DAGII - Operating Manual

DAG II
Vacuum device for shredder modules Operating Manual
Giesecke & Devrient
Hinweis
Die in dieser Dokumentation enthaltenen Informationen, Kenntnisse und Darstellungen betrachten G&D/GAO/KRMER als ihr alleiniges Eigentum, sie sind daher STRENG VERTRAULICH zu behandeln. Die Dokumentation bzw. die darin enthaltenen Informationen, Kenntnisse und Darstellungen drfen ohne die vorherige schriftliche Zustimmung von G&D/GAO/KRMER weder vollstndig noch auszugsweise, direkt oder indirekt Dritten zugnglich gemacht, verffentlicht oder anderweitig verbreitet werden. Die Geltendmachung aller diesbezglichen Rechte, insbesondere fr den Fall der Erteilung von Patenten, bleiben der Firmengruppe Giesecke & Devrient vorbehalten. Die bergabe der Dokumentation begrndet keinerlei Anspruch auf eine Lizenz oder Benutzung.
Warenzeichen
Andere Produktnamen, Firmennamen und Bezeichnungen in diesem Handbuch knnen Warenzeichen oder eingetragene Warenzeichen anderer Firmen sein und werden in diesem Handbuch nur in erklrender Weise und ohne Absicht zur Rechtsverletzung erwhnt.
Vorbehalt
Die in dieser Dokumentation gemachten Angaben stellen keine zugesicherten Eigenschaften dar.
Note
The information or material contained in this document is STRICTLY CONFIDENTIAL and any recipient of this document shall not disclose or divulge, directly or indirectly, this document or the information or material contained herein without the prior written consent of G&D/GAO/KRMER. All copyrights, trademarks, patents and other rights in connection herewith are expressly reserved to the Giesecke & Devrient group of companies and no license is created hereby.
Trademarks
Other product names, company names and descriptions in this manual may be registered trademarks from other companies. These are only used in this manual for explanatory purposes and any misuse is unintended.
Disclaimer
The information in this documentation does not represent any guaranteed characteristics.
Technische nderungen vorbehalten / Technical changes reserved.
Systemlieferant Supplier of system Giesecke & Devrient Prinzregentenstrae 159 D-81677 Munich Germany Unternehmensbereich Banknotenbearbeitungssysteme Currency Automation Division Euckenstrae 12 D-81369 Munich Germany
Hersteller DAG II Manufacturer DAG II

G. H. Krmer GmbH & Co. KG Schulstrasse 57 Postfach 1162 35301 Grnberg
Diese Maschine erfllt die Sicherheitsanforderungen der einschlgigen EG-Richtlinien und hlt die ENNormen, wie in der EG-Konformittserklrung angegeben, ein. This machine meets the safety requirements of the relevant EC directives an complies with the EN standards as listed in the EC Declaration of Conformity.
Service Hot Line
Tel. Fax
0180 531 37 32 x49 89 4119-4410
1998 GAO/KRMER Printed in Germany
Ausgabedatum / Date of issue Artikelnummer / Part no.
11/98 207943 00 1
Contents
Operating Manual
DAG II
Contents
General safety information Chapter 1
1-1 1-1 1-2 1-2 1-2
Correct use ...................................................................................................................... Incorrect use.................................................................................................................... Safety information for maintenance and repair of the vacuum device ...................... Safety rules ...................................................................................................................... EC Conformity .................................................................................................................
Description of product
Chapter 2
2-1 2-1 2-2 2-3 2-3 2-4 2-4 2-4 2-5
Introduction ..................................................................................................................... Symbols used .................................................................................................................. General note .................................................................................................................... Specification of the vacuum device .............................................................................. Scope of supply............................................................................................................... Basic equipment.............................................................................................................. Area of application, construction, mode of operation................................................. Data on the specification plate ...................................................................................... Technical specifications / device overview ..................................................................
Installation
Chapter 3
3-1 3-2 3-2 3-2 3-3 3-4
General quality of the installation room........................................................................ Weather influences ......................................................................................................... Dimensions of the installation room ............................................................................. Exhaust air and waste heat ............................................................................................ Interface to the banknote processor ............................................................................. Transport piping for shreddings....................................................................................
Putting into operation Change of collecting bags and maintenance
Chapter 4 Chapter 5
5-1 5-1 5-2 5-3
Safety information........................................................................................................... Change of the collecting bag ......................................................................................... Maintenance intervals..................................................................................................... Cleaning of the filter bag ................................................................................................
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Contents
Renewing of the filtering bag ........................................................................................ Adjustment of the filling level control ..........................................................................
5-3 5-4
Malfunctions
Chapter 6
6-1 6-1
General ............................................................................................................................ Vacuum device malfunctions ........................................................................................
Assembly of spare parts and wear parts
Chapter 7
7-1 7-1 7-2 7-3 7-3 7-3 7-3 7-3 7-4 7-4 7-4 7-4 7-4
General ............................................................................................................................ Preface to safety............................................................................................................. Device design ................................................................................................................. Switchbox........................................................................................................................ Power pack...................................................................................................................... Fuses and relays ............................................................................................................ Filling level control......................................................................................................... Terminal switch .............................................................................................................. Fan ................................................................................................................................... Motor................................................................................................................................ Impeller............................................................................................................................ Steering roller / pedestal roller..................................................................................... Rubber gasket.................................................................................................................
Anhnge / Appendix
Maskizzen / Dimension sketches................................................................................ Schaltplne / Wirering diagramms................................................................................ EG-Konformittserklrung............................................................................................. Ersatz- und Verschleiteiliste / Spare parts and Wear parts listing ..........................
A-1
A-3 A-5 A-9 A-11
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General safety information
Operating Manual
DAG II
Chapter 1
Warning Non-observance of the following safety information may lead to physical injury and damage to the vacuum device. Always follow the general safety and accident prevention rules in addition to those set forth in this manual!
Correct use
The device may only be used to vacuum dry shredder material and may not be used in open air.
Incorrect use
No liquids or aggressive gases, lightly inflammable and explosive dusts and powders or glowing particles (e.g. smoulder spots) should be vacuumed. The application of the vacuum device to lacquer spray is prohibited. The vacuum device may only be commissioned and maintained after these operating instructions have been read and understood. The vacuum device may only be used in the manner described in these operating instructions. The owner must ensure 1. that the people involved with the operation and maintenance of the equipment are thoroughly familiar with all safety information and rules and follow them accordingly. 2. that the vacuum device is only used in safe operating condition. The vacuum device may not be used without the appropriate protective and safety equipment. If a removal of the safety features will be necessary, authorized personnel only are allowed to carry out the removal. Immediately after the maintenance the safety features must be checked. The vacuum device is not to be deployed on machine tools on which the occurrence of effective ignition sparks or smoulder spots should be anticipated. Attention must be paid to ensure that the vacuumed medium is stored exclusively in undamaged collecting bags. Attention has to be paid to ensure that the connecting cable is not damaged by being driven over, jerking, crushing or other similar actions. The connecting cable must be inspected regularly for damage and aging. The vacuum device may not be operated if one or more parts (e.g. cable, plug) are damaged and the functioning is not faultless and there is visible or anticipated damage. Electrically powered vacuum devices of the Type DAG II may only be connected by using the plugs specified for the purpose - in accordance with VDE 0623 (EN 60 309 -2; 1992). The plug is to be inserted into the socket after the vacuum device
Safety information
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is in its place of deployment. After use and prior to relocating the vacuum device to a new place of the deployment and prior to maintenance, cleaning or the replacement of moving parts, the plug must be removed from the socket. Do not reach into rotating or moving parts. Attention must be paid to the electrical conductivity (earthing) of the transport ducts.
Safety information for Maintenance tasks may only be performed by appropriately instructed staff. maintenance and repair of the vacuum Adjustments, troubleshooting and repairs may only be performed by trained people or appropriately instructed staff. device Before maintenance or repair work is carried out:
1. Switch off the master switch. 2. Secure the master switch against being accidentally switched on. 3. Remove the network plug from the socket. 4. Check that none of the parts are under (electrical) power. Work on parts and equipment that are under power is not allowed. Engagement in power leading equipment is allowed only for authorized personnel. Otherwise there may be hazard of electric shock. Only approved, original spare parts may be used for maintenance and repairs.
Safety rules
The owner of the vacuum device is responsible for ensuring that it is properly installed and maintained. If the vacuum device is used outside Germany, the safety rules applicable in that country must be followed in addition to those set forth in these operating instructions. If such applicable rules demand that steps be taken which go beyond the rules applying in Germany or these instructions, then these must be complied with before the vacuum device is used.
EC Conformity
The vacuum device with CE symbol is compliant with the guidelines set forth in the EC declaration of conformity (see appendix) when used for the purposes and in the manner described in these operating instructions.
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Description of Product
Operating Manual
DAG II
Chapter 2
Description of product
Introduction
These operating instructions contain important information for the safe operation of the vacuum device. They contain essential information for the necessary maintenance work, give help in the event of malfunctions, and contain information about spare parts. The operating instructions must always be available to staff at the place the vacuum device is used. The operating instructions should be consulted for the following tasks: Operation, including rectification of faults and system care Maintenance (Maintenance, inspections, repairs) Commissioning The vacuum device may only be used after the operating instructions have been read and understood. The operating instructions are an ideal supplement to existing national rules concerning safety and environmental protection.
Symbols used
These operating instructions contain essential safety information and tips which are indicated by the following symbols: This symbol and the keyword below it indicates information concerning danger. Non-compliance with these instructions may be hazardous to health or lead to physical injury. If the symbol is followed by the keyword Danger it indicates a direct danger to the life and health of people. If the symbol is followed by the keyword Warning it indicates a possible danger to the life and health of people. If the symbol is followed by the keyword Caution it indicates a possibly dangerous situation that may lead to light or slight injury. Warning: Remote-controlled system - may start without warning. Danger - High Voltage! This symbol warns of potentially lethal voltage. It refers to tasks that may only be carried out by trained electricians.
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Attention! This symbol indicates warnings. The non-observance of these warnings may lead to damage or destruction of parts of the pneumatic module. This symbol indicates information and tips.
It is, however, equally important to follow the instructions concerning transport, installation, operation and maintenance that have no special emphasis, and to comply with the technical specifications (in the operating instructions, product documentation and on the machinery itself) in order to avert malfunctions which, directly or indirectly, may lead to serious injury or material damage. Qualified staff are people who by virtue of their training, experience and knowledge of the respective standards, provisions, safety rules and operating conditions, have been given responsibility to carry out the required activities and in doing so to recognise and avert possible dangers.
General note
For reasons of scope and due to the many possible variations, these operating instructions do not contain every detail and can, in particular, not take into account every operational constellation or state of maintenance. Should you require further information, or should particular problems occur that are not covered in full detail in these instructions, then please contact the maker for the necessary information. We expressly state that the content of these operating instructions does not constitute part of an earlier or existing agreement, promise or legal relationship, nor is it intended to change any of the above. All obligations derive from the respective purchase agreement, which also contains the complete and sole valid warranty text. The contractual provisions contained therein are neither extended nor limited by these operating instructions.
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Specification of the vacuum device
Heavy industrial specification for heavy duty deployment. Suitable for all climatic zones for deployment in buildings. Ready to plug-in device incl. switchbox, mounted on casters. Double collection unit for shredder material with manual switching. Continuous operation with interchangeable collector switching. Synchronised operation with charging collection units in parallel. Lacquer finished, Color: pebble grey RAL 7032. The basic dimensioning of the double vacuum devices DAG II are identical and differ only in the sizes of the types DAG II - 75 and DAG II - 110 by the size of the reduction joint on the suction side of the fan DN 120/80 mm, or DN 120/100 mm. The necessary electrical supply of the DAG II is by means of flexible cable (VDE,UL) with CEE plug (3-phase devices), or protected contact plug (single phase devices), with a length of 10 m. As signal cable a data line (VDE,UL) with a (9 pin) data connector is used to connect it to the banknote processor. For the different banknote processing machines two types of signal cables are used: Control type 300/1000: with 4-terminals, Length: 30 m and Control type 3000/2000: with 4 terminals, Length: 40 m. The deployment of two "One way collecting bags" for shreddings, leads to a capacity per bag of 190 l (in synchronous operation 380 l per every DAG II). This approximates to 19,000 BN 21,500 BN which is equals to a weight of approx. 17 kg - 20 kg*), depending on numbers deployed (in synchronous operation about 38,000 BN 43,000 BN per DAG).
*) In case of normed BN: Format 150 mm x 75 mm, Thickness 80 m, Paper 80 g/m
The filter bag of the DAG II is made of a polyester needle-loomed felt. The designation of the filter material is PE 7527 ASEP. With a diameter of 500 mm of the bag, the filter surface is 1.6 m2.
Scope of supply
Subframe on 4 casters. Fan completely installed in the sound insulation cabin. With integrated control board. Tubular silencer. 10 m power connection cable with plug. 30 m (controller 300/1000), or. 40 m (controller 2000/3000) signal cable. 2 collecting bags for shreddings mounted on the subframe each with a capacitive proximity switch as level indicator as well as a switch shutter (with inductive proximity switch as end switch) and with adjustable filter bag supports.
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Basic equipment
2 filter bags, Length: 1200 mm or 900 mm, DN 500 mm, Material: Polyester needle-loomed felt 6 collecting bags for DN 500 mm The device is supplied completely assembled, however, without filter and collecting bags mounted.
Area of application, construction, mode of operation
NOTE: the electrical machinery with which these operating instructions are issued are parts of high-voltage installations, assemblies and appliances. They are mainly designed for industrial applications in accordance with rules referred to on specification plates and in certificates, purchase documentation, and catalogue (eg,: VDE 0530, IEC34-1). Accordingly, the safety information in these operating instructions refers chiefly to the procedures to be followed for correct use in an industrial environment. Any additional national, local or systemspecific rules and requirements must also be taken into account. However, the vacuum device is also used in non-industrial areas, ie, in trade and office areas. If in such cases (or in special industrial applications) the safety measures taken in accordance with the documentation and specification plates is not sufficient due to special rules or provisions, then the owner of this machinery must ensure compliance with such special rules and provisions (eg, by ordering special models of the machinery, fitting additional safety equipment, appropriate installation, etc.).
Data on the specification plate
Typ G&D DAG II-__/____ Ident. No. __________ Baujahr 1998 Serial No. ______ Luftvolumenstrom ____ m/h Max. Pressung ____ kPa V~ AC _ * ___ N Hz __ VA _____ A ____
Translation: Type G&D DAG II-__/____ Ident. No. __________ Year made 1998 Serial No. ______ Air volume flow _____ m/h Max. pressure _____ kPa V~ AC _ * ___ N Hz __ VA _____ A ____
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Technical specifications / device overview
Type: DAG II 55
55/1000 50 Hz 158770 011 300/1000 [mm] [mm] [mm] [kg]
55/1000 60 Hz 158771 011 300/1000
Ident. No. Type of control (ISS/BPS) Dimensions Length Depth Hight *) Weight
*) Final height with filtering bag supports draged out complete
1890 730 2370 172
1890 730 2370 172
Max. sound pressure acc. to DIN 45 635 Vacuum performance Volume flow (maximal) Underpressure (maximal) Transportation fan Drive motor Type of rotor (DN in mm) Electrical connection DAG II Operating/Mains voltage Frequency Power consumption Power intake Heat flow (cos = 0,9)
[dB/A]
69
69
[m/h] [kPa]
400 1,4
400 1,4
[mm]
EAMR 71 G 280
EBS 71 K2 280
[V] [Hz] [VA] [A]
230 50 550 3,4
115 60 550 )
[W]
500
500
) Data will be detected at first after device is manufactured
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Type: DAG II 75
75/1000 50 Hz
75/1000 60 Hz
75/2000 50 Hz
75/2000 60 Hz
156737 011 156739 011 156738 011 156741 011 3000/2000 3000/2000 300/1000 300/1000 [mm] [mm] [mm] [kg]
1890 730 2370 175
1890 730 2370 175
1890 730 2370 175
1890 730 2370 175
[dB/A]
70
70
[m/h] [kPa]
660 1,8
660 1,8
660 1,8
660 1,8
[mm]
K21R 80 K2 K21R 80 K2 K21R 80 K2 K21R 80 K2 340 280 340 280
[V] [Hz] [VA] [A]
400 50 750 1,2
208 60 750 )
400 50 750 1,2
208 60 750 )
[W]
700
700
700
700
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Operating Manual
DAG II
Type: DAG II 110
110/1000 50 Hz
110/1000 60 Hz
110/2000 50 Hz
110/2000 60 Hz
156742 011 156744 011 156743 011 156745 011 3000/2000 3000/2000 300/1000 300/1000 [mm] [mm] [mm] [kg]
1890 730 2370 176
1890 730 2370 176
1890 730 2370 176
1890 730 2370 176
[dB/A]
70
70
[m/h] [kPa]
800 1,6
800 1,6
800 1,6
800 1,6
[mm]
K21R 80 G2 K21R 80 G2 K21R 80 G2 K21R 80 G2 340 280 340 280
[V] [Hz] [VA] [A]
400 50 1100 1,6
208 60 1100 )
400 50 1100 1,6
208 60 1100 )
[W]
1000
1000
1000
1000
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Type: DAG II 150
150/1000 50 Hz
150/1000 60 Hz
150/2000 50 Hz
150/2000 60 Hz
156746 011 156748 011 156747 011 156749 011 3000/2000 3000/2000 300/1000 300/1000
[mm] [mm] [mm] [kg]
1890 730 2370 185
1890 730 2370 185
1890 730 2370 185
1890 730 2370 185
[dB/A]
71
71
[m/h] [kPa]
1200 1,85
1200 1,85
1200 1,85
1200 1,85
[mm]
K21R 80 S2 K21R 80 S2 K21R 80 S2 K21R 80 S2 340 365 340 365
[V] [Hz] [VA] [A]
400 50 1500 2,4
208 60 1500 )
400 50 1500 2,4
208 60 1500 )
[W]
1400
1400
1400
1400
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Installation
Operating Manual
DAG II
Chapter 3
Installation
General quality of the The installation room must be dry and have a level floor. If located outside a solid building should possess a solid construction on all installation room
sides to protect the vacuum device against weather influences. In any event there should be exhaust openings in the room structure to let out the transport-air volume for shredder material suctioned off the currency processor. Attention! If the installation room is cooler than the banknote processing room by more than 15C, the suction line must be fitted with a back pressure valve in order to prevent a convective streaming back of the cold air into the banknote processing room during the standstill of the vacuum device.(Used only on basis of special discussion.) Note If the piping of the vacuum device crosses areas with temperatures more than 15C colder than the banknote processing room, the piping must be heat insulated (building contractors work). Caution At the door entry to the installation room of the vacuum device (possibly the whole room of currency processing if the vacuum device is installed there too) a warning sign Fire, Open Light and Smoking prohibited should be fitted. Danger! Installation of the vacuum device in surroundings with hazard of explosion is prohibited. Caution The vacuum device should be inspected daily to detect damages. Damages of the filter bag and the collecting bag should be searched for in particular. This inspection has especially to be organized by the user if the vacuum device will be operated in a detached installation room without surveillance.
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Installation
Warning! If inspection of the vacuum device can not safely be organized by the user and without sufficient ventilation of the installation room, it may become possible in case of trouble and under most disadvantageous circumstances (e. g. a damage of a collecting bag followed by a free blowing of shreddings into the installation room) to reach a lower ignition limit of the shreddings-air-mixture. In this case hazard of explosion is possible. If inspection of the vacuum device can not safely be organized by the user it is strictly recommended to install a surveillance device for hazards (e. g. dust, smoke, fire, etc.) by the user. If non of the above named action will be carried out the operation of the vacuum device inside the meant room is prohibited.
Weather influences
The vacuum devices may not be exposed to the influence of high air humidity (relative humidity not above 80 %), splash water, rain, snow, etc.
Dimensions of the installation room
The installation room should be sized such that the vacuum device can be accessed from at least two sides (free space approx. 0.8 m), without impairing the pipework layout. Changing the collecting bags should be possible in a simple manner and without hindrance. Recommended minimum size is 8 m. Given this also full collecting bags can be stored for the interim period until removal. The room should have a height of 2.5 m.
Exhaust air and waste The air exit of the installation room must be able to accommodate the transport air volume suctioned off, depending on the type of the vaheat
cuum device. A part of the waste heat can de discharged using the exhaust air with certain types of banknote processing machines. This quantity of heat is then transmitted to other parts of the buildings and the plant. Attention! The room temperature in the installation room may not exceed approx. 45 C. The fire protection regulations applicable at the place of installation must be observed (building contractors' performance).
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DAG II
Interface to the banknote processor
Switching On and Off: The banknote processing machine controls the function of the vacuum device via the signal cabling. A software signal (generated only in a certain shredder mode) is transferred free tension to the vacuum device. If the main switch of the vacuum device is switched on, this will start it automatically. Warning: Remote-controlled system - may start without warning. If the software signal discontinues, the vacuum device stops automatically. Note If several banknote processing machines are connected to an DAG II, then the signal connections are connected in parallel on the DAG II: Each interface switches the DAG II separately. Filling level control: A capacitive filling level control in every collecting bag reports to the banknote processing machine without tension via the signal cable that the admissible filling level of the bag is reached and that it must be changed. On switching, only the filling level control of the bag in use is evaluated. (In synchronised operation both filling level controllers are evaluated.)
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Installation
Transport piping for shreddings
For the transport of the shreddings a suitable pipe system (with smooth internal surface, pressure resistant against a vacuum of approx. on ca. 2 kPA) must be installed. The alternate use of completely flexible piping is permitted. Connections to the banknote processing machine must be rendered flexibly. The use of a tube or cable channel for the signalling cable is recommended. The flexible connections should incorporate a steel wire. This wire shall be stripped and bent at the respective ends in such a manner that it can form a conducting connection (earthing) between the banknote processing machine, pipe system and vacuum device. Attention! The distance to the of the banknote processing machine may not exceed the equivalent to 25 m pipe length. (In case of applying internally smooth piping in a straight line the equivalent length is the actual length. Bends, fittings and flexible tubes have their respective equivalent lengths which in terms of pressure loss exceeds their geometrical lengths. Inclusion of such components in the piping shortens the appropriate equivalent distance to the banknote processing machine.
Vacuum device
DAG II - 55 DAG II - 75 DAG II - 110 DAG II - 150
Cross section of pipe connection

dia 80 mm dia 100 mm dia 120 mm dia 150 mm
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Putting into operation
Operating Manual
DAG II
Chapter 4
Note Examine the vacuum device prior to commissioning for damage in transit. Caution Read operating instructions Prior to commissioning the vacuum device must be connected to the pipework and the signal cable in line with the conditions of installation and operation. Following this, the electrical supply (socket provided by constructor) is to be connected. The appropriate instructions of the local utility supplier must be observed. Danger - High Voltage! (Only for three-phase devices) After the initial switching on of the device at the installation site the rotational direction of the fan must be inspected. (Filter and collecting bags must be inflated.) The vacuum device is supplied from works with rotation set in the right direction. If applicable, the direction of rotation should be changed by an expert in the supply net. Two phases - L1, L2 or L3 - are to be changed in the power supply).
Attention! Operation of the vacuum device is only permitted with installed filter and collecting bags. If this is not observed, all warranty for damage to the device is excluded. 1. Pull filter bags over the upper rim of the samplers (pay attention to correct positioning!) and affix to the sampler by means of the spring clasp. 2. Raise filter bag supports to the appropriate height and fix by means of winged screw. 3. Pull collecting bags over the lower rim of the samplers below the rear clasps and fix by means of spring clasps (attention should be paid to airtight seating!). 4. Connect signal cable with banknote processing machine to be placed under suction. 5. Connect flexible transport piping to banknote processing machine (attention should be paid to airtight positioning).
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6. In order to prevent static charges the steel spirals in the flexible transport piping should be connected conductively between pipework, banknote processing machine and vacuum device (compare Chapter 3: Transport piping for shreddings). 7. Selection of the collecting unit (1, 2 or 1+2) by appropriate setting of the lever on the switchover. 8. Insert plug to the ( protected) socket provided. 9. Switch on main switch. Device is ready to function! Warning: Remote-controlled system - may start without warning. The on-going operation runs fully automatically in conjunction with banknote processing.
Note In case of no demand for operation of the vacuum device by the currency processor for a long period the vacuum device should be switched off line by the main switch.
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Change of collecting bags and maintenance Operating Manual
DAG II
Chapter 5
Change of collecting bags and maintenance
Safety information
Maintenance work may only be performed by appropriately instructed or trained people. CAUTION The vacuum device must be stopped whenever covers or safety features are removed for maintenance work, as described in these operating instructions. The covers and safety features must be refitted straight after the work has been completed. Danger - Risk of Injury! Follow the procedure described below for all maintenance work. Never disregard a single safety measure! You otherwise risk injury through restart, electrical shock or flying parts. Before all maintenance work: 1. Switch off the master switch and secure it against accidentally being switched on. 2. Pull plug out of the socket. 3. Check that none of the system parts are under (electrical) power. 4. Remove the necessary covers for the maintenance task. After completing maintenance work: 1. Replace all covers previously removed. 2. Check that no-one is still working on the pneumatic module before switching it back on.
Change of the collecting bag
1. During operation of the DAG II the change-over flap should be turned to the (empty) bag which is not to be changed. In the synchronous operation mode the vacuum device should be switched off. Warning! Breathing of dusts may be hazardous to health or lead to physical injury. In case of appearance of larger amounts of dust while changing the collecting bags (depending on the soiling of the currency) a protective mask for breathing should be used. 2. The filter bag should be tapped in its entirety to release the majority of the adhering shreddings and dust. Wait while the dust settles. 3. The spring clasp of the collecting bag should be released and the collecting bag removed.
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Operating Manual Change of collecting bags and maintenance
4. Close and stove away collecting bag. 5. Pull new collecting bag over the lower rim of the sampler. The edge of the bag should extend over the spring clasp by 2-5 cm. Close spring clasp carefully and check that the collecting bag is correctly positioned. 6. Switch on again vacuum devices with synchronous (parallel running collecting bags) operation
Maintenance intervals The maintenance intervals given in the table refer to average
operating conditions. Shorter intervals may be necessary under extreme conditions. The installation room should be regularly (once every week) cleaned of dust and shredder material. Accumulation of dust and shreddings on the vacuum device should be removed once every three month at the latest. In this interval the vacuum device should also be inspected for signs of visible damage. Maintenance intervals according to use Daily Weakly Monthly yearly X X X X X X
Control of the collecting bags for airtightness and damage Check power and signal cabling for mechanical damage Check quiet running of the fan Clean filter bags thoroughly Clean entire equipment Check rubber gasket of the switch-over flap from the inside after removing filter bag Change filter bag and dispose it in line with local regulations
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Change of collecting bags and maintenance Operating Manual
DAG II
Cleaning of the filter bag
The filter bag should be cleaned at regular intervals. Given average use of the vacuum device on five working days per week, cleaning once per week is recommended. At the latest the bag must be cleaned when the filter bag becomes hard on being inflated (insufficient airflow). Attention! The filter bag comprises of a special porous filter cloth which may not be washed. If washed it looses its filter properties. Therefore dry cleaning by tapping and a subsequent vacuum cleaning of the inside surface is recommended. Never use compresed air for cleaning. Breathing of dusts may be hazardous to health or lead to physical injury. Procedure 1. Tap the mounted filter bag on its entire length to ensure that dust and shreddings detach and drop into collecting bags. 2. Undo spring clasp of the filter bag. 3. At the sampler undo the fixing screw of the filter bag support and lower filter bag support. 4. Remove filter bag from filter bag support and vacuum clean the internal surface of the filter bag. 5. Pull filter bag again over the upper rim of the sampler. Subsequently close spring clasp carefully and check that filter bag is positioned correctly. 6. Finally raise filter bag support again until the filter bag is stretched out without tension and tighten the fixing screws.
Renewing of the filtering bag
After one year of regular use the filter bag should be renewed. If the bag is inflated hard after cleaning during operation (insufficient airflow) it should be replaced earlier. Attention! A filter bag which has become airtight may lead to a blockage of the pipework as the shredder material is no longer transported. The monitoring of the vacuum device of the banknote processing machine signals.
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Operating Manual Change of collecting bags and maintenance
Adjustment of the filling level control
The overfilling of the bags should be prevented by the two capacitive proximity switches of the type KD 5022. The sensitivity of the capacitive proximity switches can be adjusted by means of the worm screws which are situated on the top side and depends on the shredded material which is to be transported by vacuum. Once set, the sensitivity remains the same and should only be adjusted in case of need, or if the shredded material is changed. Procedure: 1. Adjust height of the capacitative proximity switch KD 5022 in the collecting bags in such a manner that the full bags may be closed for replacing without excessive dust. 2. The centre of the capacitative proximity switch KD 5022 determines the filling level of the collecting bags and may be set by undoing or relocating the supporting screws. 3. For setting the sensitivity of the shredded material, the collecting bags should be removed. 4. The action of the capacitative proximity switch is tested by holding a handful of loose shreddings in front of the switch. 5. A distance of 10 cm should activate the contract which may also be checked by means of an LED located on the side of the wormscrew. 6. If this not the case, the activation distance of the switch can be increased by turning the screw right and reduced by turning it left. 7. A final control of the switching sensitivity is carried out under operating conditions, during which the collecting bags is remounted.
5-4
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Malfunctions
Operating Manual
DAG II
Chapter 6
Malfunctions
General
The tables on the following pages give information about the possible causes of system messages and the action to be taken. Caution A Troubleshooting work may only be performed by appropriately instructed or trained people.
Vacuum device malfunctions

Vacuum device does not start
Cause
Action
Plant is deactivated because of a Eliminate malfunction malfunction via the cutoff switch. Search for malfunction in the banknote processor No release via banknote proces- Examine and reset cutoff switch sor. Search for malfunction at the banknote processor and the signal line. Check main fuse. No tension Power line damaged Cutoff switch Q 11 is activated Main switch is out of order Wrong rotational direction Clogging of the pipes Clogging of the vacuum device collecting bag overfilled Filter bag dirty Cutoff switch is set wrongly Motor is overloaded by: Wrong voltage Single phase running with threephase motor Defective part in supply net Fault in control circuitry Replace supply cable. (see cutoff switch activated) Replace main switch. Repole supply Locate and remove blockage Change collecting bag and inspect proximity switch thoroughly. Clean or change filter bag. Set cutoff switch
No or low transportation fan output
Cutout Q1 actuated
Ensure correct voltage Check fuses in front of cutoff. do not use automatic cutoff Switch off plan, replace part Find and eliminate fault
Cutout F10 actuated
11/98
6-1
DAG II
Operating Manual
Malfunctions
Material leakage on chan- Change-over flap not in terminal position ging collecting bag
Set change-over flap in terminal position, remove any remnant residual shreddings Rubber gasket of the switch-over is Change rubber gasket. not airtight Material leakage at collec- Collecting bag not correctly positi- Inspect bag fastenings and tighten belts oned ting bag Replace collecting bag Collecting bag damaged Filter bag not correctly positioned Inspect bag fastenings and tighMaterial leakage at filter ten belts bag Replace filter bag Filter bag damaged Replace wheel Wheel out of balance or damaged Strong vibrations and noises from the sound proReplace motor Motor bearings damaged tected booth "Full" sign on the switch- Sensitivity of the capacitative pro- Reset sensitivity ximity switch for measuring filling board stays on level is excessive Terminal switch on the switchover Adjust terminal position switch by means of the rings or replace. flap in false position or defect
6-2
11/98
Operating Manual
DAG II
Chapter 7
General Preface to safety
The following pages provide a secure overview in respect of the secure assembly of spear and wear parts. The vacuum device DAG II should be inspected regularly. In this context the entire fan casing and the impeller. The vacuum device DAG II may only be maintained by suitably trained staff. The functioning of the vacuum device DAG II is only warranted with original spare and wearing parts. Attention should be paid to the careful connecting of the supply cable to the power supply, i.e. it should not be crushed or bent at acute angles. The power supply line must be inspected at regular intervals for damage and signs of aging and if it is not in a perfect condition it should be replaced immediately. As replacement cable the cable type VDE 0 165 must be used. Replacement of the electrical connections as well as all other electrical components may only be carried out by qualified experts. Prior to cleaning, maintaining, replacing or removing of moving parts the safety switch of the motor should be switched off and safeguarded against being switched on by cutting off the vacuum device from the supply net. Coverings and opening the device DAG II or dismantling pipe connections is only permitted in a cut-off state. During works in progress the device is to be safeguarded against being switched on. In cases of unequal wear or baking on of material an imbalance may occur which may destroy the motor bearings. If imbalance is found or there are substantial symptoms of wear in the part of the impeller which is in contact with material a replacement is necessary. In dismantling and mounting of the impeller the shaft must not be exposed to impacts. In all cases a dismantling and mounting device should be used. Prior to connecting up the motor it should be established manually whether the impeller does not touch the casing of intake side. After completing all maintenance and repair work attention must be paid to the fact that the vacuum device DAG II may only be operated with the pipework attached. Furthermore the correctness of the rotational direction of the impeller must be inspected.
11/98
7-1
DAG II
Operating Manual
Device design
7-2
11/98
Operating Manual
DAG II
Switchbox
1. Open the lever at the sound insulation cover to remove the side. 2. Disconnect motor power and earthing cable. 3. Disconnect and pull out the supply points provided in the box (supply net, control cable, filling level monitor and terminal position switch as well as earthing). 4. Undo four fixing screws on the switchbox and lift off switchbox. 5. Position new switchbox and affix it in the reverse order and reconnect. 1. 2. 3. 4. Disconnect and pull out the cable of the net supply G 10. Undo and remove defective power pack from the rack. Insert new pack and fasten. Reconnect pack with the cable in accordance with the wiring diagram (cf. appendix A-5 to A-7) and fasten terminals.
Power pack
Fuses and relays Filling level control
Dismantling of the fuses and relays is executed in the same steps as for the power pack. 1. Remove pipe piece preceding the distribution box between the two samplers by undoing connecting straps. 2. Open distribution box and disconnect defective filling level control. 3. Open spring clasp of the collecting bag and remove the bag in a careful manner and seal it without dust. 4. Undo fixing screws on the filling level control and after removing the connecting cable from the terminal lugs remove the defective component. 5. Mount new filling level control in the same position and reconnect to the terminal lugs and thread in the leads into the switchbox 6. Shorten connecting cable to the appropriate length and cover by sleeves prior to reconnection accordance with the wiring diagram. 7. Close distribution box and remount pipe piece in front (pay attention to airtight fitting) 8. Set filling level control (cf. page 5-4) 1. Remove pipe piece preceding the distribution box between the two samplers by undoing connecting straps. 2. Open distribution box and disconnect defective terminal switch. 3. Undo the 2 fixing screws of the terminal switch and remove switch. 4. Mount a reconnect new terminal switch in the same position and thread connecting cable into the switchbox. 5. Shorten connecting cable as appropriate and cover by sleeves prior to reconnecting in accordance with the wiring diagram. 6. Close distribution box and remount pipe piece in front (pay attention to airtight fitting)
Terminal switch
11/98
7-3
DAG II
Operating Manual
Fan
To change the motor or the impeller the fan must be completely dismantled first. Suction-side connection of the vacuum device DAG II is to be separated, the motor must be disconnected in the terminal box and the complete unit must be lifted at the subframe. 1. Pipe connection straps are to be undone below the silencer and the silencer must be turned to side. 2. Undo the four clasps of the sound insulation and lift off half of the sound insulation cover from the subframe. 3. Undo the four screws in the lid of the stationary part of the sound insulation cover and remove it. 4. Open terminal box and pull out the cables from the loosened lugs. 5. Undo four screws on the motor support. 6. Lift fan from subframe and put it on its side. 7. Undo domed cap nuts on the fan motor base and pull fan casing from the motor mounting. 8. Undo screw M 8 from the shaft and pull the impeller off the motor shaft. 9. Remove the motor plate by undoing the four screws at the motor flange. 10.The assembly of the new motor and the new fan takes place in reverse order. However, attention should be paid to the identical positioning of the motor plate at the motor flange. In changing the impeller the same steps 1-8 must be carried out as for the change of the motor. After removing the defective impeller and mounting the new impeller the assembly takes place in inverse order. Replacing the steering and pedestal rollers is done by loosening the respective fastening screws on the subframe For this the entire vacuum device DAG II should be slightly lifted with a lifting platform. 1. Replacing the silicon rubber gaskets on the switch-over flap is done from within by the primary collector no. 1. 2. The PE collecting bag and the filter bags must be unstrapped so that the switch-over flap can be accessed. 3. Undo the countersunk hexagonal screws of the flap. 4. Remove covering of the flap and replace worn silicon rubber gaskets. 5. New silicon rubber gaskets to be cut (using old rubber gaskets with 1-2 mm oversize as templates) and inserted on the internal centering plate. 6. Affix new silicon rubber gaskets by means of the cover and tighten the six countersunk hexagonal screws.
Motor
Impeller
Steering roller / pedestal roller
Rubber gasket
7-4
11/98
Appendix
Betriebsanleitung / Operating Manual
DAG II
Anhnge / AppendixA
11/98
A-1
DAG II
Appendix
Maskizzen / Dimension sketches
A-2
11/98
Appendix
DAG II
11/98
A-3
DAG II
Appendix
Schaltplne / Wirering diagramms
A-4
11/98
Appendix
DAG II
11/98
A-5
DAG II
Appendix
A-6
11/98
Appendix
DAG II
11/98
A-7
DAG II
Appendix
A-8
11/98
Appendix
DAG II
EG-Konformittserklrung
11/98
A-9
DAG II
Appendix
A - 10
11/98
Appendix
DAG II
Ersatz- und Verschleiteiliste / Spare parts and Wear parts listing

Gltig fr / Valid for: Alle / all DAG II 115V/208V/230V/400V 50Hz/60Hz mit nderungsindex / with modification status 011, ab / from 11/98 Ersatzteile / Spare parts Artikelnr. Benennung Name Part No. 205565 000 Gummilippe fr Umschaltklappe Silikon DN120 Rubber gasket for switch-over flap, DAG II - 55 / 75 / 110 Silikon DN120, DAG II - 55 / 75 / 110 209088 000 Gummilippe fr Umschaltklappe Silikon DN150 Rubber gasket for switch-over flap, DAG II - 150 Silikon DN150, DAG II - 150 205564 000 Lenkrolle LE-VE 160R Caster wheel LE-VE 160R 205563 000 Bockrolle B-VE 160R Pedestal wheel B-VE 160R 110596 000 Erdtrennklemme Earthing insulating terminator 110316 000 Motorentstrung Interference suppressor for electric motor 124969 000 Schaltschtz 24VDC 50/60Hz Contactor 24VDC 50/60Hz 124268 000 Hauptschalter 25A Main switch 25A 127644 000 Sicherungsautomat 0,5A Automatic cut-out 0,5A 194393 000 Lampenkappe Gelb Lamp cap yellow 125245 000 Glhlampe 24V 1,2W Bulb 24V 1,2W 110439 000 Glassicherung M 500mA Glas fuse M 500mA 141513 000 Fllstandswchter (kapazitiv) IFM KD-5022 Filling level gauge (capacitive) IFM KD-5022 194394 000 Nherungsschalter (induktiv) IFM IN-5251 Approximation switch (inductive) IFM IN-5251 207972 000 Relaisklemme DEK-REL-G24/21 24 VDC Relay terminal DEK-REL-G24/21 24 VDC 205557 000 Ventilatorlaufrad DAG II Impeller DAG II 55 / 75 (60Hz) / 110 (60Hz) DN 280 55 / 75 (60Hz) / 110 (60Hz) dia 280 205558 000 Ventilatorlaufrad DAG II Impeller DAG II 75 (50Hz) / 110 (50Hz) / 150 (60Hz) DN 340 75 (50Hz) / 110 (50Hz) / 150 (60Hz) dia 340 205559 000 Ventilatorlaufrad DAG II - 150 (50Hz) DN 365 Impeller DAG II - 150 (50Hz) dia 365 205549 000 Motor fr DAG II-55 230V 50Hz Electric motor for DAG II-55 230V 50Hz 205548 000 Motor fr DAG II-55 115V 60Hz Electric motor for DAG II-55 115V 60Hz 205550 000 Motor fr DAG II-75 400V 50Hz Electric motor for DAG II-75 400V 50Hz 205551 000 Motor fr DAG II-75 208V 60Hz Electric motor for DAG II-75 208V 60Hz 205553 000 Motor fr DAG II-110 400V 50Hz Electric motor for DAG II-110 400V 50Hz 205554 000 Motor fr DAG II-110 208V 60Hz Electric motor for DAG II-110 208V 60Hz 205555 000 Motor fr DAG II-150 400V 50Hz Electric motor for DAG II-150 400V 50Hz 205556 000 Motor fr DAG II-150 208V 60Hz Electric motor for DAG II-150 208V 60Hz 205547 000 Netzteil 230V 50-60Hz / 24 VDC 1A Power pack 230V 50-60Hz / 24 VDC 1A 205546 000 Netzteil 208V 60Hz / 24 VDC 1A Power pack 208V 60Hz / 24 VDC 1A 205545 000 Netzteil DAG II-55 115V 60Hz / 24 VDC 1A Power pack DAG II-55 115V 60Hz / 24 VDC 1A 207600 000 Motorschutzschalter 2,5A DAG II-75 (50Hz) Prot. mot. circ. break. 2,5A DAGII-75(50Hz) 191957 000 Motorschutzschalter 2,5-4A DAG II Protec. mot. circuit breaker 2,5-4A DAG II 75 (60Hz) / 110 (50Hz) / 150 (50Hz) 75 (60Hz) / 110 (50Hz) / 150 (50Hz) 200607 000 Motorschutzschalter 4-6,3A DAG IIProtec. mot. circuit breaker 4-6,3A DAG II 55 (50Hz) / 110 (60Hz) /150 (60Hz) 55 (50Hz) / 110 (60Hz) /150 (60Hz) 202252 000 Motorschutzschalter 6,3-10A DAG II-55 (60Hz) Prot. mot. circ breaker 6,3-10A DAG II -55 (60Hz) 205769 000 Zeitrelais MT-6 AV (Steuerung 2000/3000) Timing relay MT-6 AV (2000/3000 control)
Stk no. 1 1 2 2 1 1 1 1 1 1 1 1 2 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2
Verschleiteile / Wear parts Stk no. 2 2 Artikelnr. Benennung Part No. 194074 000 Filtersack 121557 001 Auffangsack fr Shreddings (Transparent) Name Filtering bag Collecting bag for shreddings (transparent)
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A - 11
DAG II
Appendix
A - 12
11/98

DAGII - Operating Manual

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DAG II

Vacuum device for shredder modules Operating Manual

Giesecke & Devrient

Technische nderungen vorbehalten / Technical changes reserved.

Hersteller DAG II Manufacturer DAG II

Service Hot Line

0180 531 37 32 x49 89 4119-4410

1998 GAO/KRMER Printed in Germany

Ausgabedatum / Date of issue Artikelnummer / Part no.

Putting into operation Change of collecting bags and maintenance

General ............................................................................................................................ Vacuum device malfunctions ........................................................................................

Assembly of spare parts and wear parts

General safety information

General safety information

General safety information

Specification of the vacuum device

Area of application, construction, mode of operation

Data on the specification plate

Technical specifications / device overview

55/1000 50 Hz 158770 011 300/1000 [mm] [mm] [mm] [kg]

55/1000 60 Hz 158771 011 300/1000

1890 730 2370 172

1890 730 2370 172

[V] [Hz] [VA] [A]

230 50 550 3,4

) Data will be detected at first after device is manufactured

1890 730 2370 175

1890 730 2370 175

1890 730 2370 175

1890 730 2370 175

K21R 80 K2 K21R 80 K2 K21R 80 K2 K21R 80 K2 340 280 340 280

[V] [Hz] [VA] [A]

400 50 750 1,2

400 50 750 1,2

) Data will be detected at first after device is manufactured

Type: DAG II 110

1890 730 2370 176

1890 730 2370 176

1890 730 2370 176

1890 730 2370 176

K21R 80 G2 K21R 80 G2 K21R 80 G2 K21R 80 G2 340 280 340 280

[V] [Hz] [VA] [A]

400 50 1100 1,6

400 50 1100 1,6

) Data will be detected at first after device is manufactured

Type: DAG II 150

[mm] [mm] [mm] [kg]

1890 730 2370 185

1890 730 2370 185

1890 730 2370 185

1890 730 2370 185

K21R 80 S2 K21R 80 S2 K21R 80 S2 K21R 80 S2 340 365 340 365

[V] [Hz] [VA] [A]

400 50 1500 2,4

400 50 1500 2,4

) Data will be detected at first after device is manufactured

Dimensions of the installation room

Interface to the banknote processor

Transport piping for shreddings

Cross section of pipe connection

Putting into operation

Putting into operation

Putting into operation

Change of collecting bags and maintenance Operating Manual