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OPERATING & INSTALLATION INSTRUCTIONS

GAMMA MAJOR 8

CONTRACT NUMBER: MF09108 MACHINE NUMBER: 09108/01 ISSUE DATE: 13 February 2009

Omega Foundry Machinery Limited


8 Stapledon Road, Orton Southgate, Peterborough, Cambs. PE2 6TB Telephone: 01733 232231 Fax: 01733 237012 E-mail: sales@ofml.net Web site: www.ofml.net

IMPORTANT INFORMATION STORAGE OF MACHINES

IT IS IMPORTANT THAT IF THE EQUIPMENT COVERED BY THIS CONTRACT IS TO BE PLACED INTO STORAGE FOR ANY LENGTH OF TIME PRIOR TO INSTALLATION AND COMMISSIONING THEN OMEGA MUST BE CONSULTED FOR ADVICE IN ORDER TO ENSURE PROTECTION OF VUNERABLE ITEMS

O M E G A
FOUNDRY MACHINERY LIMITED 8 Stapledon Road, Orton Southgate, Peterborough, Cambs. PE2 6TB Telephone: 01733 232231 Fax: 01733 237012 E-mail: sales@ofml.net Web site: www.ofml.net

EC MACHINERY DIRECTIVE 98/37/EC

EC DECLARATION OF CONFORMITY
Customer: SIDERVAL Machine Type: Gamma Major 8 Serial Number : 09108/01 We hereby certify that the above equipment complies with the requirements of the following E.C. directive and also with the provision of the following other EEC Directives: Low voltage Directive 73/23/EEC, amended by 93/68/EEC Electromagnetic Compatibility Directive 89/336/EEC Name of authorised representative: Position of authorised representative: Signature of authorised representative: B. G. Barrett Design Engineer

Date:
OFML/EC2

INTRODUCTION

This operating manual has been issued by:

Omega Foundry Machinery Ltd

This operating manual is for the use of: -

Personnel responsible for the efficient operation of the equipment supplied.

Details relating to associated equipment of other manufacture's supply are covered in the applicable literature supplied with this manual.

CE CERTIFICATION
In EEC & EFTA countries a CE certificate will be included in this manual. This certificate is not required for countries outside these areas. Note: CE Certification is not issued with Reconditioned or Second-hand machines.

WARNINGS IMPORTANT
THIS EQUIPMENT SHOULD ONLY BE OPERATED BY AUTHORISED PERSONNEL SERIOUS DAMAGE AND/OR PERSONAL INJURY COULD OTHERWISE RESULT UNCURED OR WET SAND MUST NEVER ENTER THE SYSTEM THIS MAY BLIND THE SCREENS THIS EQUIPMENT MUST NEVER BE ALLOWED TO COME INTO CONTACT WITH ANY STRUCTURE, OBJECT OR SAND, BE IT MOVING OR STATIC THE WARRANTY OF ANY UNIT THAT COMES INTO CONTACT WITH ANY STRUCTURE, OBJECT OR SAND WILL BE VOID AS THIS CAN CAUSE WEAR, DAMAGE AND FAILURE THE LIFTING LUGS ON THE VIBRATORY MOTORS SHOULD NEVER BE USED TO LIFT THE MACHINE

PRE OPERATION CHECKS IMPORTANT BEFORE OPERATING THE EQUIPMENT THE FOLLOWING CHECKS SHOULD BE CARRIED OUT BY AUTHORISED PERSONELL 1. ALL MACHINE GUARDS ARE FITTED 2. ALL MACHINES ARE ADEQUATELY GUARDED 3. ALL EQUIPMENT IS FREE TO MOVE & ROTATE, & ALL TRANSIT BRACKETS & STRAPS ARE REMOVED

HEALTH AND SAFETY PRECAUTIONS


GENERAL The general principles followed in the design of guards and/or electrical safety devices for the machinery or systems supplied to the U.K. market follow those recommended by HM Factory Inspectorate. The components used should not be placed by any alternative, or the method of their function altered in any way. The machine/system must never be operated unless all guards are secured in their correct positions. INSTALLATION The engineer installing the machine/system must ensure that all guards are secured in position and that the electrical devices are set to operate correctly before the machine/system is handed over for production MAINTENANCE Before attempting to carry out any cleaning or maintenance work, always ensure that the machine/system is isolated, electrically, pneumatically & hydraulically at the main controls and that the machine/system is at rest, unless otherwise indicated in this manual. The customer is responsible for maintenance of the safety devices to ensure that they are in correct and complete working order at all times If it is necessary to operate any part of the machine/system under power with any guard removed or safety device by-passed, for maintenance purposes then every precaution must be taken by the engineer to ensure that no unauthorised personnel can approach the exposed machine/system. If necessary, temporary guards or safety barriers must be erected.

MOTOR MOUNTING BOLTS


WARNING
BOLTS SECURING OUT OF BALANCE MOTORS TO THIS MACHINE MUST BE CHECKED FOR TIGHTNESS DAILY FOR THE FIRST WEEK OF OPERATION AND THEREAFTER AT 'WEEKLY' INTERVALS. IF BOLTS ARE LEFT LOOSE, SERIOUS DAMAGE CAN RESULT TO THE MOTOR BASE PLATE, AND CRACKS DEVELOP IN STRENGTHENING WEBS. BOLTS SHOULD BE TIGHTENED WITH A SOCKET & TORQUE WRENCH TO THE FIGURES LISTED IN THE INSTALLATION SECTION OPEN ENDED AND ADJUSTABLE SPANNERS MUST NEVER BE USED ALL BOLTS SHOULD BE CHECKED ON A WEEKLY BASIS TO ENSURE NO DAMAGE CAN OCCUR TO UNIT

VIBRATORY MOTORS
WARNING
IT IS VITALLY IMPORTANT THAT VIBRATORY MOTORS HAVE THEIR WEIGHTS SET TO THE SAME POSITION AT BOTH ENDS OF THE MOTOR IN DUAL MOTOR APPLICATIONS IT IS VITAL THAT: 1. THE MOTORS ARE ADJUSTED TO THE SAME WEIGHT SETTINGS 2. THE MOTORS COUNTER ROTATE AS SHOW IN THE DIAGRAM BELLOW NOTE FAILURE TO COMPLY COULD LEAD TO THE UNIT BEING DAMAGED

MOTOR CONNECTIONS
It is vital that the cables connected into the vibratory motor/s terminal box/es are protected from the affects of vibration. The vibration can cause the cables in the terminal box to flex and eventually break. To avoid flexing and failure, anti vibration compound should be used in the terminal box around the cables to stop them moving when the unit is vibrating. The terminal box should not be completely filled, rather anti vibration compound should be fitted around the wires to stop them moving. Anti vibration compound is supplied with all new machines from Omega Foundry Machinery Ltd.

GENERAL DESCRIPTION
Refer to layout drawing on next page. Used chemically bonded foundry sand having a maximum temperature of 300 degrees C can be processed from lump to grain size in this unit, a proportion of the fines and dust are removed by the dust extraction system. Cast sand moulds are loaded onto the shakeout deck where they are subjected to a vibratory action, which breaks down the mould and reduces the sand mould to lumps. The lumps move through the top shakeout deck and fall onto the perforated screen. The lumps are further broken down and eventually fall through the 6mm holes in perforated screen and onto the wedge wire screen. Still further breaking down and attrition occurs on the wedge wire screen and the grain sized sand falls through the 1.5mm gaps in the wedge wire screen. The sand is now on the final mesh screen (size classification) where the grain sized sand passes through and is discharged from the bottom of the machine. Any oversized sand (not passing through the final mesh) is moved along the screen and continuously discharged from the end of the machine. Tramp metal, flash and larger extraneous materials are held above the perforated plate & wedge wire screens for later removal through an access doorway at the side of the machine. It is essential that this material be removed at the end of every shift, or more often if required. Failure to remove this material can seriously damage the wedge wire screens and will reduce the efficiency of the machine. Support Springs Springs are used to support the processor body and isolate the vibration Vibratory motors These are foot-mounted, out-of-balance motors and are secured by high tensile bolts to the top of the processor body. Controls A separate wall-mounting panel is supplied for controlling the vibratory motors

INSTALLATION Spring Location After installing the vibratory equipment check that the compression springs are located correctly on either spigots or clamped pads. Clearance Ensure that the equipment has adequate clearance in all directions and does not come into contact with any fixed structures. Overload Protection The electrical starting equipment should incorporate two sets of overloads giving individual protection to each motor. Power Cables The cable feeding the motors, from either a static junction box or starter equipment, should be flexible and an adequate loop made so that the vibration is totally absorbed before fixing into a junction box fitted onto the vibratory machine. Separate leads can then be taken to each motor and clipped to the machine body. Fixing Bolts All vibrator motor bolts are to be high tensile steel, grade 8.8 and fitted appropriate washers ands with nyloc or similar locking nuts. These bolts should be checked for tightness daily for the first week of operation. If the vibrator motors are removed for any reason, new nuts, bolts and washers must be used on replacement. Table 1: FIXING BOLT SIZES AND TIGHTENING TORQUE Bolt Diameter mm or Inches M24 1 UNF See maintenance section for tightening procedure. Lifting Lifting eyes on the vibrator motor casing are intended for lifting the motor itself only. The overall weight of the machine is stamped on the machine nameplate and suitable lifting equipment must be used to handle this load. Contd Torque Nm 818 818

Installation Contd Securing of Machinery All machines have either base plates, support frames or centre support tubes, all of which have drilled holes for securing the equipment to either other steelwork or a concrete base floor with suitable fixing bolts or foundation bolts respectively. Transport Bolts If machines are fitted with transport bolts please ensure these are removed after installation but before machine is switched on.

INITIAL START-UP
WARNING
ONLY AUTHORISED PERSONNEL SHOULD CARRY OUT THE FOLLOWING CHECKS: ALL EQUIPMENT MUST BE GUARDED. EXTREME CAUTION MUST BE USED.

1. To check the motors it will be necessary to remove the covers and observe the rotation 2. With the unit stopped remove the covers 2.1. Extreme caution must be observed when operating the machine with the covers removed 3. Ensure the unit is adequately guarded 4. Use extreme caution at all times 5. Start the vibratory screen 5.1. The motor should rotate in a clockwise direction, when viewing the side of the unit with the discharge on the left 5.2. For weight settings see maintenance section 6. Stop the unit and replace covers

OPERATION - TYPICAL
Starting 1) Start the Dust Extraction 2) Start the PV 3) Start the Cooler 4) Start the Gamma Major 5) Once all other plant is running, start the sand feed Stopping 1) Stop the sand feed 2) Allow the final sand to process through the plant 3) Stop the Gamma Major a) After a slight delay the shake out will go into reverse for a short period and then stop 4) Stop the Cooler 5) Stop the PV 6) Stop the Dust extraction Note This is for a typical installation, some of the plant listed in the starting / stopping sequence may or may not be included in a specific installation.

RECLAMATION TIMER SET UP


A Mitsubishi Alpha logic controller controls the reclamation plant, this unit has multiple timers, split into categories to allow the commissioning engineer to fine tune the reclamation plant. The below timers are adjusted as follows: Use the LEFT and RIGHT arrows to select the required screen. Use UP and DOWN arrows to select value to be adjusted then use + and - arrows to change time. Press OK once desired value is set.

Please note: A setting of 10 in these timers equates to a time of 1 second. Current reading is not in Amps, it is just a numerical representation. Dust Ex: on this first screen the engineer sets the time that the dust extraction unit (if fitted) will start up once the green start button has been pressed, and the time that the unit will over run once the red stop button has been pressed.

Classifier Delays: on this screen, the engineer sets the time that the cooler classifier fan (if fitted) will start up once the green start button has been pressed, and the time that the unit will over run once the red stop button has been pressed.

Fluidising Fan Delays: on this screen, the engineer sets the time that the fluidising fan on the fluidised transfer bed (if fitted) will start up once the green start button has been pressed, and the time that the unit will over run once the red stop button has been pressed.

Vator Delays: on this screen, the engineer sets the time that the Vator (if fitted) will start up once the green start button has been pressed, and the time that the unit will over run once the red stop button has been pressed.

Gamma Delays: on this screen, the engineer sets the time that the Gamma (if fitted) will start up once the green start button has been pressed, and the time that the unit will over run once the red stop button has been pressed.

Motor Safety On Delay: on this screen, the engineer sets the time after the Gamma and Vator (if fitted) start, before the PLC begins monitoring their current level. On machines with counter rotating vibratory motors, this system detects that both motors are running. If they are not both using enough current they are shut down to prevent them running out of balance damaging the machine. It is recommended that this time is kept to a minimum, just long enough for the motors to start up.

Gamma Reverse: on this screen, the engineer sets the time that the Gamma (if fitted) will reverse brake after either the red stop button has been pressed, or cooler classifer (if fitted) becomes full. As well as this, the length of time in reverse can also be set.

Vator Reverse: on this screen, the engineer sets the length of time that the Vator (if fitted) will reverse brake for after the red stop button has been pressed. As well as this, the length of time in reverse can also be set.

Gamma motors: on this screen the engineer sets the minimum level of current that the low level Gamma (if fitted) must be using (please note that this is a numerical value, not the actual current) as discussed in Motor Safety On Delay. The first 2 numbers show the current value of the 2 motors, the engineer should set the MIN value to just under the value shown by the motors during empty running of the machine. If one motor falls below this level, a message will be displayed GAMMA MOTOR LOW CURRENT SHUTDOWN and the machine will stop. To erase this message press the emergency stop button.

Vator motors: on this screen the engineer sets the minimum level of current that the Vator (if fitted) must be using (please note that this is a numerical value, not the actual current) before the machine is shutdown, as discussed in Motor Safety On Delay. The first 2 numbers show the current value of the 2 motors. The engineer should set the MIN value to just under the value shown by the motors during empty running of the machine. If one motor falls below this level, a message will be displayed VATOR MOTOR LOW CURRENT SHUTDOWN and the machine will stop. To erase this message press the emergency stop button.

HL Setup: on this screen, the engineer sets the level of sand at which the High Level (if fitted) will display the full beacon to the operator. To set this, the high level gamma should be run with sand at its full level. The engineer should adjust the value of SET to be the same as the AMPS Value. The length of time that the sand has to be at or above this level for before the full beacon is displayed can also be altered with DELAY.

HL Reset: on this screen, the engineer sets the level of sand at which the High Level (if fitted) will display the empty beacon to the operator. To set this, the high level gamma should be run with sand at a level where the operator can commence filling. The engineer should adjust the value of RESET to be the same as the AMPS Value. The length of time that the sand has to be at or below this level for before the empty beacon is displayed can also be altered with DELAY.

Clean Type: on this screen, the engineer sets which type of filter cleaning method the dust extraction system (if fitted) is using. Method should be set to 0 if a pulse jet system is being used, or 1 if a filter shaker system is in use.

Pulse Jet Over Run: on this screen the engineer sets for how long the pulse jet (if fitted) will keep working for once the dust extraction stops.

Shaker Timer: on this screen, the engineer sets the time from when the dust extraction stops working to the filter shaker running in DELAY. Also, the length of time that the shakers run for, can be adjusted in SHAKE. All times are in 10ths of seconds.

Level Probe Off Delay: on this screen, the engineer sets the length of time that the sand level inside the cooler has to be below the sand level sensor, before the classifier will begin refilling.

Diagnostic Screen: The final screen displays to the engineer which inputs and outputs are on. This can help with fault finding if the machine is not operating as expected.

RECLAMATION PLANT START UP


To start the reclamation plant you must ensure that all of the MCBs are on and that the emergency stop is reset (indicated by the safety reset button being illuminated by a blue light). The water pump, if fitted, must also be set to automatic (as described above). Once the start button has been pressed the reclamation plant will start up sequentially with delays between each set of equipment starting being adjusted as described in the RECLAMATION TIMER SET UP. The equipment will start up in the following sequence: 1. Dust extraction 2. Classifier 3. Gamma 4. Vator The water cooling tower will start when the thermostat switches on. When the stop button is pressed the plant will stop, with the Gamma and Vator entering a reverse braking sequence. The dust extraction will overrun the other equipment. When a water-cooling tower is supplied with reclamation equipment the reclamation control panel will include an auto/manual control for the cooling tower water pump. This can be set to manual during extreme cold conditions to allow the pump the keep the water in the pond circulating to avoid freezing. To return the plant to normal operation the water pump control must be set to automatic otherwise the plant will not start up. A pond heater panel is also supplied with all water-cooling towers; this provides control for the immersion heater supplied with the water-cooling tower. The heater is controlled from a separate panel so that during shutdowns the reclamation panel can be isolated form the mains supply but the heater can be left operating to stop the water in the pond freezing.

MAINTENANCE
IMPORTANT
BEFORE ATTEMPTING TO CARRY OUT MAINTENANCE WORK ON THIS UNIT. ENSURE THAT THE ELECTRICAL SUPPLY IS ISOLATED

GENERAL Screens - General Regular inspection of the screens should be made to check the conditions of the screens. The screens should be renewed as necessary. It is essential that waste material (i.e. tramp metal) be removed at the end of every shift, or more often if required. Failure to remove waste material can seriously damage the wedge wire screens and will reduce the efficiency of the machine. Mounting Springs Helical Compression Periodically inspect the springs for signs of fatigue, renew as follows, if necessary: 1. Lift the unit and support to free the spring from loading 2. Remove the old spring 3. Fit the new spring over the bottom spring retainer and lower the processor onto the spring, ensuring that the spring is correctly located on the retainers. 4. Ensure correct alignment of all springs before re-starting the unit. NOTE IT IS ESSENTIAL THAT SPRINGS ARE CHANGED AS A COMPLETE SET FAILURE TO DO THIS CAN CAUSE THE MACHINE TO BECOME UNBALANCED AND BE SERIOUSLY DAMAGED Adjusting out-of-balance weights The positioning of the out-of-balance weights on the vibratory motors are set during testing & commissioning by qualified Omega Engineers. These weights should not be adjusted without prior consultation with Omega Foundry Machinery Limited. The weights are generally set at 75% and should never be set to more than 80% without the express permission of Omega Foundry Machinery Ltd. NOTE ADJUSTING THESE WEIGHTS COULD SERIOUSLY DAMAGE THE MACHINE AND REDUCE ITS PERFORMANCE SCHEDULED MAINTENANCE DAILY OR AT THE END OF EACH HALF SHIFT

Removing tramp metal 1. Stop feeding the unit and allow it to empty 2. Open the trough doors by releasing the clamping screws, remove the doors 3. Run the vibratory motor, discharge the tramp metal 4. Refit the doors, securing them with the clamping screws 5. Ensure the rubber seal is fitted correctly and flat, and that it is in good condition Vibratory motor security During the first weeks running, check the security of the vibratory motor fixing bolts daily, thereafter this check should be made at weekly intervals WEEKLY General Clean all working parts of unit Vibratory motor security Check the security of the vibratory motor fixing bolts Springs Inspect each spring for damage and renew, if necessary, as detailed under 'General' MONTHLY Vibratory motor weight clamping Check vibratory motor weight clamping bolts THREE MONTHLY Inspection of wear plates, screens and mounts Inspect the parts under this heading and renew any item showing signs of wear or damage Shakeout Deck Inspect the shakeout grid and perforated plate for wear and renew if necessary YEARLY Vibratory Motors Check the lubrication of the vibratory motors in accordance with the instructions issued

VIBRATORY MOTORS & MOUNTING BOLTS


TIGHTENING PROCEDURE PRE-TIGHTENING 1. Each nut & bolt must include 1 off hardened washer: 1.1. One off washer located between bolt head and the motor foot 1.2. There is no washer between the nut and the fabrication 2. Inspect motor mounting surfaces, both on the fabrication and the motor, and the boltholes for physical damage. 3. All mounting surfaces MUST be flat and free from paint, dirt and scale. 4. Assemble Bolt and Washer through each motor mounting hole and into the fabrication 5. Turn the bolt to locate it into the nut, which is weld in the fabrication with a retaining plate 6. Screw the bolt fully into the nut making sure all items are seated correctly 7. Fit the rest of the bolts and washers 8. Pre-tighten the bolts until all mating surfaces are in contact. The purpose of the initial tightening is to bring the joint surfaces into close contact, and also provide a small initial tension in the bolt. 9. When the motor is hung from the underneath of a machine, the motor weight must be fully supported so the tension in the bolt is from the tightening process and not the weight of the motor The following bolts, nuts and washers are required for each motor: Bolts and Nuts High tensile Grade 8.8 UNF

Washers
TIGHTENING - TORQUE CONTROL METHOD.

Hardened plain washers

10. A calibrated tightening device should be employed. 11. The torque necessary to induce the correct bolt tension is defined in the table previously displayed ion this manual 12. Only be for lightly oiled self colour bolts and nuts. 13. Bolts and nuts, which are dry, as a result of storage, must be lightly oiled in order to prevent high thread friction. 14. The tightening order of the bolts should be in a staggered pattern a. In the case of a group of 6 bolts, or more in a single assembly, the tightening procedure should commence in the centre and progress outward.

Contd

Vibratory Motors & Mounting Bolts Contd REMOVAL OF MOTOR THE CORRECT AND COMPLETE ASSEMBLY OF THE COMPLETE SET OF SPECIFIED BOLTS AND WASHERS, FOR EACH MOTOR, IS VITAL TO THE SAFE AND EFFICIENT FUNCTION OF THE MOTOR. WHEN REMOVING & REFITING OR REPLACING THE MOTORS, NOTE: 1. ALL THE ORIGINAL BOLTS AND WASHERS MUST BE REPLACED 2. IDENTICAL PARTS (SAME GRADE SIZE & LENGTH) MUST BE USED 3. THE ORIGINAL PARTS FITTED MUST NOT BE REUSED. THE COMPLETE REPLACEMENT OF THE FULL SET, FOR EACH MOTOR, IS VITAL TO THE SAFE AND EFFICIENT FUNCTION OF THIS TYPE OF MOTOR. CHECKING BOLT TORQUE WHEN CHECKING THE TIGHTNES OF THE BOLTS, IT IS SUFFICIENT TO CHECK THAT THE BOLTS ARE AS TIGHT AS ORIGINALLY SET. THIS DOES NOT IMPLY THAT THE BOLTS ARE TO BE FURTHER TIGHTENED EACH TIME THEY ARE CHECKED! GENERAL 1. FOLLOW ALL INSTRUCTIONS RELATED TO CHECKING MOTOR BOLTS IN OPERATORS MANUAL. 2. IN CASE OF DIFFICULTIES CONSULT OMEGA FOUNDRY MACHINERY

TROUBLE SHOOTING
FAULT Gamma will not deliver satisfactory output tonnage Quality of output sand is poor Large quantity of oversize High proportion of sand coming out of oversize POSSIBLE CAUSE 1. Out of balance motor weights need to be adjusted Fine mesh screen damaged Fine mesh screen blocked REMEDY 1. Consult Omega Foundry Machinery Limited before adjusting weights Replace mesh screen Clean mesh screen

MOTOR PARTS

SPARE PARTS & AFTER SALES SERVICE


When ordering spare parts and/or after sales service, please quote: 1. Machine number 2. Contract Number 3. Description of Part

Omega Foundry Machinery Limited


8 Stapledon Road, Orton Southgate, Peterborough, Cambs. PE2 6TB Telephone: 01733 232231 Fax: 01733 237012 E-mail: sales@ofml.net

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