the machine control cabinet to position “0”.

• Use a padlock to lock the main switch, securing it against being switched back on.

3. Remove electric power from the generator.

Secure the generator against being switched back on unintentionally.

4. Switch off the battery isolation switch.

The battery circuit breaker must not be switched off un-der any circumstances during ongoing power generation.

5. Close all still open control cabinets.

This will otherwise result in severe injury or death.

Failing to comply can cause danger to the limb and life of the personnel !

N O T E

Personal protective equipment must be worn when working in the danger area. Protective equipment (e.g. protective gloves) must be adapted appropriately to the materi-als/medium used and to the required temperatures for pro-duction!

This may otherwise result in injuries.

If the regulations for hazardous materials or bio-materials apply to the product being processed, appropriate working clothes must be worn and applicable hygiene regulations must be complied with.



5.3.2. Transport locks Before transport, the following components must be locked in place: 1 Make sure that the system has been emptied and that no

rest-material is left in the hopper. 2 Option: Fold the hopper top loader barrier in. 3 Option: Dismantle the wind sifter pipelines strictly before

folding in the conveyor belts, as otherwise these may get damaged. Pipes and pipe clamps should be properly stowed away.

4 Set all discharge conveyor belts to transport position and close the associated transport locks.

5 Place and secure the jointed double ladder in transport posi-tion.

6 Open the shut-off valves on the hydraulic cylinders of the support feet.

7 Move the hydraulic supports to transport position and hitch the machine to the tractor.

8 Completely retract the hydraulic supports and close the shut-off valves again.

9 Switch off the main switch on the control cabinet. 10 Switch off the generator.

11 Switch off the battery isolation switch.

12 Option: Push in the extendable low-floor drawbar 13 Option: Make sure that the gusset shoe for the coupling ring

is secured with a cotter pin for wheel loader transport. 14 Install the light strip. 15 Remove the brake wedges and bring them to transport posi-

tion.

N O T E

Before commencing transport on the open road, ensure that no components extend beyond the authorized dimensions of the vehicle.

N O T E

System configuration features, as well as the options, are listed in the separate manual "Technical data" of this operat-ing manual in Chapter 3.2 “Configuration of the delivered machine“.



5.3.3. Transport by truck

Fig. 5-2 Transport by truck

Prior to each trip, the following checks must be carried out

The air reservoir for the brakes and pneumatic spring system should be charged to operating pressure.

Visual checks: • Cleanliness of the System

(clean as necessary. Attention: Danger caused by falling objects)

• Tire air pressure

• Wheel attachment

• Function of the lighting and braking system

• When the brake pad wear indicator on the linkage plate is a horizontal position, the brake pad thickness should be checked.

• Air suspension rotary slide valve in the drive position (OP-TION)

• Air-suspension bellows in the normal drive height, no buck-ling formation of the air-suspension bellows (OPTION)

W A R N I N G

Transport must only be carried out by trained expert person-nel under due consideration of transport data and the local conditions.

This may otherwise result in severe injuries.

This personnel must be trained in the field of transport. Fail-ing to comply with the transport specifications may also lead to material damage.



N O T E

An exact description of the chassis can be found in the sepa-rate manufacturer's documentation in the attachment "Suppliers' operation manuals“.

N O T E

For the protection of the axle and brake system, it is abso-lutely essential to carry out a tractor/trailer synchronisation between the tow vehicle and the trailer / semitrailer.

We cannot assume liability for damages resulting from non-compliance.

N O T E

Follow the country specific regulations concerning the di-mensions of the trailer. The overall length of the machine can optionally be reduced to 10,600 mm via the extendable low-floor drawbar.

N O T E

If the System is equipped with a courtyard undercarriage only, it has no approval for public road traffic!

N O T E

Follow the "Shut-down procedures before transport" chapt. 5.3.1 and the "Transport locks" chapt. 5.3.2

N O T E

After each transport or whenever the machine has been moved it must be realigned in working position and the con-veyor belt track of all belts must be checked and possibly readjusted.

This may otherwise result in material damage.



5.3.4. Transport by wheel loader (option)

2 1

2 1

Fig. 5-3 Gusset shoe for drawbar

For transportation by wheel loader the gusset shoe (1) to take up the ball pivot by means of bolt (2) and cotter is mounted to the drawbar and secured.

W A R N I N G




N O T E

Pay attention to the "Shut-down procedures before transport" chapt.: 5.3.1 and the "Transport locks" chapt.: 5.3.2

N O T E

After each transport or whenever the machine has been moved it must be realigned in working position and the con-veyor belt track of all belts must be checked and possibly readjusted.

This may otherwise result in material damage.



For manoeuvring, the machine can also be moved without a truck, depending on the undercarriage. For this purpose, the brake must be released by pressing the black knob on the op-erator control panel. After manoeuvring, the brake must be re-set again by pulling out the black knob. This works only with sufficient air in the tank.

Fig. 5-4 Brake on the undercarriage

W A R N I N G

For manoeuvring with a released brake, particular caution must be taken since the chassis must only be braked by the manoeuvring vehicle.

The manoeuvring vehicle must be authorised accordingly for manoeuvring operation with tensile loads!


N O T E

An exact description of the undercarriage can be found in the manufacturer's documentation in the appendix “Suppliers' Operating Instructions”.

A



5.3.5. Transport by crane

Fig. 5-5 Transport by crane

Fig. 5-6 Fastening points (lifting points)

W A R N I N G




N O T E

Pay attention to the "Shut-down procedures before transport" chapt.: 5.3.1 and the "Transport locks" chapt.: 5.3.2

Consequences may be material damage and/or severe or injuries.



5.4. Installation and commissioning

W A R N I N G

Installation and assembly is to be carried out by Komptech GmbH or by the customer's specialist personnel, who must have been appropriately trained for these related work tasks.


• Only install the plant on a level and secure surface.

• Install the plant in accordance with the floor plan, ensuring an unobstructed flow of material. Also consider the spatial requirements for operation, maintenance and repair work.

5.4.1. Commissioning • Read all 4 manuals carefully.

• Remove if applicable the preservative in fresh air with wa-tery, alkaline process cleaners or solvent cleaners such as Techniclean FC plus from Castrol. Avoid contact of the pre-servative with eyes and skin. Avoid any run-off of released materials in the earth, ground water, drains and sewers.

• Option: Activate both Perma lubrication cans on the wind sifter above the coarse screen (see manufacturer's docu-mentation in the appendix).

Fig. 5-7 Activation of Perma lubrication cans



5.4.2. Installation

1. Park the machine and put the brake wedges (1.1) in place. Remove the light strip.

2. Switch on the battery isolation switch (2.1). Put the gen-erator into operation. For this purpose it must be switched to automatic mode (2.2) (preparation for remote starting on control cabinet).

N O T E

An exact description can be found in this manual in chapt. 6.8 and in the separate manufacturer documentation in the appendix "Supplier's operating instructions".

3. Start the generator on the control cabinet of the machine with the key switch (3.1).

4. Switch on the main switch (4.1) on the control cabinet.

1.1

2.2

2.1

4.1

3.1 5.1



5. Press the reset button (5.1) to switch on the control volt-age.

6.2 6.1 6.5 6.3 6.4

right (on operator side)

left (opposite operator side)

6. Open the shut-off valves (6.1) of the hydraulic support and extend these, so that the machine can be decoupled from the truck. For this, the main push-button (6.2) and the respective valves (6.3) are to be actuated (two-hand-operation).

Decouple the machine from the truck and unwind the leads (compressed air and electric connections). Hang these on the hook (6.4) on the base frame of the machine. As an option the machine is fitted with detachable con-nections.

After decoupling the machine use a spirit level (6.5) and the hydraulic levers (6.3) to align the machine horizontally and close the shut-off valves (6.1) again.



7.2 7.1

7. Release the latches (7.1) on both sides of the fine grain discharge conveyor (7.2).

8. Now extend the fine grain discharge conveyor (7.2). For this purpose operate the main button (8.1) and the corre-sponding hydraulic lever (8.2) (two-hand-operation).

9. Take the bolt (9.1) out of its bracket, insert it into the cor-responding bore (9.2) and lock the bolt with the cotter pin.

10. Lift the fine grain discharge conveyor (7.2), until the de-sired working height is reached.

N O T E

The optimal inclination of the discharge belts is 30°. Other inclinations may lead to undesired leakages and belt tracking problems.

8.2 8.1

9.1

9.2



11. After releasing the transport securing device (7.1), the medium grain discharge conveyor (11.1) can now be folded out corresponding to the fine grain discharge con-veyor (7.2).

12. Fold the material guide plates on both discharge convey-ors (12.1) up manually.

13. Option - Now extend the oversize grain discharge con-veyor. For this purpose operate the main button (13.2) and the corresponding hydraulic levers (13.3) (two-hand-operation).

12.1

13.1 13.2 13.3

11.1



14.2 14.3 14.4 14.1

14. Option - Open the shut-off valve (14.1) and fold out the hopper top loader barrier (14.2). For this purpose operate the main button (14.3) and the corresponding hydraulic levers (14.4) (two-hand-operation). Close the shut-off valve (14.1) again.

D A N G E R

There is a risk of falling objects when unfolding the hopper top loader barrier.

This will otherwise result in severe injury.

The hopper top loader barrier must be retracted before the machine can be transported, as otherwise the approved transport height of 4 m is exceeded!

15. Option - Now assemble the delivered pipes for extraneous matter in the wind sifters to the corresponding blow-out nozzles.

W A R N I N G

The pipelines should be routed into a closed container.

Thrown out particles may otherwise cause severe injuries.

When climbing up ladders follow the health and safety stan-dards at work.



5.4.3. Commissioning

N O T E

A detailed description of the operation can be found in chap-ter 6.

5.4.4. Out of service

If the machine is temporarily shut down (longer than 2 weeks) the following precautions must be taken:

• Clean the entire machine.

• The screen deck in particular must be checked for resi-dues and entanglements in order to avoid caking and contaminant deposits.

• Lubricate the roller chains of the screen deck.

• Clean and preserve the bunker chain with biodegradable agents to avoid corrosion and buckling resistance.

• In low temperatures be mindful of frost and winter diesel.



5.5. Adjustments on the wind sifter (optional) Adjusting the suction power on the wind sifter

The suction power of the wind sifter must be individually adapted to the material being screened. The quality of the lightweight material separation can be influenced via the ad-justable suction intake duct.

Fig. 5-8 Wind sifter fine screen Fig. 5-9 Wind sifter coarse screen (medium grain) (oversized grain)

Wind sifter on fine screen (medium grain)

The higher the mechanical adjustment device, the lower the suction power and vice versa.

Wind sifter on coarse screen (oversized grain)

The shorter the chain, the lower the suction power and vice versa.

Frequency converter (option)

Depending on the configuration of the plant, the speed of the electric motor and thus the capacity of the wind sifter, can also be regulated by means of the frequency converter on the control cabinet . The higher the rotation speed, the stronger the suction force, and vice-versa.

N O T E

If the suction force is too strong, organic particles will also be extracted from the screening material. This can cause exces-sive wear of the wind sifter.



Medium grain wind sifter (option) not used

The wind sifter (1) can optionally be "folded up" when not used. For this purpose the fine grain discharge belt (2) must be set to transport position. Only then the lever arm (3) can be moved into position and the fine grain discharge belt can be folded up.

• Position A → wind sifter not in use (folded up) • Position B → wind sifter in use (folded down)

N O T E

Disassemble the pipelines for extraneous matter in the wind sifters before folding in the discharge conveyor belts.

Otherwise consequential damage cannot be ruled out.

Otherwise the pipelines may be damaged.

C A U T I O N

Stand on a stable base when loosening the pipe clamps.

Otherwise you may suffer minor injuries.

2 1 3 2 1

A

B



5.6. Switchover 3- / 2-fraction screening (option)

By executing the work steps described below one can switch between the 3-fraction and 2-fraction screening modes.

5.6.1. Switching from 3- to 2-fraction screening If the System is setup to operate in the 3-fraction screening mode, it is possible set up the machine to 2-fraction screening within a few minutes. This set up of the machine should be car-ried out by the customer's specialist personnel, who must have been appropriately trained for this type of work.

N O T E

The system must have been driven empty.

The control voltage must be switched on by the reset button.

D A N G E R

Ensure that no persons are inside the plant when setup work is started!




1. Remove the protective shroud (1.1).

2. Unlock the locking mechanisms (2.1) for the separating wedge (2.2) on both sides.

3. Pull the separating wedge (3.1) out of the System and keep it in a secure place.

1.1

2.1 2.2

3.1



4. Raise the medium grain discharge conveyor with the ap-propriate hydraulic lever (4.1) and the main push-button (4.2) until the retaining cable for this belt is no longer pulled taut (two-hand-operation).

5. Remove the retaining cable from the medium grain dis-charge conveyor by pulling on the spring cotter (5.1) and dismantling the large washer. Hang the cable in the des-ignated hanger assembly (5.2) and replace the spring cot-ter and the washer onto bolt.

W A R N I N G

Under no circumstances should the articulated joint locking bolt be removed!


This may be removed only when the machine is to be placed in the transport mode.

5.1 5.2

4.2 4.1



6. Operate the corresponding valve (4.1) and the main switch (4.2) to lower the medium grain discharge con-veyor (6.1) to an almost horizontal position. Make sure that the belt (6.1) does not collide with the drawbar (6.2)!

7. Remount the protective shroud (1.1).

8. Observe the belt tracking. Correct if necessary, as de-scribed in Chapter 8.4.4 of the "Maintenance instructions" manual.

9. Set the selector switch (9.1) to the 2-fraction screening mode [ I ] and start the System.

10. Watch the belt tracking and correct if necessary.

6.1 6.2

9.1



5.6.2. Switching from 2- to 3-fraction screening If the System is setup to operate in the 2-fraction screening mode, it is possible reconfigure the machine to 3-fraction screening within a few minutes. This set up of the machine should be carried out by the customer's specialist personnel, who must have been appropriately trained for this type of work.

N O T E

The System must be emptied.

The control voltage must be switched on by the reset button.

D A N G E R

Ensure that no persons are present in the System when re-configuration work is started!

This will otherwise result in severe injury.

1. The medium grain discharge conveyor (1.1) is in horizon-tal position.

1.1



2. Raise the medium grain discharge conveyor by means of the corresponding valve (2.1) and the main push-button (2.2) until the retaining cable can be attached to the me-dium grain discharge conveyor belt (two-hand-operation).

3. Remove the retaining cable from the hanger assembly (3.1) and attach it to the medium grain discharge con-veyor by means of washer spring cotter (3.2).

W A R N I N G

Under no circumstances should the articulated joint locking bolt be removed!


This may be removed only when the machine is to be placed in the transport mode.

4. Lower the belt to the desired height.

3.1 3.2

2.2 2.1



5. Remove the protective shroud (5.1).

6. Push the separating wedge (6.1) into the machine so that it can be subsequently secured on both sides with the locking mechanisms (6.2).

7. Reassemble the protective shroud (5.1).

5.1

6.1

6.2 6.1



8. Set the selector switch (8.1) to the 3-fraction screening mode [ 0 ] and start the System.

9. Watch the belt tracking and correct if necessary.

8.1



6. Operation

W A R N I N G

The machine must be operated by specialist personnel only, who are qualified and have been trained for the operation.


Expert personnel must be trained before operation.

6.1. Operating controls 6.1.1. Operating controls on the hydraulic system

Fig. 6-1 Operating elements hydraulic system

1 EMERGENCY STOP Actuation stops the machine immediately.

W A R N I N G

The depressed emergency stop push-button may be disen-gaged only after the cause for the actuation has been deter-mined and rectified. Consequences may be severe or even fatal injuries. The machine must then be restarted. The emergency stop push-button must not be used to stop the machine normally!

2 1 3



2 Main button Hydraulic elements can be controlled in conjunction with the Main button (two-hand operation)

3 Hydraulic lever Actuation allows for the raising or lowering of the discharge conveyors, as well as the extension or retraction of the ma-chine support feet and the folding out or in of the hopper top loader barrier (option) (2-hand operation).

Medium grain discharge conveyor

Fine grain discharge conveyor

Support feet, right (on the operator-side)

Support feet, left (opposite to the operator-side)

Hopper top loader barrier (option)

Discharge conveyor, oversize grain (op-tion)



6.1.2. Operating controls on the wireless remote control (option) If the system is equipped with a wireless remote control, the fol-lowings functions will be controlled:

Fig. 6-2 Operating controls wireless remote control (standard)

1 STOP Actuation of this button will stop the machine.

W A R N I N G

The remote control is only equipped with a MACHINE STOP and is therefore not deemed a safety component.

Failing to comply may result in severe injuries.

2 Hopper Start/Stop Actuation of this button will start or stop the hopper.

3 Hopper + Actuation of this button will increase rotation speed of the hopper.

4 Hopper - Actuation of this button will reduce the rotation speed of the hopper.

1 2 3 4



At the customer's request, the wireless remote control can be equipped as follows:

Fig. 6-3 Operating controls wireless remote control (option)

1 STOP Actuation of this button will stop the machine.

W A R N I N G

The remote control is only equipped with a MACHINE STOP and is therefore not deemed a safety component.

Failing to comply may result in severe injuries.

2 System start Actuation of this button will start the machine.

3 Emptying the plant Actuation of this button will run the machine empty.

4 RESET After successful rectification of faults the control can be re-set.

1 2 3 4



6.1.3. Operating controls in the control cabinet

Fig. 6-4 Operating elements on control cabinet

1 Generator

Actuation will switch the generator ON or OFF.

2 Control voltage, ON button / collective fault reset

During commissioning of the machine pressing the reset button switches on the control voltage. After successful rec-tification of faults the control can be reset.

2 4 3

5 6 1 7



3 Selector switch Manual-Automatic

With this key switch the operator chooses the desired mode of operation Pos. I: Automatic operation Pos. II: Manual operation Pos. 0: The plant runs empty

4 Selector switch, 3- or 2-fraction screening (option)

Actuation selects/changes the appropriate machine pro-gram mode: Pos. 0: 3-fraction screening Pos. I: 2-fraction screening

5 Touch panel

Various parameters, such as motor rotation speed, etc., can be viewed or changed via the touch panel. (more de-tailed information is provided in the following chapters)

6 Fuel level gauge

The diesel tank fill level is indicated.

7 Main switch (with Emergency Stop function)

Actuation will shut down the machine immediately.

D A N G E R

If the main switch is switched off because of cleaning, main-tenance or repair work, it must (by any person) be secured with a padlock to prevent it from being switched back on without permission.

Otherwise severe or even fatal injuries may occur.

Non-compliance with the shut-down procedures / safeguard-ing against accidental switching on: life-threatening and/or unexpected movements are possible.



6.2. Operating modes Operation differs between the Automatic mode and the Manual mode of operation.

Automatic operation

The Automatic mode of operation serves as the normal operat-ing mode. This guarantees that the System will be started and run empty in the technically correct sequence.

In the event of a component failure (e.g. motor protection switch), the plant section upstream of the affected component will be shut down immediately and the downstream section will be run empty in the technically correct sequence. This way safe operation of the plant is guaranteed.

Manual operation

In manual mode individual components can be switched ON or OFF independently of other components in order to perform functional checks, for example, or to carry out maintenance or repair work. The Manual mode does not serve as a normal mode of operation.

Failure of an individual component does not lead to a shut-down of the System.

N O T E

The System will not be automatically monitored in the Manual mode of operation!



6.2.1. Switching the machine on and off Installation and setup

N O T E

An exact description of installation and commissioning can be found in chapter 5.4.

1. Put brake wedges into place

2. Remove the light bar

3. Switch on the battery isolation switch

4. Start operation of the generator (see also separate suppli-ers' operating instructions).

5. Switch on the main switch and the control voltage (via the reset button) on the operator control panel on the control cabinet.

6. Extend the hydraulic outriggers until the machine can be decoupled from the towing vehicle.

7. Decouple the machine from the towing vehicle.

8. Align the system by means of the hydraulic outriggers.

9. Loosen the transport locks on the foldable discharge con-veyor belts.

10. Unfold the discharge conveyor belts, secure with bolts and lift to working position

11. Fold up the material guide plates on the discharge conveyor belts

12. Option: Lift the oversized grain discharge conveyor belt to working position.

13. Option: Mount the pipelines for extraneous material from the wind sifter

14. Option: Fold out the hopper top loader barrier

D A N G E R

There is a risk of falling objects when unfolding the hopper top loader barrier.


Wear a hard hat.

15. Check the safety equipment. Has all safety equipment been unlocked?



Switching on 1. Switch on the battery isolation switch.

2. Switch on the generator by the key switch on the control panel

3. Switch main switch ON.

4. Switch on the control voltage by the Reset button on the control panel

5. Select Automatic mode of operation.

N O T E

If the System is to be driven in manual mode, proceed as described in chapt. 6.5.

6. Actuate plant ´START´ on the touch panel

7. The individual assembly groups start up in the technologi-cally correct sequence as follows:

• Wind sifter (optional)

• Oversized grain discharge conveyor (optional)

• Medium grain discharge conveyor

• Fine grain discharge conveyor

• Fine grain cross conveyor

• Fine grain collector conveyor

• Fine screen deck

• Medium grain collector conveyor

• Coarse screen conveyor

• Dosing drum

• Hopper

8. Feed plant with material

N O T E

If a wind sifter is installed, this unit can be switched ON or OFF manually, also during automatic operation.



Switching off

1. Stop the System or run it empty

2. The individual assembly groups shut down in the techno-logically correct sequence as follows:

• Hopper

• Dosing drum

• Coarse screen conveyor

• Medium grain collector conveyor

• Fine screen deck

• Fine grain collector conveyor

• Fine grain cross conveyor

• Fine grain discharge conveyor

• Medium grain discharge conveyor

• Oversized grain discharge conveyor (optional)

• Wind sifter (optional)

3. Switch off the main switch

4. Switch off the generator by the key switch on the control panel

5. Switch off the battery isolation switch

N O T E

The battery circuit breaker must not be switched off under any circumstances during ongoing power generation.

N O T E

An exact description of the generator can be found in the appendix of the Suppliers' operating instructions.



6.2.2. Selecting the mode of operation

Fig. 6-5 Operating elements on control cabinet

By actuating the selector switch (1) for the mode of operation, a choice can be made between the Manual or Automatic modes of operation.

Fig. 6-6 no operating mode

If no mode of operation has yet been selected, this will be shown in the display.

N O T E

The display views vary in dependence on the equipment of the machine.

1

1



Fig. 6-7 View "Automatic operation"

During operation the aggregates currently running in automatic mode are shown in green.

N O T E

A detailed description of automatic mode can be found in chapter 6.4.

Fig. 6-8 View "Manual operation"

During operation the aggregates currently running in manual mode are shown in yellow.

N O T E

A detailed description of manual mode can be found in chap-ter 6.5.



6.3. Overview of touch panel

1 2 3 4

Fig. 6-9 Overview touch panel

Displays in the upper section:

1. Operating hours

2. Machine type

3. Machine serial number

4. Date and time

Representation of the plant in the middle section:

5. Representation of plant: The colours in the displayed aggregates inform about their status:

grey off

green active in automatic mode

yellow active in manual mode

red Fault

6. Status of plant: Colour and text in the status display represent the current status of the plant (see chapter 6.4 and 6.5).

5

6



12 7 8 9 10 11 13

Fig. 6-10 Overview touch panel

Control buttons in the lower section:

7. Start page

8. Speed range adjustment (see chapter 6.6.1)

9. Recipes (see chapter 6.6.2)

10. Settings (see chapter 6.6.3)

11. Fault messages (see chapter 6.6.4)

12. Start plant (see chapter 6.4)

13. Stop plant (see chapter 6.4)

N O T E

The control buttons for "Start" (12) and "Stop" (13) appear as soon as all frequency converters are at standby.



6.4. Automatic operation 6.4.1. Overview of aggregates

N O T E

The display view varies in dependence on the equipment of the machine.

Basic equipment

4 3 7 2 1 5 8 6 9

Fig. 6-11 Overview basic equipment

Representation with basic equipment:

1. Scraper floor in hopper

2. Dosing drum in hopper

3. Coarse screen

4. Medium grain collector conveyor

5. Medium grain collector conveyor

6. Medium grain discharge conveyor

7. Fine grain collector conveyor

8. Fine grain cross conveyor

9. Fine grain discharge conveyor

r



Full equipment

12 11 10 13

Fig. 6-12 Overview of full equipment

Additional aggregates in case of full equipment:

10. Wind sifter, fine (option)

11. Wind sifter, coarse (option)

12. Oversized grain discharge conveyor (option)

13. Medium grain rolling body separation (option)

N O T E

The exact equipment of the machine can be found in the sepa-rate manual "Technical data" in chapter: 3.2. .



6.4.2. Display view

Fig. 6-13 Start view automatic operation - plant stopped

If automatic mode was selected with the key switch, the touch panel will show the above view. If the System is at a standstill, the system status display appear against a grey background showing the status: "System stopped". Press the START button at the left border to start the plant.

Fig. 6-14 Plant starts

When the plant is starting, the plant status display appears against an orange background and shows the status: "Plant starting". Green areas (status of the corresponding aggregate) and blue arrows (material flow) represent the current dynamics of the machine.



Fig. 6-15 Plant running

Once the plant is running, the plant status display appears against a green background and shows the status: "Plant run-ning". This view shows the dynamics for the complete machine. Press the STOP button at the right border to stop the plant.

Fig. 6-16 Plant stopped

If the System is stopped, the plant status display appears against an orange background and shows the status: „System stopped“. The dynamics of the machine decreases and the cor-responding green areas and blue arrows disappear one after the other.



6.4.3. Switching on the wind sifters (option)

Fig. 6-17 Start view automatic operation - plant stopped

Option: If an wind sifter is available, it can be activated or deac-tivated by simply pressing the associated control button.

green Air classifier activated

grey Air classifier deactivated

The activated wind sifters will then start automatically when the machine is started.

With the wind sifter switched on the fan symbol is filled green during operation.

green Air classifier switched on

grey Air classifier switched off



6.5. Manual operation

Fig. 6-18 Start view "Manual operation"

If manual operation was selected with the key switch, the plant status display appears against a yellow background and the "Hand symbols" appear next to the corresponding aggregates.

N O T E

The display view varies in dependence on the equipment of the machine.

The "Hand symbols" are used to switch the corresponding ag-gregates on or off. The current selection appears against a yel-low background.

By pressing the corresponding control button "rev" one can re-verse the hopper motion in jog mode for a short while, in order to free possible blockages.

N O T E

Manual mode is no normal operating mode, but serves solely the purpose of maintenance and repair activities.



6.6. Menu 6.6.1. Rotary speed adjustment

Fig. 6-19 Overview

Pressing the control buttons "Hopper", "Coarse Screen", "Fine Screen" or "Speed" brings you to the rotary speed adjustment.

Fig. 6-20 Rotary speed adjustment Manual Fig. 6-21 Rotary speed adjustment Automatic

This view shows and overview of the actual speeds and motor currents for all drives.

1. To change the speed of an aggregate one must first activate this aggregate via the corresponding control button.

2. I one would like to change the rotary speed of all drives of this screen deck at the same time, this can only be done via the function keys on the left side:

++ ⇒ the rotary speeds are increased by 5 % ++ ⇒ the rotary speeds are increased by 1 % - ⇒ the rotary speeds are reduced by 1 % - - ⇒ the rotary speeds are reduced by 5 %

3. In order to adjust the rotary speed of an individual motor, the user activates the submenu for this motor by touching the respective rotation speed bar.



Fig. 6-22 Motor speed adjustment

The upper section informs about the current status, the motor current and the actual rotary speed.

The bar below shows a graphic display of the speed range. The vertical dash represents the nominal value. Adjustments are only possible within the grey/middle section of the bar. The blue areas outside represent the speed limits. These are indicated with numbers underneath, which have been present in the fac-tory.

You can adjust the rotary speed of this drive either via the "+" and "-" keys by 1 %, or via a numerical key pad in the display, after pressing the control button for the nominal value.

With the arrow keys at the right border you can leaf through fur-ther drives of this assembly.

To be able to change the rotary speeds of drives in other as-semblies, one must first press the control button "Rotary Speed" to return to the overview.

Fig. 6-23 Numerical block



6.6.2. Recipes

Fig. 6-24 Overview

Working with recipes gives you the possibility to quickly adapt the system to the various material configurations, without having to separately adjust the drive system every time.

F A C D E

Fig. 6-25 Recipes

Here you find a list of various preset recipes.

B



Selecting a recipe

To choose a recipe from this list, one must:

1. select the desired recipe via the associated control but-ton (A). This then appears against a green background. The nominal speeds (B), which are assigned to the cho-sen recipe, appear at the top right.

2. press the control button "Activate Recipe" (E).

Saving a new recipe

If a new recipe is to be saved, one must:

1. press the associated control button (A) to choose the recipe that should be overwritten. This then appears against a green background. The nominal speeds (B), which are assigned to the chosen recipe, appear at the top right.

2. rename the recipe by clicking on the corresponding rec-ipe name and entering the new name using the key pad that appears in the display.

3. press control button (C) to accept the current actual speeds from the frequency converters The new nominal values appear to the top right.

or

enter the desired nominal speeds directly at the associ-ated display (B) via the key pad.

4. press the control button "Save Recipe" (D).

5. press the control button "Activate Recipe" (E).

Fig. 6-26 Key pad



6.6.3. Settings

Fig. 6-27 Overview

Press the control button "Settings" to access further submenus.

Times and remote maintenance

Fig. 6-28 Settings 1

This view shows the times for start-up warning, fault warning and hopper reversing time. The fault warning time can be in-creased or reduced via the associated "+" and "-" keys. Start-up warning and hopper reversing time have been preset in the fac-tory and cannot be changed.



The reception intensity of the remote maintenance is addition-ally displayed. It is possible from eWON LEVEL "18" and is re-leased via the handle switch in the control cabinet.

Fig. 6-29 Modem switch

With the arrow key at the right border one can leaf to the next menu page.

Fig. 6-30 Settings 2

This view shows the times for making and breaking delay, fault warning and hopper reversing time. These have been preset in the factory.

The values for brightness and contrast can be increased or re-duced via the associated "+" and "-" keys.

The time can be set via the corresponding control buttons and the numerical keypad that appears in the display.

With the arrow key at the right border one can leaf back to the previous menu page.



Changing the user The plant is operated via the standard user. If one would like to reset the daily hour meter, e.g. if the machine is to be rented out, one must log in as "User 1".

Fig. 6-31 Overview

For this purpose press the control button "User" on the settings page.

Fig. 6-32 Changing the user

In the control button next to "User 1" enter the password by us-ing the numerical keypad that appears in the display.

After "User 1" has finished his work, he needs to be logged off again.

The users "ALBG" and "Elektro" are only intended for service personnel.



Operating hours

Fig. 6-33 Overview

Press the control button "Settings" to access further submenus.

Fig. 6-34 Operating hours "Standard " Fig. 6-35 Operating hours "User 1"

This screen shows the total operating hours and the operating hours per day.

The daily operating hours can only be reset by "User 1" press-ing the "Reset" button. If "User 1" is logged in this is indicated at the top left.



Language

Fig. 6-36 Overview

Press the control button "Languages" to access the correspond-ing submenu.

Fig. 6-37 Languages

Pressing a flag changes to the associated language.



Manuals

Fig. 6-38 Overview

Touching the book or maintenance symbol opens the associ-ated short instructions.

The book symbol is linked with a pictured short instruction man-ual for the touch panel.

By touching the control button with the maintenance symbol one can view the maintenance plan.

N O T E

Attention: The maintenance plan stored in the touch panel only serves as an example:

For maintenance work one must follow the machine related original maintenance plan in the operating instructions, which is a separate manual.

In certain intervals the display will draw your attention to the next maintenance interval.



6.6.4. Fault If the plant had been stopped because of a fault, the faulty ag-gregate will appear in red in the overview.

Fig. 6-39 Overview with fault message

The control button "Fault" brings you to the fault messages.

Fig. 6-40 Current faults Fig. 6-41 Rectified faults

When setting the filter to "Fault" and ""K, Kq", all currently exist-ing faults will be listed. Once this faults have been rectified and reset via the Reset button below the touch panel, they will dis-appear from the display.

If one would like to view the history of all rectified faults, you must set the right hand filter to "KG, KGQ, KGq".



6.7. Failure of the touch panel

Should the touch panel fail, there is still the possibility to oper-ate the machine in emergency mode.

For this, the operation mode key switch (1) must be switched to the automatic mode on the control cabinet. The machine can then be re-started (only ba a skilled electrician) with the emer-gency operation key switch (2) on the inside of the control cabi-net.

Pos. I: The System runs without wind sifter Pos. II: The plant runs with wind sifter (optional)

In the emergency operation, the MULTISTAR L3 runs at the last saved rotation speed. These rotation speeds can be changed via the touch panel.

N O T E

If the touch panel fails during operations, then the System must be driven empty with the operating mode key switch (0-position) before the machine is switched off.

1 2

1 2



6.8. Generator 6.8.1. Control module PowerWizard PW 1.1 and 2.1

Brief description

1 Display 2 AC overview key 3 Motor overview key 4 Main menu or Home button 5 Alarm confirmation button 6 Press the event reset 7 Event protocol button 8 Auto button 9 Stop button 10 Execute button 11 Escape button 12 Up button 13 To the right button 14 OK or input button 15 Down button 16 To the left button

N O T E

Take generator and motor data from the separate manual "Technical Data" chapt.: 3.5.

A detailed description can be found in the Manufacturer's documentation in the appendix "Supplier's operating instruc-tions".



C A U T I O N

The electric generator may be operated only when the screening system is stationary!

Otherwise you may suffer minor injuries, Fault / alarm - resetting process

If one of these information lamps is flashing or lights, there is a warning or a machine has been shut down.

Press the STOP button!

Press the event reset button.

Press the input button to delete all warnings and / or shut-downs.

Press the ESCAPE button to can-cel.



6.8.2. Control module PowerWizard PW 1.0 and 2.0

Brief description

1 LCD display 2 Alternating current (AC) overview button 3 Motor overview button 4 Warning indicator lamp 5 Shutdown indicator lamp 6 Alarm confirmation button 7 Lamp test button 8 START button 9 AUTO button 10 STOP button

11, 13, 15, 16 Display navigation keys 12 QUIT button 14 ENTER button

N O T E

Take generator and motor data from the separate manual "Technical Data" chapt.: 3.5.

A detailed description can be found in the Manufacturer's documentation in the appendix "Supplier's operating instruc-tions".



C A U T I O N

The electric generator may be operated only when the screening system is stationary!

Otherwise you may suffer minor injuries, Fault / alarm - resetting process

If one of the display lamps is flashing or is continuously illuminated, this indicates a warning or a pending shutdown.

Press the STOP button!

Detection and rectification of a fault is facilitated with reference to the Op-eration Manual.

Press the "Alarm acknowledgement" button and hold it depressed for 3 seconds.

Press the ENTER key to delete all warnings or shutdown processes (or)

press the EXIT key to abort.



6.9. Signal lamp with horn

Fig. 6-42 Signal lamp with horn

The signal lamp indicates the status of the plant.

Red: (lights) → Fault → Warning (e.g. folding/unfolding

belts)

Green: (lights) → Plant runs in automatic mode

Orange:

(lights) → Plant starts → Plant stops

(flashes)

→ Start of overloading on one of the screen decks. The hopper stops automatically, until normal condi-tions are re-established. During this time the hopper must not be filled.

The horn sounds as a warning when starting the machine and in case of faults.



6.10. Power failure

The plant will come to an immediate standstill. Operation of the plant must be re-assumed (see chapt. 5.4: "Installation and commissioning")

N O T E

If the screening system has been stopped without it having been previously emptied (i.e. due to a generator failure), it is essential that any residual material is removed before the plant is switched back on. Otherwise, the screen stars can be destroyed by the jammed materials.



7. Emergency D A N G E R

In an Emergency situation or with a threatening hazard to man or machine, push the closest

• Emergency Stop switch without delay or

• switch off the main switch in order to immediately stop the machine and its component.


Only trained personnel should work on the plant.

Fig. 7-1 Emergency stop push-button and main switch

The main switch is located on the electrical control cabinet.

One emergency stop button is located next to the hydraulic levers. Two additional emergency stop buttons are mounted to the left and right of the medium grain discharge conveyor.

Main switch

Emergency stop

Med

ium

gra

in

Ove

rsiz

ed g

rain

Material feed Emergency stop

Emergency stop

Fine grain



The emergency stop button or the main switch can be unlocked by turning to the right or pulling.

W A R N I N G

The depressed emergency stop push-button may be disen-gaged only after the cause for the actuation has been deter-mined and rectified. Consequences may be severe or even fatal injuries. The machine must then be restarted. The emergency stop push-button must not be used to stop the machine normally!

Komptech GmbH Kühau 37 8130 Frohnleiten Austria [t] +43 3126 505 - 0 [f] +43 3126 505 - 505 [e] [email protected]

Komptech Vertriebsges. D. mbH Carl-Zeiss-Straße 2 59302 Oelde Germany [t] +49 2522 92197 - 340 [f] +49 2522 92197 - 310 [e] [email protected]

Anlagenbau Günther GmbH Im Tiegel 7 36367 Wartenberg Germany [t] +49 6641 96 54 - 0 [f] +49 6641 96 54 - 112 [e] [email protected]

www.komptech.com

All rights reserved - Rev.12 - Edition: 03/2014 Document name: BA-L3-3BA_12_6736_en.docx Translation of the original operating instructions

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