OPERATION MANUAL

Punching module with

cooling/lubrication system and
dust collector

Version: 1
Order-no.: 09202373
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GENERAL

Address of the manufacturer:

SCHOBER GmbH Werkzeug- und Maschinenbau

Industriestraße 2
71735 Eberdingen
Germany

Phone: +49 (7042) 790-0

Fax: +49 (7042) 7007

Description:

Punching module with cooling/lubrication system and dust collector

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TABLE OF CONTENTS

Page

1. General description ................................................................................................6

1.1. Proper use........................................................................................................ 7
1.2. Technical data .................................................................................................. 8
[Link]. Module ........................................................................................ 8
1.3. Document history ........................................................................................... 10

2. Safety instructions................................................................................................11

3. Installation .............................................................................................................14
3.1. Installation requirements ................................................................................ 15
3.2. Installation of the module................................................................................ 16
3.2.1. Notes................................................................................................. 16
3.2.2. Procedure.......................................................................................... 17
3.3. Drive of the module ........................................................................................ 18
3.3.1. Notes................................................................................................. 18
3.3.2. Mode of operation ............................................................................. 18
3.4. Electrical equipment ....................................................................................... 19
3.4.1. Notes................................................................................................. 19
3.5. Waste removal ............................................................................................... 20
3.5.1. Notes................................................................................................. 20
3.5.2. Mode of operation ............................................................................. 20
3.6. Protection guards ........................................................................................... 21

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4. Set-up and operation ............................................................................................22

4.1. General notes................................................................................................. 23
4.2. Basic alignment of the tools............................................................................ 24
4.2.1. Notes................................................................................................. 24
4.2.2. Procedure.......................................................................................... 24
4.2.3. Punching test..................................................................................... 25
4.3. Threading of the material web ........................................................................ 26
4.4. Cross adjustment of the module..................................................................... 27
4.4.1. Notes................................................................................................. 27
4.4.2. Pictures ............................................................................................. 27
4.5. Eccentric adjustment of the upper tools.......................................................... 28
4.5.1. Notes................................................................................................. 28
4.5.2. Procedure.......................................................................................... 29
4.6. Adjustment of clamping sleeves at the gears ................................................. 30
4.6.1. Notes................................................................................................. 30
4.6.2. Picture ............................................................................................... 30
4.6.3. Procedure.......................................................................................... 30
4.7. Adjusting the format gears free from backlash ............................................... 32
4.7.1. Notes................................................................................................. 32
4.7.2. Picture ............................................................................................... 32
4.7.3. Procedure.......................................................................................... 33
4.7.4. Aligning the cover for the format gear ............................................... 34

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5. Maintenance...........................................................................................................35
5.1. General notes................................................................................................. 36
5.2. Wear of punches and dies.............................................................................. 37
5.2.1. Notes................................................................................................. 37
5.2.2. Fault elimination ................................................................................ 37
5.3. General information for the replacement of tools............................................ 38
5.3.1. Notes................................................................................................. 38
5.3.2. Installation rules ................................................................................ 38
5.4. Replacement of punches with clamping screw............................................... 39
5.4.1. Notes................................................................................................. 39
5.4.2. Procedure.......................................................................................... 40
5.5. Replacement of dies with clamping screw...................................................... 41
5.5.1. Notes................................................................................................. 41
5.5.2. Procedure.......................................................................................... 42
5.6. Replacement of punch segments ................................................................... 43
5.6.1. Notes................................................................................................. 43
5.6.2. Procedure.......................................................................................... 44
5.7. Aligning the shaft encoder .............................................................................. 45
5.7.1. Notes................................................................................................. 45
5.7.2. Procedure.......................................................................................... 45
5.8. Inspections ..................................................................................................... 46
5.8.1. Notes................................................................................................. 46
5.8.2. Cleaning ............................................................................................ 46
5.8.3. Daily inspection ................................................................................. 46
5.8.4. Maintenance...................................................................................... 46
5.9. Connection of oil lubrication/closed circuit oil cooling..................................... 47
5.9.1. Notes................................................................................................. 47
5.9.2. Procedure.......................................................................................... 48
5.10. Lubrication of bearings and gears ................................................................ 49
5.10.1. Notes............................................................................................... 49
5.10.2. Replacement of lubrication oil ......................................................... 49

6. Appendix ................................................................................................................50

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General description

1. General description

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General description

1.1. Proper use

• The module has been designed for the following specific use:
- Punching with exchangeable punch bars
Á Round hole Ø 5 mm
Á 6 patterns across a' 200 mm = 280 g
Á 8 patterns across a' 145 mm = 200 g
Á 8 patterns across a' 150 mm = 200 g

• Each furthermore use is classified as not conventional. For damages/harms resulting from
this the manufacturer will not assume any warranty.

• The module can process following materials:

- PET foil
Á Thickness: 0.012 mm
• All materials need to be checked for processibility and safe handling prior processing
through this module.

WARNING
Use the module only in a technically perfect
condition!
Follow the operation manual!
Only authorised personnel are allowed to
execute operations with regard to the use,
production customisation, changeover or
adjustment of the module as well as
inspections, maintenance and repair!

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General description

1.2. Technical data

Drawing no. 232560098 Schema Stanzeinheit

Drawing no. 232560749 Anschlagschema für Stanzeinheit

Drawing no. 232559736 Schema Absaugung

Drawing no. 232559959 Schema Capri Sonne Format 145 mm

Drawing no. 232559967 Schema Capri Sonne Format 150 mm

Drawing no. 232559970 Schema Capri Sonne Format 200 mm

Drawing no. 242559913 Teilplan Matrize Formate Capri Sonne

Drawing no. 242560135 Teilplan Matrize Formate Capri Sonne

[Link]. Module
Length 600 mm
Length of base frame 680 mm
Total length (with deviating rollers) approx. 850 mm
Width 1700 mm
Width of base frame 1960 mm
Total width (incl. oil return) approx. 2500 mm
Height 810 mm
Height of base frame 797 mm
Total height (with deviating rollers) approx. 1850 mm

Inner width 1500 mm

Working width 1320 mm
Web path level 1201.7 mm
Tool circumference approx. 900 mm
Tool diameter approx. 286.48 mm

Maximum mechanical/operating speed approx. 400 m/min

Side adjustment of module +/- 10 mm

Connection diameter for vacuum hub 180 mm

Colour RAL 9010 (pure white)

Electricity
Power supply 400/230 V
50 Hz
3-Phases + N + PE

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General description

Cooling/lubrication system
Cooling capacity approx. 5 kW
Power supply 400/230 V
50 Hz

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General description

1.3. Document history

Version Changes Description
1 Creation

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Safety instructions

2. Safety instructions

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Safety instructions

SAFETY NOTES
Only authorized personnel are allowed to operate the equipment.
Operators must read and understand the instruction manual.
The instruction manual must be stored in a safe location easily accessible to the operator.
In addition to the operating instructions the general as well as the local regulations
concerning the prevention of accidents are to be provided and to be adhered to.
Please contact SCHOBER concerning any problems.
The technical content of the instruction manual has been reviewed carefully. We do not
guarantee this manual to be free of errors.
We reserve the right to change the technical content of this manual without prior
notification.
Only materials released by the manufacturer may be used. (If necessary, make inquiries.)

DANGER
Never touch exposed electrical connections.
De-energise the machine before starting maintenance, conversion or repair.
Prevent unintentional restart! (Remove main switch!)

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Safety instructions

WARNING
The module must not be put into operation unless the safety equipment has been
checked and corresponds to the European Standard EN 294.
The end user (operating company) of the machine has to take care that all local security
guidelines are complied with.
Before starting the module all safety devices have to be fixed according to the standards
and have to be operative.
Before putting the module into operation all necessary safety regulations with regard to
machine access and all mechanical and electrical aspects have to be provided.
Safety devices may only be removed when machine is shut down.
Before starting the module all safety devices have to be fixed according to the standards
and have to be operative.
Only authorized personnel being familiar with the operating instruction and having an
appropriate technical training are permitted to work on the module and to maintain it.
(SCHOBER provide an on side technician, at separate charge.)
Do not touch moving or turning parts during operation.
Never get your hand or tools in the operating cylinders.
Never touch the edges of moving webs.
A new material web is only to be introduced by hand when the machine is stopped or in
jogging mode.

CAUTION
Immediately replace machine parts that are not in perfect condition.

NOTICE
Without prior permission by the equipment manufacturer structural changes, additions or
modifications to the equipment are not permitted.
Use only replacement and consumable parts approved by the manufacturer.
If non-approved replacement and consumable parts are used, proper function is not
assured. The warrantee and/or guarantee become null and void.

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Installation

3. Installation

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Installation

3.1. Installation requirements

• The module is to be used at an environment with constant temperature and humidity.
• The room temperature should be 21° C (70° F) and the relative air humidity 60%.
• The area must be sufficiently ventilated!
• Avoid heat, dust or chemical vapours and direct sunlight!

• The module is to be mounted so that no distortion or vibrations are transmitted to it.

• Please note that the module, with the shafts installed, has been checked for parallelism,
concentricity and run-out at the factory.
• It is imperative that the module is installed on a level surface.
Á This has to be checked prior to installation. If the module is installed on an uneven
surface we cannot guarantee the functionality of the equipment.

• After installation of the module the parallelism must be checked with a water level along
and across the entire module.

• Allow module to stabilize to ambient temperature for 24 hours.

• If there is a difference in ambient temperature between the module holding room and the
production room environment the module has to be moved next to the machine 24h before
installing it.

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Installation

3.2. Installation of the module

3.2.1. Notes

• The built-in module is foreseen for installation in the customer's machine.

• It is within the customer's responsibility to install the module.

• The module should be installed into the machine by means of a lifting device.
Á Eye bolts are mounted on the module.
Á The eye bolts are mounted on the upper side of the module.

WARNING
Falling and tilting weights

Severe or fatal injuries

Observe the maximum capacity of the lifting device!

Secure danger zone!
Attach the holding ropes vertically!
Consider the attaching scheme
Á Drawing 232560749
Consider the centre of gravity when lifting the module!

• Lower the built-in module carefully and take care that it does not become in a bind!
• The base frame is equipped with levelling wedges for aligning of the complete module.

• Initial operation of the machine (incl. cooling/lubrication system and dust collector) by
mechanics of company SCHOBER.

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Installation

3.2.2. Procedure
1. Move the module into the machine and align horizontally.

2. Align the module horizontally using the levelling wedges:

- Adjust levelling wedges to maximum height before installing the module.
- Install the module.
- Level the module by lowering the levelling wedges under load.
- Clamp the module using the 4 connecting angles.

3. Connect drive link.

Á By mechanics of company SCHOBER.

4. Install electrical connections for:

- Motor
- Cooling/lubrication system and dust collector
- Temperature sensors- und accelerometer

5. Supply the module with oil.

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Installation

3.3. Drive of the module

3.3.1. Notes

• The machine manufacturer or the customer connects the drive link.

• The drive connection may not transfer forces or vibrations to the module.
• Consider running direction!

3.3.2. Mode of operation

• The drive belt (driving gear) drives the lower cylinder.

• Format gears drive the upper cylinder.

• Format gears are mounted on both sides to avoid distortions.

• A split format gear can adjust the backlash on both format gear pairs.

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Installation

3.4. Electrical equipment

3.4.1. Notes

• Information for electrical equipment can be found in the separately delivered wiring
diagrams.

DANGER
High voltage current

Risk of death

Only authorized personnel are allowed to make the electrical

installation!

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Installation

3.5. Waste removal

3.5.1. Notes

• Waste removal has to be provided by the customer.

• Waste removal has to be made available every time.

• Correct functionality must be guaranteed for avoiding damage on the tools by the waste.

• Switch on the waste removal before starting the machine.

3.5.2. Mode of operation

• The waste is to be exhausted through the die cylinder.

• Connect the central vacuum unit to the die cylinder.

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Installation

3.6. Protection guards

SAFETY NOTES
Since this module is a built-in module and we do not know all of the machine details, not
all necessary protection guards are installed.
Only the following parts are mounted:

• In- and outfeed sheet steel

• Protective cover at the top

• Protective cover on operator side

All other necessary protection guards have to be provided and installed by the machine
user or machine manufacturer.
SCHOBER does not assume any responsibility or liability.

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Set-up and operation

4. Set-up and operation

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Set-up and operation

4.1. General notes

CAUTION
Only authorised personnel are allowed to
operate the equipment.
Operators must read and understand the
instruction manual.
The instruction manual must be stored in a safe
location easily accessible to the operators.
Please contact SCHOBER concerning any
problems.

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Set-up and operation

4.2. Basic alignment of the tools

4.2.1. Notes

• Align the upper tools to the lower tools.

Á Alignment punch

• There are alignment dies fixed in the die tool (beside the product pattern).
• Alignment punches can be inserted in the punch holder (beside the product pattern).

• After basic alignment of the tools, alignment punches have to be dismounted.

NOTICE
When unscrewing the screws on the clamping sleeves or on the
format gears and if loosening the shaft key on the punch holder the
basic alignment gets lost.

Damage of tools.

Restore the basic alignment of the module before initial operation.

4.2.2. Procedure
1. Dismount all punch segments.

2. Remove covers/protective enclosures:

- Macrolone cover of the format gears
Á 14 clamping bolts M8

3. Loosen the clamping sleeves of the format gears.

Á Adjustment of clamping sleeves at the gears (Page 30)

4. Install adjustment punches.

Á Drive and operator side

5. Turn the tools so that the alignment punches and alignment dies are in position prior to
contact.

6. Turn the tools carefully by hand until the adjustment punches and dies are fully engaged.

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Set-up and operation

7. Adjusting the format gears free from backlash.

Á Adjusting the format gears free from backlash (Page 32)

8. Tighten the clamping sleeves of the format gears.

Á Adjustment of clamping sleeves at the gears (Page 30)

9. Remount covers/protective enclosures.

10. Remove adjustment punches.

11. Install punch segments.

Á Replacement of punch segments (Page 43)

12. Make punching test by hand.

4.2.3. Punching test

• Lead a piece of material web through the punching tools to check the punching quality.
• Check the punching quality manually or in jogging mode.
• If the punching result is not ok the punches and the dies have to be checked for wear or
damage.
Á If necessary replace them.

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Set-up and operation

4.3. Threading of the material web

WARNING
Rotating tools

Danger of severe bodily injury! Keep clear of

rotating tools!

When threading the web machine MUST be in

jogging mode!
Keep hands and objects away from turning
tools or shafts!
De-energize the machine, before open
protective covers!

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Set-up and operation

4.4. Cross adjustment of the module

4.4.1. Notes

• The cross adjustment enables to move the module across the web by about ±10 mm.

• The adjustment handle of the cross adjustment is self-locking.

• A certain force is necessary for this adjustment.

4.4.2. Pictures

Picture 1 Adjustment button (locking element)

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Set-up and operation

4.5. Eccentric adjustment of the upper tools

4.5.1. Notes

• The upper shaft is eccentrically beared.

• This can adjust the penetration depth of the tools.
• Adjustment has to be carried out on both sides.

• After adjustment of the eccentric the backlash has to be adjusted again for aligning the
axle distance.

NOTICE
The punches can be disengaged if the punch tools are lifted too
much.
In this condition the positions of punches and dies can be displaced
from each other.

Damage of tools when re-engaging without new basic adjustment.

Repeat the basic adjustment of the punching tools.

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Set-up and operation

4.5.2. Procedure
1. Remove the covers of the format gears from the oil boxes.

2. Increase the backlash of the format gears.

Á Adjusting the format gears free from backlash (Page 32)

3. Loosen the 4 hexagon screws on the bearing bushings.

4. Turn the bearing bushings with the threaded spindle until the tools engage correct.
Á Threaded spindle with hexagon socket

5. Tighten the hexagon screws crosswise.

6. Check tool adjustment.

7. If necessary, repeat item 3 to 5.

8. Re-adjust the backlash of the format gears.

Á Adjusting the format gears free from backlash (Page 32)

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Set-up and operation

4.6. Adjustment of clamping sleeves at the

gears

4.6.1. Notes

• If the module comes with format gears on both sides adjust the backlash of the format
gears before clamping the second clamping sleeve.
Á No distortion of the shaft/format gears

• After a replacement or re-mount of the format gears the format gears must be checked for
correctly face running.
Á To guarantee that no fluctuations of the gear pitch appear.
Á Maximum concentricity error: 0.01 mm
Á Maximum face running error: 0.03 mm
• The face running is to check with a dial indicator.
• In addition, the clamping screws of the clamping sleeve are to brace with approximately
50 % of the maximum torque.
• After correct orientation of the gears clamp the clamping sleeve with full clamping torque
of the clamping screws.
• Use a torque wrench with maximum setting close to the desired torque!

4.6.2. Picture

• 1 – Format gear
• 2 – Clamping sleeve
• 3 – Clamping screw(s)

Picture 2 Clamping sleeve

4.6.3. Procedure
1. Install clamping sleeve on the shaft.

2. Install gear on the clamping sleeve.

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Set-up and operation

3. Fix the clamping screws of the clamping sleeve with about 50 % of full clamping torque.
Mounting position Designation Clamping torque [Nm]
Format gear (split) DS 95.125.52 20
Format gear DS 90.120.52 20
Driving belt DSM 42.2 20
Driving belt DSM 55.2 20
Table 1 Clamping sleeves – clamping torques (50 %)

4. Use a dial indicator to check the concentricity of the gear in the ground surface.

5. Tighten the screws of the clamping sleeve constantly and crosswise.

6. Check the concentricity again. If necessary correct.

7. Repeat steps 5 and 6 until the screws reach full clamping torque.
Mounting position Designation Clamping torque [Nm]
Format gear (split) DS 95.125.52 40
Format gear DS 90.120.52 40
Driving belt DSM 42.2 40
Driving belt DSM 55.2 40
Table 2 Clamping sleeves – clamping torques (100 %)

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Set-up and operation

4.7. Adjusting the format gears free from

backlash

4.7.1. Notes

• Adjust the format gears free from backlash after each replacement of tools.

• The format gears have to run absolutely free of backlash.

• The format gears are located on both sides to avoid torsions.

• Therefore, adjust the backlash of format gears on both sides.

• Adjust the format gears so that driving force is on the fixed gear!

4.7.2. Picture

• (1) split format gear

• (2) excentric bolt for split format gear
• (3, 4) clamping bolts for split format
gear
• (5) unseparated format gear

Picture 3 split format gear

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Set-up and operation

4.7.3. Procedure
1. Remove covers/protective enclosures:
- Macrolone cover of the format gears
Á 14 clamping bolts M8

2. Turn the tools in running direction until the eccentric bolt (Item 2) of the split format gear
(Item 1) is in opposite position to the gear mesh.
Á 12 o' clock position, if the split format gear is above
Á 6 o' clock position, if the split format gear is below

3. Place the tools in working position.

Á Distance between axis / engagement

4. Remove the punches/punching bars completely so that the upper tool is rotating
unrestricted.
Á Replacement of punches with clamping screw (Page 39)

5. Release the hexagon screws (Item 3, 4) on the split format gear.

6. Turn the eccentric bolt (Item 2) until the tooth flanks of the format gears touch lightly.
Á Brace the format gears lightly to avoid backlash.

7. First tighten the 2 hexagon head screws, which are on the opposite side to the eccentric
bolt (Item 3).

8. Release the eccentric bolt again.

9. Tighten the remaining hexagon head screws (Item 4) crosswise.

10. Check format gear sound through quick rotation.

11. If concentricity is not OK repeat point 5 to 10.

12. Re-mount the punches/punching bars.

Á Replacement of punches with clamping screw (Page 39)

13. Remount covers/protective enclosures.

14. Remount the covers of the format gears on the oil boxes.
Á Aligning the cover for the format gear (Page 34)

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Set-up and operation

15. Mount the vacuum hub:

- Attach the vacuum hub and insert the clamping screws.
- Centre the vacuum hub with the 2 taper pins.
- Tighten the vacuum hub.

4.7.4. Aligning the cover for the format gear

1. Remount the cover for the format gear.
Á Do not tighten the clamping screws completely!

2. Attach the centring ring on the flange and push the ring in completely.
(1) Oil pan
(2) Cover for the format gear
(3) Clamping screws (14 x)
(4) Centring ring
Á Drive side: small
Á Operator side: large

Picture 4 Centring ring

3. Tighten the cover for the format gear.

Á 14 clamping screws

NOTICE
Fracture of the cover if the clamping screws are tighten too much

Cover becomes leaky

Tighten the clamping screws evenly and only until the subjacent
rubber seal is slightly flattened!

4. Remove the centring ring.

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Maintenance

5. Maintenance

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Maintenance

5.1. General notes

CAUTION
Only authorised personnel are allowed to
maintain the equipment.
Maintenance personnel must read and
understand the instruction manual.
The instruction manual must be stored in a safe
location easily accessible to the maintenance
personnel.
Please contact SCHOBER concerning any
problems.
Give sufficient notice to the operators before
starting maintenance, inspection or repair.
De-energise the machine.
Prevent unintentional restart! (Remove main
switch!)
Do not remove protection guards when the
machine is running.
Fasten and secure large assemblies carefully on
the lifting devices.
Ensure that all screw connections are tight
during re-installation.
Re-install all protection guards appropriate after
completion of maintenance, inspection or
repair.
Check proper function of all protection guards.

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Maintenance

5.2. Wear of punches and dies

5.2.1. Notes

• The installed punches and dies are subject to normal wear.

Á This is due to the material to be punched and the edge friction on the dies.
• The punching tools may be used without web only for adjustments.
Á Otherwise the punches and dies are subject to increased wear.

5.2.2. Fault elimination

• In case that the punching result is not good:

- Turn the punch by 180°,
- Replace the punches,
- If necessary replace the dies.

NOTICE
Worn or damaged punches and dies must be replaced. Only the
same type may me used.
Use only original parts.

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Maintenance

5.3. General information for the replacement of

tools

5.3.1. Notes

• When installing the punches high punching pressure is created.

• Therefore, replace each punch individually.

• Note this also when installing the punches the first time.
Á During installation of the module

• Punching test for each new punch has to be done by hand.

• Turn the tools always in running direction.

5.3.2. Installation rules

• Rotate the tools by hand carefully in web direction.

Á Do not use force!
• The insertion of punches should be done in a row around the circumference.
• We do not recommend inserting complete cross rows of punches simultaneously due to
the high pressure at first tool contact.

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Maintenance

5.4. Replacement of punches with clamping

screw

5.4.1. Notes

• It must be possible to insert the punches easily manually.

• If this is not the case, the punches and the mounting holes need to be checked for burr and
if necessary the burr must be removed.
• The punches should be checked for deformations.
Á If necessary replace the punches.
• In case of punches with lateral clamping surfaces the clamping screws need to clamp on
the lateral clamping surfaces of the punches.

NOTICE
If the punches do not fit correct the penetration depth of each punch
change.

This can have a negative influence to the punching result.

The tools can be damaged.

Check the concentricity of the punches with a dial indicator!

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Maintenance

5.4.2. Procedure
1. Loosen the punch.
Á Loosen the clamping screw.

2. Pull out the punch.

3. Clean the mounting hole and bearing surface of the punch thoroughly.

4. Insert new punch.

Á Ensure by easy tapping with a copper hammer that the punch is definitely mounted.

5. Fix the new punch with the clamping screw.

6. Rotate the tools by hand, so that the new punch engages once.
Á Consider running direction!

7. If the punch is engaged correct make a punching test with material web.

8. Repeat point 1 to 7 with all other punches.

9. Make punching test.

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Maintenance

5.5. Replacement of dies with clamping screw

5.5.1. Notes

• It must be possible to insert the dies easily manually.

• If this is not the case, the dies need to be checked for burr and if necessary the burr must
be removed.
Á If necessary replace the dies.
• In case of dies with lateral clamping surfaces the clamping screws need to clamp on the
lateral clamping surfaces of the dies.

NOTICE
If the dies do not fit correct the penetration depth of each punch
change.

This can have a negative influence to the punching result.

The tools can be damaged.

Check the concentricity of the dies with a dial indicator!

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Maintenance

5.5.2. Procedure
1. Release the die.
Á Release the clamping screw.

2. Pull out die.

Á If necessary use die puller

3. Clean the mounting hole and bearing surface of the die thoroughly.

4. Insert new die.

5. Fix the new die with the clamping screw.

6. Rotate the tools by hand, so that the new die engages once.
Á Consider running direction!

7. If the die is engaged correct make a punching test with material web.

8. Repeat steps 1 to 7 with all other dies.

9. Make punching test by hand or in jogging mode.

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Maintenance

5.6. Replacement of punch segments

5.6.1. Notes

• It must be possible to insert the punch segments easily manually.

• If this is not the case, the punch segments and the guides need to be checked for burr and
if necessary the burr must be removed.
• The punch segments should be checked for deformations.
Á If necessary replace the punch segments.

• Use a torque wrench with maximum setting close to the desired torque!

NOTICE
If the punch segments do not fit correct the penetration depth of the
segments change.

This can have a negative influence to the punching result.

The tools can be damaged.

Check the concentricity of the punch segments with a dial indicator!

Stand: 2009-12-01 43
[Link]
Maintenance

5.6.2. Procedure
1. Loosen the clamping screws M8 of the punch segment.

2. Remove the punch segment.

3. Clean mounting holes and supporting surfaces thoroughly.

4. Insert the new punch segment and centre it with the locating pins.

(1) Bores for locating pins

(2) Clamping screws for the segment
(3) Clamping screw for the punch

Picture 5 Segment “Capri Sonne”

5. Tighten the clamping screws alternately. (Clamping torque: 15 Nm)

6. Remove locating pin.

7. Make punching test by hand or in jogging mode.

Stand: 2009-12-01 44
[Link]
Maintenance

5.7. Aligning the shaft encoder

5.7.1. Notes

• Align the mounting bracket for the shaft encoder with the centre bolt.
• Therefore, install the mounting bracket first and afterwards the shaft encoder.

5.7.2. Procedure
1. Attach the centre bolt on the tappet.

Picture 6 Aligning the shaft encoder – centring bolt

2. Install and tighten the mounting bracket.

3. Remove the centre bolt.

4. Install the shaft encoder.

5. Tighten the coupling of the shaft encoder. (lateral clamping screw)

Picture 7 Aligning the shaft encoder – shaft encoder coupling

Stand: 2009-12-01 45
[Link]
Maintenance

5.8. Inspections

5.8.1. Notes

• Inspections are to carry out by the operation staff.

• For maintenance and repair of components from other manufacturers see the separate
operation and maintenance manuals.

5.8.2. Cleaning

• Clean all parts regularly from dust and dirt to avoid failures:
Á Use air gun or vacuum device

5.8.3. Daily inspection

• Visual inspection: Function of all safety devices

• Visual inspection: Mechanical damage or unfixed screwed joints
• Visual inspection: Damaged electrical connections, pushbuttons, switches or connectors

• Visual inspection: condition of the exhaust equipment

5.8.4. Maintenance

• The module should be visual inspected every month.

Stand: 2009-12-01 46
[Link]
Maintenance

5.9. Connection of oil lubrication/closed circuit

oil cooling

5.9.1. Notes

• The customer or the machine manufacturer does the oil lubrication supply.
• The task of the oil lubrication is:
- Lubrication of the format gears
- Lubrication of the bearings
• The task of the closed circuit oil cooling is:
- Compensation of variations in temperature

• The bearing temperature is controlled with a resistance thermometer PT 100 on the

bearings. The temperature can be seen on the indicator (not included in delivery).

• On the upper sides of both oil pans a manifold is located.

• For connection of the oil supply on each manifold a quick-release-coupling is located.
• The quick-release-coupling juts out on the upper side of the oil pan.

• Pipes with throttle stop valve leads from the manifolds towards:
- Lubrication (format gears and bearings)
- Closed circuit oil cooling

• On the drive side of the module the locking coupling for the oil return pipe is installed.
• The coupling can be closed with a plug.
• By means of the ball valve the oil supply can be stopped.

NOTICE
Bearings and gears must be greased adequate.
Make adjustments on location.

Stand: 2009-12-01 47
[Link]
Maintenance

5.9.2. Procedure
1. Connect the oil pipes of the oil supply (not part of delivery) on both quick-release-
couplings.

2. Connect the four resistance-thermometers on the indication device of the machine.

3. Adjust throttle stop valves on the pipes for lubrication.

Á In either case oil needs to flow through the pipes to ensure lubrication of the format
gears and bearings!

4. Adjust throttle stop valves on the pipes for cooling of the bearings:
- Distribute the inflow so that an even bearing temperature is reached.
Á To determine by tests.
Á Do not adjust the throttle stop valves lopsided! In either case oil needs to flow through
any pipe to ensure lubrication of all format gears and all bearings.
Á Check the bearings: At any time oil must flow off on the bottom

Stand: 2009-12-01 48
[Link]
Maintenance

5.10. Lubrication of bearings and gears

5.10.1. Notes

• The format gears and the bearing areas of the punch and die shaft are oiled by the oil
lubrication of the machine.

• Take notice of sufficient lubrication by the oil lubrication.

• Additional lubrication is not necessary.

• Please note that the sealing rings installed on the bearings are subject to wear and can get
leaky.
• In this case replace the sealing rings.

5.10.2. Replacement of lubrication oil

• The oil should be replaced after approx. 5000 operating hours.

Á Depending on the oil temperature
• Recommendation:
- AVIA FLUID RSL 32 (hydraulic oil HLP, DIN 51524 part 2, ISO-viscosity class 32)
• Any other oil with corresponding classification can be used.

Stand: 2009-12-01 49
[Link]
Appendix

6. Appendix

Spare parts list

Drawings

Wiring diagrams

Separate operating manuals for:

• Dust collector (DONALDSON)
• Cooling/lubrication system (DHS)

Safety data sheets:

• Lubricating oil: AVIA FLUID RSL 32

Stand: 2009-12-01 50
[Link]

Wearing parts Component 202560098

Name Processing unit
Item Number Order number Name
7 450 229506226 Punch
8 450 229506227 Die bushing
11 9 229560936 Adjustment punch

Stand: 26.11.2009 1
[Link]

Wearing parts Component 211559183

Name Punching module THL Capri Sonne
Item Number Order number Name
300 1 210559238 Hollow die cylinder complete S-287,18-2017
1900 72 210559455 Segment complete Capri Sonne
2300 2 210560332 Segment complete pattern marking

Stand: 26.11.2009 2
[Link]

Wearing parts Component 210559200

Name Frame complete 1500-100-600
Item Number Order number Name
133 1 122000787 O-ring seal
162 1 101001552 Radial shaft sealing ring
163 3 101000300 Shaft sealing ring
179 3 122000103 O-ring seal

Stand: 26.11.2009 3
[Link]

Wearing parts Component 210559210

Name Carrier shaft complete 255,18-2075
Item Number Order number Name
204 2 229550716 Adjustment punch

Stand: 26.11.2009 4
[Link]

Wearing parts Component 210559238

Name Hollow die cylinder complete S-287,18-2017
Item Number Order number Name
301 1 221559239 Hollow die cylinder

Stand: 26.11.2009 5
[Link]

Wearing parts Component 210559503

Name Bearing FL-100-220-110
Item Number Order number Name
416 1 101001117 Shaft sealing ring
418 1 122000133 O-ring seal

Stand: 26.11.2009 6
[Link]

Wearing parts Component 210559651

Name Bearing LL-100-220-110
Item Number Order number Name
513 1 101001117 Shaft sealing ring
514 1 122000133 O-ring seal

Stand: 26.11.2009 7
[Link]

Wearing parts Component 210559445

Name Bearing FL-100-300-110
Item Number Order number Name
614 1 122000868 O-ring seal
615 1 101001117 Shaft sealing ring

Stand: 26.11.2009 8
[Link]

Wearing parts Component 210559357

Name Bearing LL-100-320-220
Item Number Order number Name
703 1 229559850 Radial shaft sealing ring
712 1 122000888 O-ring seal

Stand: 26.11.2009 9
[Link]

Wearing parts Component 210559333

Name Oil return
Item Number Order number Name
1211 2 122000869 O-ring seal
1212 2 122000169 O-ring seal
1213 2 122000150 O-ring seal

Stand: 26.11.2009 10
[Link]

Wearing parts Component 210559817

Name Oil return
Item Number Order number Name
1315 1 122000123 O-ring seal

Stand: 26.11.2009 11
[Link]

Wearing parts Component 210559860

Name Brushes for punch
Item Number Order number Name
1401 2 229559556 Brush

Stand: 26.11.2009 12
[Link]

Wearing parts Component 210559720

Name Brushes for web
Item Number Order number Name
1501 4 229559556 Brush

Stand: 26.11.2009 13
[Link]

Wearing parts Component 210559455

Name Segment complete Capri Sonne
Item Number Order number Name
1901 1 227559453 Segment Capri Sonne

Stand: 26.11.2009 14
[Link]

Wearing parts Component 210560332

Name Segment complete pattern marking
Item Number Order number Name
2301 1 227560333 Segment pattern marking

Stand: 26.11.2009 15
[Link]

Wearing parts Component 210560236

Name Driving belt punching module
Item Number Order number Name
2403 1 223560248 Synchronous belt

Stand: 26.11.2009 16
 Installation, Operation and
Maintenance Manual

TORIT DCE DUSTCOLLECTOR TYPE TDP450, TDP675, TDP900, TDP1350

Publication 262-3047 (UK) 04/2007 Rev. 08

Donaldson reserve the right to alter design without notice. Freedom from patent restrictions must not be assumed
 Installation, Operation and Maintenance Manual
TDP

IMPORTANT

PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLATION

THIS MANUAL SHOULD BE READ IN CONJUNCTION WITH THE RESPECTIVE PRODUCT

MANUAL AND CIRCUIT DRAWINGS SUPPLIED WITH THE DUST COLLECTOR

EXPLANATION OF SYMBOLS USED

Refers to special information regarding the most efficient use.

Refers to special information directed towards preventing damage.

Refers to special information designed to prevent injury or extensive damage.

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 Installation, Operation and Maintenance Manual
TDP

IMPORTANT

These details correspond to the serial nameplate

located on the side panel of the equipment
to which this Manual refers

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 Installation, Operation and Maintenance Manual
TDP

TABLE OF CONTENTS

1. SAFETY RECOMMENDATIONS .....................................................................................................5

2. INTRODUCTION ..............................................................................................................................6
2.1 Product information....................................................................................................................6
2.2 Function .....................................................................................................................................6
3. PRIOR TO INSTALLATION .............................................................................................................7
3.1 Location......................................................................................................................................7
3.2 Required tools and equipment...................................................................................................8
3.3 Delivery and inspection..............................................................................................................8
4. INSTALLATION ................................................................................................................................8
4.1 Unloading and transport to location ...........................................................................................8
4.2 Installation and assembly...........................................................................................................9
4.2.1 Leg installation ......................................................................................................................................................9
4.2.2 Fan Set ..................................................................................................................................................................9
4.2.3 In- and Outlets .......................................................................................................................................................9
4.2.4 Platforms and Ladders ..........................................................................................................................................9
4.2.5 Control Box..........................................................................................................................................................10
4.2.6 Compressed Air Connection................................................................................................................................10
4.2.7 Electrical connection ...........................................................................................................................................10
4.2.8 Duct connections and damper valve ...................................................................................................................10
5. START-UP CHECKLIST ............................................................................................................... 12
6. OPERATION SCHEDULE............................................................................................................. 12
7. SERVICE ....................................................................................................................................... 13
7.1 Dust Removal.......................................................................................................................... 13
7.2 Change of filter Elements........................................................................................................ 14
7.3 Diaphragm valve ..................................................................................................................... 15
8. TROUBLE SHOOTING GUIDE..................................................................................................... 16
9. SPARE PARTS ............................................................................................................................. 18
10. CONTACT ADDRESSES ........................................................................................................... 20
11. CE DECLARATION .................................................................................................................... 21

LIST OF FIGURES
FIGURE 1 : TYPICAL INSTALLATION VIEW .............................................................................................................................................6
FIGURE 2 : OPERATIONAL SCHEMATIC.................................................................................................................................................7
FIGURE 3 : DUST REMOVAL FOR QUICK RELEASE DUST DISPOSAL SYSTEM...........................................................................................14
FIGURE 4 : BALANCE PIPE PACK ........................................................................................................................................................14
FIGURE 5 : EXCHANGING FILTER ELEMENT .........................................................................................................................................15
FIGURE 6 : DIAPHRAGM VALVE..........................................................................................................................................................16
FIGURE 7 : SPARE PARTS .................................................................................................................................................................19

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 Installation, Operation and Maintenance Manual
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1. SAFETY RECOMMENDATIONS
This manual contains specific precautionary statements relative to worker safety in appropriate
sections. To avoid dangerous situations we give you the following advices :

refers to special information on how to use the dust collector most efficiently.

refers to special information directed towards preventing damage.

refers to special information designed to prevent injury or extensive damage.

a) The dust collector has been built in accordance with state-of-the-art standards and recognized
safety rules. Nevertheless if not handled carefully, it may put people at risk, or also cause
damages.

b) The dust collector must only be used in technically perfect condition in accordance with its
designated use and the instructions set out in the operation manual. Any functional disorders,
especially those affecting the safety, should therefore be rectified immediately.

c) Make sure to give proper training to operators before start-up.

The dust collector is designed exclusively for use in accordance with the scope of delivery,
drawing(s) and the specification sheet.

d) The dust collector is not designed for applications with combustible materials involving a
potential dust explosion risk (e.g. buffing lint, paper, wood dust, aluminium and magnesium).

e) It is not allowed to put lit cigarettes or any burning object into the hood or ducting of any dust
collection system;

f) Regular maintenance is important for a good performance of your dust collector.

A prudent user of Torit DCE equipment should consult and comply with all relevant Fire Codes
and/or other appropriate codes when determining the location and operation of dust collector
equipment.

A hand operated supply disconnecting device is necessary for each incoming electrical supply in
accordance with EN 60204-1.

g) To prevent accidents the access to the fan wheel must be impossible during operation. Refer to
EN 294.

h) Disconnect all power before servicing. All electrical work must be done by a qualified electrician
according to local codes.

i) All exposed conductive parts of the electrical equipment and the dust collector shall be
connected to the protective bonding circuit (refer to EN 60204-1).

j) Shutoff and bleed-off compressed air supply before doing any service work.

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 Installation, Operation and Maintenance Manual
TDP

k) The dust collector cannot be used in a potentially explosive atmosphere (according ATEX
directive 94/9/EC), unless stated otherwise on the nameplate of the unit and scope of delivery.

l) The user of the dustcollector is responsible to dispose of any dust generated by the process,
according to local regulations.

2. INTRODUCTION

1. Hopper 7. Filter regulator *

2. Inspection cover 8. Shut-off valve
3. Inlet 9. Compressed air supply
4. Controlbox 10. Silencer *
5. Magnehelic [Link] bin
6. Fan *
(*) items are ot included with the dust collector
Figure 1 : Typical Installation View

2.1 Product information

The Dust collector is used for the collection of airborne dust and particulate. Whether in answer to the
problem of air pollution, or as part of a manufacturing process, the Dust collector provides highly
efficient, continuous, on-line dust collection.
The filter elements are the heart of the Dust collector. These filter elements help ensure that only
cleaned air is returned to the plant environment.
Technical and field support are available from your local Torit DCE Representative or Distributors to
answer your questions.

2.2 Function
During operation, contaminated air enters the Dust collector through the dirty air inlet area and passes
through the filter elements.
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 Installation, Operation and Maintenance Manual
TDP

Dust is collected on the outside surface of the filter elements. The filtered air flows through the center
of the filter elements into the clean air chamber, where it exits through the clean air outlet and can be
recirculated into the environment.

To ensure the optimal performance of your dust collector it is necessary that the filter elements are
cleaned automatically and sequentially.

During the filter cleaning sequence, the timer energises a solenoid valve, causing the corresponding
diaphragm valve to send a pulse of compressed air through the filter elements (from the inside
outward), removing the collected dust from the outside surfaces of the filter elements.
The dust falls through the hopper into the dust disposal system.

Operation Filter element cleaning

1. Clean air outlet
2. Dirty air inlet
3. Hopper
4. Filter element
5. Tube sheet
6. Diaphragm valve
7. Air pulse
8. Dust (falling)
Figure 2 : Operational Schematic

3. PRIOR TO INSTALLATION
3.1 Location
The dust collector should be located with consideration for :
• emptying the dust disposal (item 11, fig. 1)
• shortest runs of inlet and outlet ductwork
• radius bends on elbows as big as possible
• easy access to electrical and compressed air connections
• convenience of maintenance.

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 Installation, Operation and Maintenance Manual
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Consult the technical specification sheet and drawings for the dust collector weight and
dimensions.

For calculating for foundation or supporting structure consider the following factors :
• the weight of the dust collector
• the material being collected
• and all auxiliary equipment
• live loads
• for outdoor installation snow and wind loads

3.2 Required tools and equipment

• Crane/Fork lift
• Slings/ Clevis Pins and adequate lifting equipment
• Standard tools (e.g. screwdrivers, wrenches, etc.)
• Drill
• Pipe Sealant

3.3 Delivery and inspection

The Dust collector is normally shipped by truck as a completely mounted dust collector and
should be checked for any damage that may have occurred during shipping. Compare the parts
received against the packing list. If there is damage or parts missing, notify the delivery company
and your local Torit DCE representative.

Parts shipped loose with the delivery (depending on your order) :

• Dust disposal system

• Transition pieces
• Fan set (if not premounted)
• Fan box
• Silencer
• Platform
• Spare parts
• Anchor bolts
• Hardware/Sealant

4. INSTALLATION
4.1 Unloading and transport to location

Before unloading remove all packing and strapping.

• A crane is recommended for the unloading, transport and installation of the dust collector.

Connect lifting sling to the lifting lugs with clevis pins and distribute loads equally. Use spreader
bar if necessary.

• Eventually a fork lift can be used. If using lifting profiles (option) pay attention not to hit the
optional quick release dust disposal system.

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 Installation, Operation and Maintenance Manual
TDP

4.2 Installation and assembly

Anchor the dust collector to the foundations.

If one of the following equipment is ordered and not mounted please follow the according
instructions.

4.2.1 Leg installation

Assembly of demountable legs (optional)
1. Stand the leg set up and position as shown in the drawing at the anchor bolt location.
2. Lift the dust collector into position over the leg set and lower into position carefully.
3. Use a set of drift pins to align the holes in the collector and legs, and attach the legs with the M10
x 25 bolts and washers. Do not tighten hardware at this time!
4. Use a set of drift pins to align the holes in the wind bracings to the rear side of the leg set. Attach
the windbraces with M10 x 25 bolts and washers. Do not tighten the hardware at this time!

The windbracing supplied with the legs (in case of demountable legs) must be fixed in both
directions.

5. Recheck the position of the leg sets and windbracing against the outline drawing.

The dust collector must be anchored (refer to the replacement part list for the type of anchor).

6. Level the dust collector while it is still being supported by a forklift (or crane). Tighten all
hardware on legs, windbracing and foundation anchors.
7. Before releasing the dust collector from the forklift (or crane), recheck all of the hardware to
make sure it is securely tightened.

4.2.2 Fan Set

If the fan set is not premounted, place and anchor it on the foreseen position.

When installing your fan :

• Rotate the fan wheel before and after installing into the fan housing to assure proper clearance.
• Check the rotation of the fan wheel (direction of the arrow).

4.2.3 In- and Outlets

If not premounted, mount the in- and outlets as shown on the specific drawings.

4.2.4 Platforms and Ladders

When installing platforms and ladders care must be given during the erection for a safe handling with
a crane or a forklift.

Make sure all bolts are securely tightened and the legs of the platform and ladder will be
anchored to the foundations.

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 Installation, Operation and Maintenance Manual
TDP

4.2.5 Control Box

The control box is factory mounted on the dust collector, according to our standards (except
when specified by order).

All the instructions related to the controls are mentioned in a separate manual [(1A3119-8064)
(IPC)].

4.2.6 Compressed Air Connection

• Compressed air pressure must be between 6 and 7 bar.

• Be sure that all compressed air components are adequately sized to meet the maximum system
requirements of 45 Nliters per pulse at max 7 bar supply pressure (= design pressure).
• It is a requirement that adequate precaution is taken to avoid exceeding this pressure. Relief,
safety valve is required if the connected supply can exceed this pressure. A label is also attached
to each manifold indicating manifold design details.
• Compressed air supply be both oil and moisture free.
• The piping should be installed to provide a fall in the directions of the air flow to assist in the
drainage. A blow-down cock should be provided at the lowest point of the installation.
• Purge compressed air lines to remove debris before connecting to the manifold.
• Connect the compressed air supply line to the compressed air connection of the dust collector
(item 8 fig. 1)
• Use thread-sealing tape or pipe sealant on all compressed air connections.
• A compressed air shut-off valve, a filter/water separator with automatic condensate drain, a
pressure regulator with gage must be installed on the compressed air supply line.

Locate these components for convenient service, in the immediate vicinity of the dust collector.

4.2.7 Electrical connection

Amperage and voltage information is shown on the nameplate ratings of the fan motor. Over
amperage of manufacturer’s recommended service of motor will cause damage.

• If the fan is not premounted, connect the fan motor to the control box according wiring diagram.
• Connect the main power to the control box according the wiring diagram included in the control
box.

Check the rotation of the fan wheel (direction of the arrow on the fan housing). If the fan is
running in the wrong way, it will deliver only approximately 40 % of its rated air volume.

Lock out all electrical input power and interchange any two wire leads (3 phase only) on the
output side of the motor starter to reverse fan rotation.

4.2.8 Duct connections and damper valve

Connect :

• Fan and dust collector

• Inlet
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 Installation, Operation and Maintenance Manual
TDP

• Outlet if needed

All connections have to be sealed properly.

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 Installation, Operation and Maintenance Manual
TDP

If not integrated in the unit it is ABSOLUTELY NECESSARY to install a damper valve to adjust
the airflow.

5. START-UP CHECKLIST

• Follow all steps before first start-up and when the dust collector is not been used for a long
period.
• For daily use follow steps 1, 2, 4, 5 and 7.

1. Check that the outlet of the fan is free of debris before starting.
2. Make sure the dust disposal system is properly installed under the hopper.

Too much airflow can cause electrical failure of the fan motor or dramatically reduce the life of
the filter elements.

3. Check if the damper valve is 50 % closed.

4. Check if the access covers are closed.
5. Switch main power on and press switch ‘on’.
6. Check the airflow with a pitot tube and a micro-manometer in the ductwork and adjust the
damper valve to the desired airflow.

In case of an integrated damper valve, switch the fan off before opening the access cover.

7. Turn on the compressed air supply. Adjust to 6.5 bar of pressure with the compressed air
regulator.

Do not increase compressed air pressure beyond 7 bar as component damage may result.

The cleaning cycle only starts when necessary. For customized settings see the controls manual.

6. OPERATION SCHEDULE
To ensure a good performance of your dust collector follow the checkpoints mentioned below
according the timetable.

No. Checkpoint Type of control Recommended action Day Weeks

2 4 8 26
1. Control board Visual check alarm light (illuminated) See trouble shooting guide X
in Control manual

2. Dust disposal Check contents of dustbin(s) If ¾ full, empty dustbin X

system (see chapter 7.1)
3. Fan set Excessive noise See trouble shooting guide X
chapter 8
4 Clean air Emission : dust carry over in clean air See trouble shooting guide X
chamber chamber chapter 8

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 Installation, Operation and Maintenance Manual
TDP

No. Checkpoint Type of control Recommended action Day Weeks

2 4 8 26
5 Controls Check settings of both potentiometers Interval time normally to be X
settings (pulse time 100 milliseconds, interval set at 10 seconds. Pulse
time 10 seconds) on the control board time 100 milliseconds.
(see separate manual)
6 Filter/regulator Oil and/or water is in the reservoir Switch off and bleed X
compressed air prior
servicing. Clean oil/water
separator. Check
compressor.
7 Diaphragm Noise of escaping air is produced See trouble shooting guide X
valves chapter 8
8 Covers Visual check gaskets Replace gaskets if X
necessary
9 Connecting Check for leakage Repair if necessary X
ducts
10 Dust collector Check damage, strenght and Repair or replace if X
and platform corrosion necessary
11 Filter element Preventive replacement of all filter Unless otherwise specified in the scope of delivery
elements (see chapter 7.2) every 2 years.

7. SERVICE

• Disconnect electrical power before servicing.

• Shut off and bleed compressed air supply before servicing any compressed air components.
• No welding should be performed inside without fire protection.
• Avoid contact or exposure to dust during servicing or maintenance.

7.1 Dust Removal

Do not let the dustbin overfill. It can cause poor dust collector performance.

Turn off the dust collector and empty the dustbin on a regular base (recommend to empty the dustbin
when 3/4 full).

The bin can be installed and removed as shown below :

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 Installation, Operation and Maintenance Manual
TDP

1. Lift the handle 3. Install the bin

2. Remove and empty the bin 4. Push handle completely down

Figure 3 : Dust removal for quick release dust disposal system

If plastic bags used a pressure balance pipe is recommended. If shipped loose it has to be mounted
according figure 7.

1. Socket 4. Rubber sealing

2. Hose clamp 5. Plastic bag
3. Pressure balance pipe 6. Elbow balance pipe
Figure 4 : Balance pipe pack

A hole is already predrilled in the back of the hopper for the connection. If the system is installed to
remove the bin from the back (0° position), a hole (dia 28.5 mm) has to be drilled on the opposite side
of the hopper. The predrilled hole has to be cleared.

7.2 Change of filter Elements

(see figure ‘Exchanging filter element’)

All filter elements should be changed at the same time.

Dust loaden filter elements may be heavy and difficult to handle. Provide appropriate means of
access to replace filter elements safety in case no platform is installed.

1. Open the dirty air chamber cover.

2. Remove filter element by unscrewing the crank counter clockwise by hand. Set crank aside.

3. Rotate the filter elements to break the gasket seals between the filter element and the tube sheet
(see figure ‘Operational schematic’) and dump any loose build up dust off of the top of the filter
element.
Push nut of the crank out of the slot and take the filter element out of the dust collector.

• The genuine Torit DCE filter element is the only replacement filter element that will provide the
high level of performance that you expect from your investment in the Torit DCE Dust collector.
• Do not drop or rap the new filter element on the floor or any other hard surface. Damage to the
filter element will occur, resulting in leakage.
It is necessary to clean the dust off of the tube sheet all around the opening to ensure a positive
seal of the filter element gasket.

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 Installation, Operation and Maintenance Manual
TDP

4. Apply a thin coating of grease or vaseline film to the gasket and hang the element on the
bracket with the square nut descended into the slot provided for this purpose. The gasket has to
face the tube sheet.

5. Turn the crank by hand. Tighten securely, to prevent leakage, by hand, do not use any tools to
achieve this.

• If the gasket is damaged it has to be replaced.

• Lack of compression of the filter element gaskets can cause leakage.

1. Crank 5. Filter element

2. Square nut M12 6. Bracket
3. Lock Nut M12 7. Tube sheet
4. Gasket of filter element 8. Sealring
Figure 5 : Exchanging filter element

7.3 Diaphragm valve

Valve disassembly and reassembly

Depressurize valve before making repairs.

To avoid damage to the valve body, DO NOT OVERTIGHTEN PIPE CONNECTIONS. If Teflon
tape, paste, spray or similar lubricant is used, use extra care due to reduced friction.

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 Installation, Operation and Maintenance Manual
TDP

Depressurize valve. Proceed in the following manner :

1. Remove bonnet bolts and valve bonnet.
2. Diaphragm assembly is now accessible for cleaning or replacement. Replace diaphragm
assembly if worn or damaged.
3. Reassemble in reverse order of disassembly paying careful attention to exploded views provided
for placement of diaphragm assembly.
4. When replacing diaphragm assembly be sure marking "THIS SIDE OUT" on diaphragm
assembly faces valve bonnet and that bleed hole in diaphragm assembly is in alignment with
cavity in valve body and bonnet. The external contours of the diaphragm, body and bonnet must
all be in alignment.
5. Replace bonnet bolts and tighten in a crisscross manner. Torque bonnet bolts (4) 7 ± Newton
meters.
6. After maintenance operate the valve a few times to be sure of proper opening and closing.

1. Retainer clip (*) 8. Core assembly (*)

2. Coil 9. Valve bonnet
3. Washer spring 10. Marking "THIS SIDE OUT" on diaphragm assembly
4. Bonnet bolts (4) to face valve bonnet
5. Sol base sub assembly (torque to 20 Nm) 11. Diaphragm valve (*)
6. Silencer (*) 12. Bleed hole in diaphragm assembly must be in
7. Spring (*) alignment with cavity in valve body and bonnet. The
external contours of the diaphragm assembly, body
and bonnet must be in alignment.
[Link] body
(!) Place conical spring end on top
(*) Parts included in the diaphragm repair kit
Figure 6 : Diaphragm Valve

8. TROUBLE SHOOTING GUIDE

Please consult other manuals if necessary (e.g. controls, fans, …)

Disconnect all power and compressed air supply before services.

TROUBLE POSSIBLE CAUSE REMEDY

A. Fan does not start 1. Not wired correctly. Check and correct internal motor wiring for
proper connections for your voltage (see
Wiring Diagram)

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 Installation, Operation and Maintenance Manual
TDP

2. Proper wire size not used for motor Rewire per national and local electric codes
for proper wire size.
TROUBLE POSSIBLE CAUSE REMEDY
B. Fan set starts, but does not 1. Incorrect overload protection is installed Check for proper motor overload protection.
keep running Reset or replace if needed for proper value.
2. Dust collector covers are open or not closed Tighten covers securely (see figure 1)
tight
3. Hopper open to atmosphere Install dust bin under hopper and seal
securely
4. Damper valve not adjusted properly Check airflow in ducting for proper
requirements. Adjust the damper valve until
the proper airflow is achieved. Do not
attempt to run without inlet ducting attached.
(see chapter 5)
5. Electrical circuit fuses Check if the supply circuit has sufficient
power to run all equipment
C. Excessive noise/vibration of 1. Dust deposit on the blades Clean the blades
the fan

If this happens it should

be rectified at once
2. Worn blades The fan wheel has to be replaced
3. Worn bearings The bearings has to be replaced
D. Dust emission 1. Filter elements installed improperly Check that gaskets on the filter element(s)
are firmly pressed to the tube sheet (the
cranks should be fully tighten by hand).
2. Filter element damage, dents in the end caps, Replace the filter elements. (see chapter
gasket damage or holes in pleated media 7.2)
3. Covers not airtight Tighten covers securely and check sealing
E. Insufficient airflow 1. Fan wheel rotating wrong way Check fan rotation. Refer to rotation sticker
on fan housing (see cahpter 4.2.2)
2. Openings not properly sealed Check covers, that they are closed and
tightened securely (see figure 1). Also check
hopper area that openings are closed off
and that the hopper dust disposal is
installed.
3. Outlet is restricted Check outlet for blockage. Remove material
or debris that is blocking the outlet.
4. Filter elements plugged :
a. Lack of compressed air Check compressed air supply for 6 bar
minimum. Increase pressure at maximum 7
bar.
b. Pulse cleaning not energized Refer to the trouble shooting guide from the
Control manual
c. Dust disposal system is too full or plugged Clean out dust disposal system as
described in chapter 7.1
d. Hopper full of dust or plugged Clean out the hopper
e. Slidegate valve (if fitted) closed under hopper Open slide gate cover under hopper
f. Filter elements need to be replaced Replace the filter elements (see chapter 7.2)
5. Solenoid valves/diaphragm valves are not
functioning
a. Solenoid valves/diaphragm valves are leaking Check for debris, obstruction, valve wear
compressed air or diaphragm failure by removing the
diaphragm cover on the solenoid valves.
Also check for solenoid leakage damage.
If diaphragm valves or solenoid valves are
damaged replace it or replace damaged
part(s).
b. Pulse control printed circuit board has failed Refer to Operating manual of the
or is out of adjustment Controls.
F. Excessive noise of a 1. Failure on the diaphragm valve Check for debris, obstruction, valve wear
diaphragm valve or failure by removing the diaphragm
cover. If the diaphragm valve is damaged,
replace it or replace damaged part(s).

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 Installation, Operation and Maintenance Manual
TDP

9. SPARE PARTS
Item N° Part number Description

4 262-5002 Torit DCE filter element Ultra-Web® see scope of

®
4 262-5023 Torit DCE filter element Ultra-Web FR delivery for type of
®
4 262-5061 Torit DCE filter element Fibra Web filter element
4 262-5074 Torit DCE filter element Torit-Tex™ installed in your
dust collector
1 262-0139 Diaphragm valve 1”
fig 6 262-0087 Diaphragm valve repair kit
262-0138 Leaded coil repair set
2 0701-1625 seal ring
3 262-2569 Gasket - inspection cover (2.5 m)
5 0701-1144 Female connection 1” BSP
6 262-2310 Latch
7 262-3004 Lock nut
8 262-3003 Square nut
9 262-3002 Seal ring
10 262-3001 Crank
11 262-2325 Anchor bolt M12 (optional)
12 1A31599361 Controlbox IPC
12 1A31599362 Controlbox IPC Delta P
13 0701-1615 Multiwire (per m) (7 x 1 mm²) please specify
length
14 0701-1640 Bulkhead socket
15 262-1295 Terminal board pack
16 262-2015 Magnehelic
17 262-3025 Elbow female
18 262-3024 T piece M8
19 262-0025 Nylon tubing black dia 6x4

When ordering parts, give model number and serial number of dust collector, description and
quantity of parts desired.

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 Installation, Operation and Maintenance Manual
TDP

Figure 7 : Spare Parts

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 Installation, Operation and Maintenance Manual
TDP

10. CONTACT ADDRESSES

Donaldson Europe B.V.B.A.
Torit-DCE Products
Interleuvenlaan 1
B - 3001 Leuven (Heverlee)
Belgium
Tel.(gen) : + 32 (0)16 383 811
Tel.(sales) : +32 (0)16 383 970
Fax : +32 (0)16 383 938

Donaldson Donaldson
Torit-DCE Products Torit-DCEScandinavia
Humberstone Lane Adalsvej 50
Thurmaston DK-2970
Leicester LE4 8HP Horsholm
United Kingdom Denmark
Tel. +44 (0) 116 269 6161 Tel. : +45 45 57 00 77
Fax : +44 (0)116 269 3028 Fax : +45 45 57 00 44

e-mail : IFS-europe@[Link]

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 Installation, Operation and Maintenance Manual
TDP

11. CE DECLARATION

UK
EC DECLARATION OF CONFORMITY
(Machinery directives 98/37/EEC)

Manufacturer : Donaldson® Europe B.V.B.A.

Interleuvenlaan 1 - B-3001 Leuven, Belgium

Manufacturing Centres: Donaldson Filtration (GB) Ltd.

Humberstone Lane, Thurmaston, Leicester LE4 8HP,
England

Donaldson Industrial CR – concern s.r.o.

Kralovsky vrch 1986, 432 01 Kadan, Czech Republic

Customer Service Centre: Donaldson Europe B.V.B.A.

Pathoekeweg 166, B-8000 Brugge, Belgium

Description of the machinery : Dust Collector


Brand : Donaldson Torit DCE

Description : see attached scope of delivery

The undersigned, authorized by Donaldson, certifies that the machine described above, provided that
it is installed, maintained and used in accordance with the instructions for use and the codes of
practice, meets the essential safety and health requirements of the following Directives:

- Machinery directives 98/37/EEC

- Low voltage directive 2006/95/EEC
- Pressure equipment directive 97/23/EC
- Electromagnetic compatibility directive 89/336/EEC
- Equipment and protective systems intended for use in Potentially
Explosive Atmospheres 94/9/EC

IMPORTANT ! Read the Operation and Instruction Manual before using this machine. If you require
additional copies contact your local Donaldson representative.

The machinery must not be put into service until the machinery into which it is to be incorporated has
been declared in conformity with the provisions of the above mentioned directives.

Signature:

Name: Heiner Carstensen

Position: Product Development Director Date: 15 March 2007

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Installation, Operation and Maintenance Manual
TDP
[Link] Seite 1 Mittwoch, 19. November 2008 10:15 10

Type 702042 Type 702044 Type 702041

JUMO iTRON
Compact
microprocessor
Type 702043 controllers
B 70.2040
Operating Instructions
Type 702040 2008-11-11/00357918
[Link] Seite 2 Mittwoch, 19. November 2008 10:15 10

) Please read these Operating Instructions carefully before starting up the instrument. Keep
these operating instructions in a place which is at all times accessible to all users. Please
assist us to improve these operating instructions where necessary. Your suggestions will be
most welcome.
Phone in Germany (0661) 6003-727
from abroad (+49) 661 6003-0
Fax in Germany (0661) 6003-508
abroad (+49) 661 6003-607

) All necessary settings are described in these operating instructions. However, if any difficul-
ties should still arise during start-up, you are asked not to carry out any unauthorized ma-
nipulations on the unit. You could endanger you rights under the instrument warranty!
Please contact the nearest subsidiary or the main factory in such a case.

E
When returning chassis, assemblies or components, the regulations of EN 100 015 “Protec-
tion of electrostatically sensitive components” must be observed. Use only the appropriate
ESD packaging for transport.
Please note that we cannot accept any liability for damage caused by ESD (electrostatic dis-
charge).
 [Link] Seite 3 Mittwoch, 19. November 2008 10:15 10

Contents
1 Identifying the instrument version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Displays and keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Operation of the timer function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Contents
5 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Process value input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Logic input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4 Limit comparator (alarm contact) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.5 Ramp function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.6 Self-optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.7 Level inhibit via code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.8 Timer function (extra code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Configuration and parameter tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7 Alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
 [Link] Seite 4 Mittwoch, 19. November 2008 10:15 10

1 Identifying the instrument version

(1) (2) (3) (4) (5) (6)

1 Identifying the instrument version

7020 . . / . . – . . . – . . . – . . / . . . ,...

(1) Basic type 40 = 48 x 24, 41 = 48 x 48, 42 = 48 x 96 (portrait), 43 = 96 x 48 (landscape), 44 = 96 x 96

(bezel in mm)
(2) Basic type 88 = controller type configurable1
extension 99 = controller type configured to customer specification2
(3) Inputs 888 = inputs configurable1
999 = inputs configured to customer specification2
(4) Outputs 000 = Standard Type 702040/41 Type 702042/43/44
Output 1 relay (n.o. make) relay (n.o. make)
Output 2 logic 0/5V, optionally logic 0/5V
configurable als logic input
Output 3 (not available) relay (n.o. make)

Options Type 702040/41 Type 702042/43/44

113 = Output 2 logic 0/12V, optionally logic 0/12V
(outputs 1+3 as for configurable als logic input
Standard)
101 = Output 2 relay (n.o. make) not possible
(output 1 as for Standard) (logic input is always available)
1. single-setpoint controller with limit comparator, see factory settings under configuration and parameter level 4
2. see customer’s ordering text or settings under configuration and parameter level
 [Link] Seite 5 Mittwoch, 19. November 2008 10:15 10

(5) Supply 16 = 10—18V DC

22 = 20—53V AC/DC, 48—63Hz
23 = 110—240V -15/+10% AC 48— 63Hz

1 Identifying the instrument version

(6) Extra code 210 = Timer function
220 = Timer function + limit switch1
Delivery package Type 702040/41 Type 702042/43/44
1 mounting frame 2 mounting brackets
1 seal, 1 Operating instructions 70.2040
1. The linearizations for KTY11-6 and thermocouple B have been deleted.

5
 [Link] Seite 6 Mittwoch, 19. November 2008 10:15 10

2 Installation

2 Installation
Installation 702042 1. Push on seal 3. Push on mounting brackets
as 702044. 2. Insert instrument 4. Tighten screws
Type (bezel) Panel cut-out (WxH) Edge-to-edge-mounting
in mm (minimum spacings of panel cut-outs)
horizontal vertical
702040 (48mm x 24mm) 45+0.6 x 22.2+0.3 > 8mm > 8mm
702041 (48mm x 48mm) 45+0.6 x 45+0.6 > 8mm > 8mm
702042 (48mm x 96mm) 45+0.6 x 92+0.8 > 10mm > 10mm
702043 (96mm x 48mm) 92+0.8 x 45+0.6 > 10mm > 10mm
702044 (96mm x 96mm) 92+0.8 x 92+0.8 > 10mm > 10mm 6
 [Link] Seite 7 Mittwoch, 19. November 2008 10:15 10

3 Electrical connection
Installation notes
- The choice of cable, the installation, the fusing and the electrical connection must conform to
the requirements of VDE 0100 “Regulations on the Installation of Power Circuits with nominal

3 Electrical connection
voltages below 1000V”, or the appropriate local regulations.
- The electrical connection must only be carried out by qualified personnel.
- If contact with live parts is possible when working on the instrument, it must be isolated on
both poles from the supply.
- A current limiting resistor interrupts the supply circuit in the event of a short-circuit. The load
circuit must be fused for the maximum relay current in order to prevent welding of the output
relay contacts in the event of an external short-circuit.
- Electromagnetic compatibility conforms to the standards and regulations listed under
Technical Data.
- Run input, output and supply lines separately and not parallel to each other.
- Do not connect any additional loads to the supply terminals of the instrument.
- The instrument is not suitable for installation in hazardous areas.
- Apart from faulty installation, there is a possibility of interference or damage to controlled
processes due to incorrect settings on the controller (setpoint, data of parameter and 7
 [Link] Seite 8 Mittwoch, 19. November 2008 10:15 10

configuration levels, internal adjustments).

Safety devices independent of the controller, such as overpressure valves or temperature
limiters/monitors, should always be provided and should be capable of adjustment only by
specialist personnel.
Please refer to the appropriate safety regulations in this connection. Since auto-tuning (self-
optimization) cannot be expected to handle all possible control loops, there is a theoretical

3 Electrical connection
possibility of unstable parameter settings. The resulting process value should therefore be
monitored for its stability.
- All input and output lines that are not connected to the supply network must be laid out as
shielded and twisted cables (do not run them in the vicinity of power cables or components).
The shielding must be grounded to the earth potential on the instrument side.

8
 [Link] Seite 9 Mittwoch, 19. November 2008 10:15 10

Type 702040/41 Output 21 Output 1

Logic output Relay
5V(12V)/20mA 250V/3A
2 Supply
+ –
see label

3 Electrical connection
1 2 3 4 5 6 8 9 N L1
AC
ⵒ
1 110—240V
Logic input
Thermocouple
floating contact AC/DC
+ – ⵒ
Pt100/1000 – +
(3-wire) J
20—53V

Pt100/1000

V nection
J
The electrical con- DC
KTY11-6 =
(2-wire) must only – +
be carried out by
Current qualified personnel. 10—18V
0/4—20mA
+ –
Voltage 1. Output or logic input (configurable)
0/2—10V 2. resistive load

– +
Process value input 9
 [Link] Seite 10 Mittwoch, 19. November 2008 10:15 10

Type 702040/41 with Outputs

2 relay outputs (option) Relay 250 V/3 A Supply

see label
2 1

3 Electrical connection
1 2 3 4 5 7 8 9 N L1
AC
ⵒ
Logic input 110—240V
Thermocouple
AC/DC
+ – ⵒ
Pt100/1000 – +
(3-wire) J
20—53V
Pt100/1000
V must
KTY11-6 J The electrical connection DC
(2-wire) only be carried out =
– +
by qualified personnel.
Current 10—18V
0/4—20 mA
+ –
Voltage
0/0.2—1 V
+ -
Process value input 10
 [Link] Seite 11 Mittwoch, 19. November 2008 10:15 10

Output 2 Output 1 Output 3

Type 702042/43/44
Logic output Relay Relay
2 2
5V(12V)/20mA 250V/3A 250V/3A Supply
+ –
see label

3 Electrical connection
1 2 3 4 5 6 7 9 10 12 13 N L1
AC
ⵒ
110—240V
Logic input
Thermocouple
floating contact AC/DC
+ –
ⵒ
Pt100/1000 – +
(3-wire) J
20—53V
Pt100/1000 DC
KTY11-6 J =
(2-wire)

V
– +
The electrical connection must
Current only be carried out by qualified 10—18V
0/4—20mA personnel.
+ –
2. resistive load
Voltage
0/2—10V
– +
Process value input 11
 [Link] Seite 12 Mittwoch, 19. November 2008 10:15 10

4 Operation
4.1 Displays and keys
(1) Display
7-segment display 4 places, green
Display alternates when
setpoints, parameters and
codes are entered and
indicated.

4 Operation
Character height Type 702040/41/42: 10mm
Type 702043/44: 20mm
Display range -1999 to +9999 digit
Decimal places none, one, two
°
Unit C/ °F (process value display)

(2) Status indicators

LED two LEDs for the outputs 1 and 2, yellow
Example: Type 702041 (3) Keys
q, i, d for operating and programming the instrument.
Dynamic modification of settings and parameters.
h Increase value with i
h Decrease value with d
Automatic value acceptance after 2 seconds.
12
 [Link] Seite 13 Mittwoch, 19. November 2008 10:15 10

4.2 Principle of operation

Normal display
The display shows the process value.
Operating level
The setpoint SP is input here. On active setpoint switching via the logic input, SP 1 or SP 2 ap-
pears in the display. When the ramp function is active, the ramp setpoint SPr is displayed. With
activated timer function, the timer value t i or the timer start value t i 0 is shown.
The setpoint is altered dynamically using the i and d keys. The setting will be accepted auto-

4 Operation
matically after approx. 2 sec.
Parameter level
The setpoints, the limit value of the limit comparator, the controller parameters and the ramp slo-
pe are programmed here.
Configuration level
The basic functions of the controller are set here.

A In order to make the settings, it is necessary to change to the configuration level

via the parameter y:0 (parameter level).
Timer level
The current timer value (only when the timer has been started) and the timer start value are al-
tered here. The parameters at this level are marked with an underscore in the display.
Time-out
If no operation occurs, the controller returns automatically to normal display after approx. 30 sec
(exception: with timer functions starting via power ON, the timer value is displayed). If the timer
value is displayed at the operating level, time-out is not active. 13
 [Link] Seite 14 Mittwoch, 19. November 2008 10:15 10

Normal display Operating level Parameter level

> 2s
- setpoint 1+2
Pb:1
Process value Ramp setpoint*
(display only) SPr - limit value for
limit comparator
259 - controller parameters
- ramp slope
after last
parameter Y.0
Time-out
after last
parameter A > 2s
via y.0 !

4 Operation
(30s) Configuration level
or C111
q+ d
Setpoint
(with setpoint
SP - configuration codes
- standard signal scaling
- process value correction
switching - switching differential
SP 1 or SP 2) of limit comparator

Timer level (timer stopped!)

> 2s
alter current
timer value
(only when timer has
ti
Timer value*
(operating only;
different display
ti been started)

depending on i/i+d
timer condition (see table)) set/alter
Time-out
timer start value ti0
* only displayed if function is configured Underscore to differentiate operating
and timer level
14
 [Link] Seite 15 Mittwoch, 19. November 2008 10:15 10

4.3 Operation of the timer function

The timer can be operated with the keys (start, stop, cancel, acknowledge) if the timer at opera-
ting level is indicated. Time-out is not active here. If the logic input is configured accordingly,
then a key, such as the i key, can be used. In this case, the timer can also be operated even if
the timer value does not appear in the display.
Possible displayed parameters for timer function at operating level
Display State/Action Display State/Action

4 Operation
Timer not running Timer has stopped
h Start with i h Continue with i
h Cancel with i + d

Timer has been started but Timer has run down

the tolerance limit has not h Acknowledge with any key
yet been reached
(timer start value t i 0 is
h Cancel with i + d
indicated)
Timer running; With time-delayed control
t i is displayed (C120=3), acknowledge
h Stop with i with i + d
h Cancel with i + d
When the timer has been started, the decimal point in the display for the timer value will blink!

15
 [Link] Seite 16 Mittwoch, 19. November 2008 10:15 10

5 Functions
We recommend the following procedure:
h Familiarize yourself with the controller functions
h Enter the configuration codes and the parameter values in the tables provided for this pur-
pose in Chapter 6. Write down the appropriate values ( ), or mark selection with a cross
(X ). The parameters and the configuration codes are listed in the order of their
appearance. Parameters which are not relevant are masked out (see table below).

5 Functions
h Enter the configuration code and parameters on the instrument

Configuration Masking out the parameters for Parameter

Single-setpoint controller Double-setpoint controller Pb:2, Cy 2, db, HyS.2
Double-setpoint controller Limit comp. for Type 702040/41 C114, HySt, AL
Logic input for Type 702040/411 C117
Limit comparator no function Limit comparator HySt, AL
Limit comparator activated Logic input for Type 702040/411 C117
Resistance thermometer, thermocouple Standard signal scaling SCL, SCH
Ramp function off Ramp function rASd, SPr
Setpoint switching not activated Setpoints at the parameter level SP 1, SP 2
Timer function: no function Timer function t i , C121, C122, C123
Type 702040/41 Output 3 C118
1. not for Type 702040/41 with 2 relay outputs (option) 16
 [Link] Seite 17 Mittwoch, 19. November 2008 10:15 10

5.1 Process value input

Symbol Notes
C111 Transducer/probe (process value input) vpage 31

C112 Unit of process value (°C/°F)/decimal places of display vpage 31

SCL Start/end value of value range for standard signals vpage 35

Example: 0—20 mA→20—200°C: SCL = 20 / SCH = 200

5 Functions
SCH
OFFS Process value correction vpage 35
Using the process value correction, a measured value can be corrected by a programmable
amount upwards or downwards (offset).
Lead compensation can be implemented in software for 2-wire circuit through process value
correction.

Examples:
Measured value Offset Displayed value
294.7 + 0.3 295.0
295.3 - 0.3 295.0
dF Filter time constant (damping) to adapt the digital input filter (0sec = filter off) vpage 36
if dF high: - high damping of interference signals
- slow reaction of the process value display to changes in the process value
- low cut-off frequency (2nd order low-pass filter)

17
 [Link] Seite 18 Mittwoch, 19. November 2008 10:15 10

5.2 Logic input

Key inhibit Operation is possible from keys. No operation from keys.

Level inhibit Access to the parameter and No access to the parameter and
configuration levels is possible. configuration levels.
Starting self-optimization is possible. Starting self-optimization is not possible.

5 Functions
Ramp stop Ramp running Ramp stopped
Setpoint switching Setpoint SP 1 is active Setpoint SP 2 is active
The appropriate symbols SP 1 and SP 2 are displayed at the operating
level.
Timer control Acknowledge start/stop/continue/timer run-down (edge-triggered)

Symbol Notes
C117 Function of the logic input vpage 33
On Type 702040/41, the parameter C117 is masked out if output 2 has been programmed as
controller output (C113) or the limit comparator has been configured (C114) (double assign-
ment; not on Type 702040/41 with 2 relay outputs (option)).

18
 [Link] Seite 19 Mittwoch, 19. November 2008 10:15 10

5.3 Controller
Controller structure
The controller structure is defined via the parameters Pb, dt and rt.
Example: Setting for PI controller →Pb .1=120, dt=0sec, rt=350sec
Symbol Notes
C113 Controller type and assignment of the controller outputs to the physical
outputs 1+2 vpage 32
Outputs in fault condition vpage 33

5 Functions
C116 The switching states of the outputs are defined here in the event of over/underrange, probe
break/short circuit or display overflow.
v Chapter 7
C118 Assignment of the outputs vpage 33
Only for Type 702042/43/44; overwrites the assignment of C113 (controller type as C113)
Pb:1 Proportional band 1 (controller output 1) vpage 36
Proportional band 2 (controller output 2)
Influences the P action of the controller. If Pb=0, the controller structure is not effective.
Pb:2
dt Derivative time vpage 36
Influences the D action of the controller. If dt=0, the controller has no D action.
rt Reset time vpage 36
Influences the I action of the controller. If rt=0, the controller has no I action.
Cy 1 Cycle time 1 (controller output 1) vpage 36
Cycle time 2 (controller output 2)
The cycle time has to be selected so that the energy supply to the process is virtually
Cy 2 continuous, while not subjecting the switching elements to excessive wear. 19
 [Link] Seite 20 Mittwoch, 19. November 2008 10:15 10

Symbol Notes
db Contact spacing vpage 36
for double-setpoint controller

HYS.1 Differential 1 (controller output 1) vpage 36

5 Functions
Differential 2 (controller output 2)
for controllers with Pb.1=0 or Pb.2=0
HYS.2

Y:0 Working point (basic load) vpage 36

Output if process value=setpoint
Y:1 Output limiting vpage 36
y:1 - maximum output
Y:2 y:2 - minimum output

H For controllers without controller structure (Pb.1=0 or Pb.2=0), it is necessary

that y:1=100% and y:2=-100%.

20
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5.4 Limit comparator (alarm contact)

lk1 On lk2 On lk3 On

lk4 On lk5 On lk6 On

5 Functions
On On
lk7 lk8 lk1—lk6: Monitoring referred
to the setpoint.
lk7 / lk8: Monitoring referred
to a fixed value AL.

w = setpoint, x = process value

Symbol Notes
C114 Limit comparator function (lk1— lk8) vpage 32

Hyst Differential of limit comparator vpage 35

AL Limit value of limit comparator vpage 36 21

 [Link] Seite 22 Mittwoch, 19. November 2008 10:15 10

5.5 Ramp function

J ramp setpoint SPr
process value
SP1

5 Functions
SP2

t1 t2 t3 t4 t5 t6 t

t1 power ON (SP 1 active)

t2— t3 power failure or overrange/underrange
t4—t5 ramp stop
t6 setpoint switching to SP 2

Symbol Note
C115 Ramp function (on/off, time unit) vpage 32

C117 Ramp stop via logic input (floating contact) vpage 33

rAsd Ramp slope in °C/h or °C/min vpage 36

22
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5.6 Self-optimization
Self-optimization determines the optimum controller parameters for PID or PI controllers.
The following controller parameters are defined: rt, dt, Pb:1, Pb:2, Cy 1, Cy 2, dF
The controller selects procedure a or b, depending on the size of the control deviation:
a) Self- Start b) Self- Start
optimization optimi-
in the Switching zation

5 Functions
approach level at set-
phase point
x = process value
w = setpoint
Starting self-optimization

H Starting self-optimization is not possible with active

level inhibit and ramp function.
i + d >2s

260
Self-optimization is automatically terminated, or can be can-
celled.
i+ d
tunE
23
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5.7 Level inhibit via code

As an alternative to the logic input, the level inhibit can be
set via a code (logic input has priority).
h Set the code using q + d (at least 5sec) in
normal display

Level inhibit via the logic input will lock the parameter and configuration levels (corresponds to

5 Functions
code 011).

Code Operating level Parameter level Configuration level Timer level

000 enabled enabled enabled enabled
001 enabled enabled inhibited enabled
011 enabled inhibited inhibited enabled
111 inhibited1 inhibited inhibited inhibited2

1. The values at the operating level can only be indicated but not modified.
2. Timer operation (start/stop/continue/cancel) will continue to be possible.

24
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5.8 Timer function (extra code)

Using the timer function, the control action can be influenced by means of the adjustable time
t i 0 . After the timer has been started by power ON, by pressing the key, or via the logic input,
the timer start value t i 0 is counted down to 0, either instantly or after the process value has
gone above or below a programmable tolerance limit. When the timer has run down, several
events are triggered, such as control switch-off (output 0%) and setpoint switching. Furthermo-
re, it is possible to implement timer signalling via an output.
Example:

5 Functions
w - setpoint
x - process value
S P - programmed setpoint
t i 0 - timer start value
----- - timer signalling
(here: C122=1)
i - increment key

25
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Notes on the timer function in conjunction with the ramp function

- Generally, the setpoints can also be approached using the ramp function.
- Stopping the timer does not influence the ramp function.
- If control is active after the timer has run down, the current setpoint is approached with the
ramp. Cancellation of the timer is followed by a setpoint step without ramp.
- For timer functions with a tolerance limit, only the setpoint (=ramp end value) is monitored.

5 Functions
Note on setpoint switching via the logic input
- Setpoint switching via the logic input is generally possible. An exception here is the timer
function “Time-dependent setpoint switching”. In this case, configured setpoint switching via
the logic input will not be active.

Note on the display status in the event of a power failure

- The state of the display before the power failure will be restored, except for events that are
related to the timer (start, cancel, continue, stop). Then the timer value will be shown in the
display.

26
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Symbol Notes
C120 Timer function vpage 34
C120=1 Time-limited control: The control is switched off after the timer has run down (output 0%)
C121=1, 2, 5 or 6 C121=3, 4, 7 or 8

Diagrams with and

without start above
tolerance limit.

5 Functions
---- Tolerance limit

C120=2 Time-dependent setpoint switching: After the start of the timer function, the process is con-
trolled to setpoint SP2. After the timer has run down, the controller automatically switches over
to SP1.
C121=2 or 6 C121=1 or 5 C121=3, 4, 7 or 8

27
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Symbol Notes
C120 Time-delayed control: The control action starts after the timer has run down.

H
C120=3 C121=1, 2, 5 or 6
After the timer has run down (End), the
i + d keys are used for acknowledge-
ment.
Set ti0 > 0s

5 Functions
C120=4 Timer: After the start of the timer function, t i 0 is counted down to 0. The control action is
independent of the timer. Here, too, the timer run-down can be signalled via an output.
C121=1, 2, 5 or 6

Timer signalling C122=1

C122=3

28
 [Link] Seite 29 Mittwoch, 19. November 2008 10:15 10

Symbol Notes
C121 Start condition of the timer vpage 34
The timer start value t i 0 is counted down as selected in the following events:
1. Power ON or logic input/keys
2. Start via keys/logic input
3. Process value has reached tolerance limit (1°C or 5°C) (start via keys/logic input)
The position of the tolerance limit depends on the controller type:
- 1-setpoint controller (direct): tolerance limit above setpoint
- 1-setpoint controller (reversed): tolerance limit below setpoint
- 2-setpoint controller: tolerance limit below setpoint

5 Functions
If, during the control process, the process value goes above/below the tolerance limit, the
timer will be stopped for the duration of the infringement.

Response to a power failure vpage 34

After a power failure, the condition before the power failure can be restored, or the
timer function can be cancelled. If the timer had run down before the power failure, the timer
start value will be loaded. The timer will start automatically when C121=1 or 5.
The timer value is saved at one minute intervals, to cover the case of a power failure.
C122 Timer signalling vpage 35
From the start of the timer function until timer run-down, or after the run-down, a signal can be
produced via an output.
C123 Time unit for the timer vpage 35

29
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Programming example
After the start via the logic input or from the keys, the process has to be controlled for 30 min-
utes to a setpoint of 80°C. The control action is to be cancelled in the event of a power failure.
Configuration:
- C111— C116: Controller programming
- C117=5: Logic input = timer control
- C120=1: Timer function = time-limited control

5 Functions
- C121=6: Start condition for timer = via logic input/keys - cancellation on power failure
- C122=0: Timer signalling = no function
- C123=1: Time unit (timer) = [Link]
Operation:
h Enter the setpoint SP (80°C)
h Press the q key until t i0 is indicated
h Change over to the timer level using q (at least 2sec)
h Enter the timer start value t i0 _ (30.00)
h Return to the operating level (timer value) with q
h Start the control action via the logic input or with i 30
 [Link] Seite 31 Mittwoch, 19. November 2008 10:15 10

6 Configuration and parameter tables

C111 Transducer X C112 Decimal places/unit X

6 Configuration and parameter tables

001 Pt 100 (3-wire) q 0 9999/°C
q 006 Pt 1000 (3-wire) 1 999.9/°C
>2s 601 KTY11-6 (2-wire) 2 99.99/°C
003 Pt 100 (2-wire) 3 9999/°F
4 999.9/°F
y:0 005
039
Pt 1000
Cu-Con T
(2-wire)
5 99.99/°F
040 Fe-Con J
041 Cu-Con U q
. 042 Fe-Con L
...
.
.
q 043
044
NiCr-Ni
Pt10Rh-Pt S
K

045 Pt13Rh-Pt R
046 Pt30Rh-Pt B
048 NiCrSi-NiSi N
Pb:11 052 Standard signal 0 – 20mA
053 Standard signal 4 – 20mA
q 063 Standard signal 0 – 10V2
>2s 071 Standard signal 2 – 10V3
X Mark your selection with a
Normal display/ cross.
Operating level
1. SP 1, AL or Pb:1 is shown here, depending on the configuration
2. 0 – 1V for Type 702040/41 with 2 relay outputs (option) 31
3. 0.2 – 1V for Type 702040/41 with 2 relay outputs (option)
[Link] Seite 32 Mittwoch, 19. November 2008 10:15 10

C113 Controller type Output 1 (relay) Output 2+3 X

(logic+relay)

6 Configuration and parameter tables

10 single setpoint (reversed) controller LK/timer signalling1
11 single setpoint (direct) controller LK/timer signalling1
30 double setpoint controller output 1 controller output 2
20 single setpoint (reversed) LK/timer signalling1 controller
21 single setpoint (direct) LK/timer signalling1 controller
33 double setpoint controller output 2 controller output 1
1. A programmed limit comparator (LK) has priority
q over the timer signalling.
Further settings for the outputs with Type 702042/43/44, see C118.
C114 Limit comparator (LK) X C115 Ramp function X
0 no function q 0 ramp function off
1 lk 1 1 ramp function (°C/min)
2 lk 2 2 ramp function (°C/h)
3 lk 3
4 lk 4 q
5 lk 5
6 lk 6 ...
7 lk 7
8 lk 8
reversed = heating (output is active when process value is below setpoint) = controller output 1
direct = cooling (output is active when process value is above setpoint) = controller output 2 32
[Link] Seite 33 Mittwoch, 19. November 2008 10:15 10

C116 Outputs on fault X C117 Logic input X

6 Configuration and parameter tables

0 0%1 LK/timer 0 no function
1 100%2 signalling OFF 1 key inhibit
2 -100%1 2 level inhibit
3 0%1 LK/timer 3 ramp stop
4 100%2 signalling ON 4 setpoint switching
5 timer control
1. Minimum output limiting y.2 is effective
2. Maximum output limiting y.1 is effective
q
... C118 Output 1: Relay (K1) Output 2: Logic (K2) Output 3: Relay X

q 0
1
for 2-setpt. contrl. for 1-setpt. contrl. Functions of outputs as defined under C113
controller output limit comparator timer signalling
2 controller output timer signalling limit comparator
3 limit comparator controller output timer signalling
4 limit comparator timer signalling controller output
5 timer signalling controller output limit comparator
6 timer signalling limit comparator controller output
7 controller output 1 controller output 2 limit comparator/timer
8 controller output 1 limit comparator/timer controller output 2
9 controller output 2 controller output 1 limit comparator/timer
10 controller output 2 limit comparator/timer controller output 1
11 limit comparator/timer controller output 1 controller output 2
12 limit comparator/timer controller output 2 controller output 1 33
[Link] Seite 34 Mittwoch, 19. November 2008 10:15 10

C120 Timer function X

6 Configuration and parameter tables

0 no function
1 time-limited control
2 time-dependent setpoint switching
3 time-delayed control
4 timer (control independent of timer)

q
... C121 Start condition for timer Action on power failure X
1 after power ON, logic input/keys Condition as before the
q 2 via logic input/keys power failure
3 via logic input/keys; timer counts 1°C
from tolerance limit
4 via logic input/keys; timer counts 5°C
from tolerance limit
5 after power ON, logic input/keys Cancellation of
6 via logic input/keys timer function
7 via logic input/keys; timer counts 1°C (StOP appears in the
from tolerance limit display)
8 via logic input/keys; timer counts 5°C
from tolerance limit
The start conditions with tolerance limit (C121=3, 4, 7, 8) are not valid for C120=3 or 4.
If C120 is altered, the validity of C121 must be checked.
34
[Link] Seite 35 Mittwoch, 19. November 2008 10:15 10

C122 Timer signalling X C123 Unit of time (timer) X

q

6 Configuration and parameter tables

0 no function 1 [Link] (max. 99.59)
1 timer start until run-down 2 [Link] (max. 99.59)
2 after run-down for 10sec 3 hhh.h (max. 999.9)
3 after run-down for 1min. s = seconds; m = minutes;
4 after run-down until h = hours
acknowledgement
One output has to be configured q
correspondingly(C113/C118).
Parameter Explanation Value range factory-set Your
setting
SCL start value of the -1999 to +9999digit1 0
standard signal
sCH end value of the -1999 to +9999digit1 100
standard signal
SPL lower -1999 to +9999digit1 -200
setpoint limiting
SPH upper -1999 to +9999digit1 850
setpoint limiting
q OFFS process value correction -1999 to 9999digit1 0
... HySt switching differential of 0 — 9999digit1 1
the limit comparator
1. For displays with one or two decimal places, the value range and the factory setting
change accordingly.
Example: 1 decimal place →value range: -199.9 to +999.9 35
[Link] Seite 36 Mittwoch, 19. November 2008 10:15 10

Parameter Explanation Value range factory- Your

set setting

6 Configuration and parameter tables

sP 1 setpoint 1 SPL — SPH 0
sP 2 setpoint 2 SPL — SPH 0
AL limit value of -1999 to +9999digit1 0
limit comparator
Pb:1 proportional band 1 0 — 9999digit1 0
Pb:2 proportional band 2 0 — 9999digit1 0
dt derivative time 0 — 9999sec 80sec
rt reset time 0 — 9999sec 350sec
Cy 1 cycle time 1 1.0 — 999.9sec 20.0sec
Cy 2 cycle time 2 1.0 — 999.9sec 20.0sec
db contact spacing 0 — 1000digit1 0
HYS.1 differential 1 0 — 9999digit1 1
HYS.2 differential 2 0 — 9999digit1 1
Y:0 working point -100 to 100% 0%
Y:1 maximum output 0 — 100% 100%
Y:2 minimum output -100 to +100% -100%
dF filter time constant 0.0 — 100.0sec 0.6sec
rAsd ramp slope 0 — 999 °C/h (°C/min)1 0
1. For displays with one or two decimal places, the value range and the factory setting
change accordingly.
36
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7 Alarm messages

Display Description Cause/response

The displays for the process Over/underrange of process value.
value or timer value flashes Controller and limit comparators referred to
“1999”. the process value input behave in accord-
Display current timer value by ance with the configuration of the outputs.

7 Alarm messages
repeatedly pressing the q The timer is stopped.
key.
The display for the timer value The timer function has been cancelled due to
alternates between showing a supply failure. The timer value that was
“StOP” and the time. present at the time of the supply failure will be
h Acknowledge by using any indicated.
key, (the timer start value
t i 0 is loaded)

H The following events come under the heading over/underrange:

- Probe break/short-circuit
- Measurement is outside the control range of the probe that is connected
- Display overflow

37
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Measurement circuit monitoring (• = recognized)

Transducer Overrange/ Probe/ Probe/lead break
underrange lead short-circuit
Thermocouple •/• - •
Resistance thermometer •/• • •
Voltage 2 – 10V and0.2 – 1V •/• • •
0 – 10V and 0 – 1V •/- - -

7 Alarm messages
Current 4 – 20mA •/• • •
0 – 20mA •/- - -

38
 [Link] Seite 39 Mittwoch, 19. November 2008 10:15 10

8 Technical data
Input for thermocouple Input for resistance thermometer
Designation Range 1 Designation Range
Fe-Con L -200 to + 900°C Pt100 EN 60751 -200 to +850°C
Fe-Con J EN 60584 -200 to +1200°C Pt1000 EN 60751 -200 to +850°C
Cu-Con U -200 to + 600°C
Cu-Con T EN 60584 -200 to + 400°C KTY11-6 -50 to +150°C
NiCr-Ni K EN 60584 -200 to +1372°C Measurement accuracy:

8 Technical data
NiCrSi-NiSi N EN 60584 -200 to +1300°C Pt100/1000: ≤0.1% / 50ppm/°C
Pt10Rh-Pt S EN 60584 0 — 1768°C KTY11-6: ≤1.0% / 50ppm/°C
Pt13Rh-Pt R EN 60584 0 — 1768°C Sensor lead
Pt30Rh-Pt6Rh B EN 60584 0 — 1820°C resistance: 20Ω max. per lead
Measurement accuracy: ≤0.4% / 100ppm/°C Meas. current: 250µA
Cold junction: Pt100 internal
1. These ranges refer to the ambiente temperature of 20°C Outputs
Relay:
Input for standard signals
n.o.(make) contact; 3A at 250V AC resistive load;
Designation Range 150,000 operations at rated load
Voltage 0 — 10V, RE > 100kΩ2 Logic 0/5V:
2 — 10V, RE > 100kΩ3 Current limiting: 20mA; Rload ≥250Ω
RE - input resistance Logic 0/12V:
Current 4 — 20mA, voltage drop ≤1,5V Current limiting: 20mA; Rload ≥600Ω
0 — 20mA, voltage drop ≤1,5V
Supply
Measurement accuracy: ≤0.1% / 100ppm/°C 110 — 240V AC -15/+10% 48 — 63Hz, or
2. 0—1V, RE>10MΩ for Type 702040/41 with 2 relays 20 — 53V AC/DC 48 — 63Hz, or
3. 0.2—1V, RE>10MΩ for Type 702040/41 with 2 relays 10 — 18V DC (Connect to SELV or PELV) 39
 [Link] Seite 40 Mittwoch, 19. November 2008 10:15 10

Controller Data backup: EEPROM

Controller type 1-setpt. controller with Housing type
limit comparator, 2-setpt. controller plastic housing for panel mounting
Controller structure P/PD/PI/PID to DIN 43700
A/D converter resolution >15 bit Cleaning the front panel
Sampling time 210msec (250msec with timer use warm or hot water (add mildly acidic, neutral
function) or mildly alkaline detergents, if necessary). Do
Accuracy of timer: 0.7% / 10ppm/°C not use any abrasive cleaning agents or high-

8 Technical data
pressure cleaners. Limited resistance to organic
Test voltages (type test) solvents (e. g. spirits, benzol, etc.).
to EN 61 010, Part 1, March 1994,
overvoltage category II, pollution degree 2, Housing mounting
for Type 702040/41 in panel to DIN 43 834
overvoltage category III, pollution degree 2, Ambient and storage temperature
for Type 702042/43/44 0 to 55°C / -40 to +70°C
Power consumption: 7VA max. Climatic conditions
Electrical connection ≤75% rel. humidity, no condensation
at the rear via plug-in screw terminals, Operating position: any
conductor cross-section ≤2.5mm2 (1.3mm2 with Weight (approx.)
Type 702040/41) solid wire or 75g (702040) 160g (702043)
1.5mm2 (1.0mm2 for Type 702040/41) stranded wire with 95g (702041) 200g (702044)
ferrules 145g (702042)
Electromagnetic compatibility: EN 61 326 Protection
Immunity to interfer.: Class B, Interfer. emission: industrial IP66 (front) to EN 60529
requirements IP20 (rear)
40
Approval: UL and CSA (only devices with JUMO indication) Safety regulation: to EN 61010
 [Link] Seite 1 Mittwoch, 19. November 2008 10:15 10

JUMO GmbH & Co. KG JUMO Instrument Co. Ltd. JUMO Process Control, Inc.
Street adress: JUMO House 8 Technology Boulevard
Moltkestraße 13 - 31 Temple Bank, Riverway Canastota, NY 13032, USA
36039 Fulda, Germany Harlow, Essex CM20 2TT, UK Phone: 315-697-JUMO
Delivery address: Phone: +44 1279 635533 1-800-554-JUMO
Mackenrodtstraße 14 Fax: +44 1279 635262 Fax: 315-697-5867
36039 Fulda, Germany e-mail: sales@[Link] e-mail: info@[Link]
Postal address: Internet: [Link] Internet: [Link]
36035 Fulda, Germany
Phone: +49 661 6003-0
Fax: +49 661 6003-607
e-mail: mail@[Link]
Internet: [Link]