Original manual

OPERATING INSTRUCTION
TROUGH VIBRATORY MACHINE
Type WR60

AVALON MACHINES SP. Z O. O. tel. (0048)59 8622667

84-351 Nowa Wieś Lęborska mob. (0048)602234909
ul. Grunwaldzka 38 e-mail: [email protected]
POLAND http://www.avalon-machines.pl
 CONTENTS
1 GENERAL RECOMMENDATIONS ................................................................................ 3
2 TECHNICAL DATA ...................................................................................................... 3
3 STRUCTURE OF THE MACHINE .................................................................................. 4
3.1 CONTROL PANEL...........................................................................................................5
3.2 NAMEPLATE ..................................................................................................................6
3.3 INSTRUCTION FOR USE TIMER TA-040 .........................................................................6
3.4 INSTRUCTION FOR DOSING PUMP ...............................................................................7
4 TRANSPORT.............................................................................................................. 8
5 INSTALLATION OF THE MACHINE .............................................................................. 9
6 STARTING THE MACHINE .......................................................................................... 9
7 TECHNICAL INSPECTIONS .......................................................................................... 9
7.1 DAILY TECHNICAL INSPECTION DTI ..............................................................................9
7.2 TEMPORARY TTECHNICAL INSPECTION TTI ..................................................................9
7.3 MAJOR REPAIR............................................................................................................10
7.4 EMPTING THE WORKING CHAMBER ..........................................................................10
8 COMMON PROBLEMS AND FAILURES ..................................................................... 11
9 ELECTRIC SYSTEM DIAGRAM ................................................................................... 12
10 EVALUATION OF SAFETY AND WORK CONDITIONS .................................................. 12
10.1 INTRODUCTION.......................................................................................................12
10.1.1 THE AIM OF DRAWING-UP ..............................................................................12
10.1.2 LEGAL BASE......................................................................................................13
10.2 RISKS DESCRIPTION .................................................................................................14
10.2.1 MEANS OF PROTECTION AGAINST RISKS ........................................................14
10.2.2 FUTHER NOTICE AND RECCOMMENDATIONS ................................................14
11 THE GUARANTEE CERTIFICATE ................................................................................ 15

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1 GENERAL RECOMMENDATIONS

1. Trough vibratory machine WR60 is used for grinding, deburring or polishing products depending on the
abrasive media used and the machine settings.
2. Removing the working media after the process is easy and user-friendly. The machine is durable and
reliable. The material of which the container is made is extremely wear-resistant (about 8 times compared
to steel).
3. It is recommended for the machine to be used by only one, relatively two working operators, who are
responsible for technical condition of the machine. Careful operation as well as professional maintenance
will allow continuous readiness of the machine to work.
4. The technical inspections, described in the following instruction, needs to be carried systematically.
5. Minor defects should be recognized and immediately repaired to prevent expensive and long-term repairs.
6. Use of media offered by AVALON is recommended to protract working life of the machine.

Before operating the machine, make sure you know and follow these rules:
 Before operating the machine familiarize with the instruction manual and strictly follow the
recommendations.
 Proceed with daily technical inspection, every day (see paragraph 7.1)
 Keep the machine and the work stand clean,

2 TECHNICAL DATA

 Power supply .......................................................................................... 230V, 50Hz;

 Installed power ....................................................................................... 0,44kW
 Nominal volume ..................................................................................... 60l
 Weight .................................................................................................... 266kg
 Dimensions ............................................................................................. 1350x520x810mm
 Noise level .............................................................................................. 65-85dB

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3 STRUCTURE OF THE MACHINE

1
7
2
6

3 5

1. Control panel
2. Dosing pump
3. Fluid container
4. Media container
5. Manual separator
6. Chamber plug
7. Lid

The machine body is welded steel construction. The main part of the machine is the frame, on which is the
working chamber made of polyurethane (hardness of 95° Sh ) is placed. Working chamber is propelled into
vibrating movement by means of electric motor. To machine may be added a barrier. Barrier is designed to
divide workpiece to prevent it before damage by each other

To machine can be used manual or automatic separator. In separator is stop bar. The stop bar can be replaced
on left or right side. It depend on which side must be the handcart

Trough vibratory machine is simple and safe to use, rotating elements have a fixed covers. The design does
not have sharp edges that may cause injury.

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3.1 CONTROL PANEL

5
2

3 4

1. Rotation speed display

2. Rotation speed regulation knob
3. Emergency switch
4. Main switch
5. TA040 timer

1. System for changing the direction of rotation

2. Rotation direction reverse time dial
3. Reversing switch

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It is possible to automatically change the direction of rotation of the engine, to do this:
 Turn off the machine power supply.
 Open the control panel using the key on the side of the control panel.
 Activate the reverse rotation system by setting the switch (3) to the ON position.
 Set the appropriate time after which the engine rpm will change automatically (the set time must
not be less than 2 minutes).
 Close the control panel using the key.
 Start the machine.

WARNING !
The time of automatic change of the direction of rotation must not be less than 2 minutes.

3.2 NAMEPLATE

3.3 INSTRUCTION FOR USE TIMER TA-040

1 7

3 4 5 6

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 1. Program Number Display
2. Indicator light
3. START button
4. STOP button
5. Cursor DOWN
6. Cursor UP
7. Main Display

After connecting the machine to electricity grid, the remainder of the process will appear on the main display
(7) and recently implemented program number on the display (1) (eg:>> 1 <<). Clock allows you to save a
persistent memory of 10 different time schedules.

To make changes to the program set, press the START key for 3 seconds.
The first step is to select the program number you wish to change or re-programmed. Press cursor ↑ (up) or
↓ (down) until the program you wish to change appears on display (1). Press the START button (3). On the
main display, on the position of hour, display will flash e.g.: "02".05. Set the number of hours by cursors ↑
(up) and ↓ (down). Then press the START key and hold it for few seconds. On the position of minute, display
will flash 02 "05". Set the number of minutes by cursors ↑ (up) and ↓ (down) and confirm the value by START
button. This will automatically save the set value in driver memory.

To start the machine, select the cursor ↑ (up) or ↓ (down) on the appropriate program number. Than press
the START button. Confirmation of the controller response is shining LED (2) and the flashing dots 02».«05.
The set time will be counted down from the set value to 0.
To correct the set time, during the operation, press the STOP button – this will stop the machine - make
adjustments in the same way as for setting the time.

Press START to temporarily stop the machine and to restart it. This operation can be performed multiple
times during the cycle.
Pressing the STOP button during operation will stop the machine while resetting a specified time. After
countdown of the set time the device will stop and the display will show previously set time. In the case of
power failure, the machine stops. According to current standards, the operator must restore the machine to
work himself. It should be noted that the machine starts with a small delay (ok.2s) - this is needed for certain
processes.

In the case of co-operation of the clock with the controls, where inverter is installed, it is possible to display
2 different error messages:
ER1 – shows the fluid sensor error (lack of liquid in reservoir),
ER2 – indicates an inverter error.

In both cases, the device should be disconnected from the mains, remove the cause of the error and restart
the machine.

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3.4 INSTRUCTION FOR DOSING PUMP

1 4

2 5

1. Control Panel
2. bleed valve
3. ON/OFF switch*
4. Flow rate (%)regulation potentiometer
5. Maximum speed (:5) and dosage impulse LED
6. Maximum frequency selector
7. Maximum frequency and dosage pulse LED
Flow rate range: 4-8 l/h
To turn on the pump put the switch (2) in ON position*. Regulate the flow rate with Flow rate (%)regulation
potentiometer (3). If necessary it is possible to change the frequency range. There are two available 0-20%
and 0-100%. To change frequency range press the Maximum frequency selector. LEDs (4) and (6) indicate
which frequency range is chosen.
First run:

 Switch on the pump,

 Unscrew the valve (2) and wait until the liquid starts to drain out through the valve (2),
 Close the bleed valve (2).

*In case of dosing pump without ON/OFF switch. To turn on the pump press the (SEL) button till LEDs (4 and
6) will blinking.

4 TRANSPORT
In road transport the machine can be laid vertically. The machine should be protected against moving during the
transport. For time of transport the working chamber should be immobilized. In the case of an open transport
the machine should be secured against the influence of external factors.

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5 INSTALLATION OF THE MACHINE
 Level the machine
 Remove the transport beams
 Plug the machine to property electricity grid
 Provide water to the machine
 Provide technological sludge disposal to the sludge tank

6 STARTING THE MACHINE

1) fill the working chamber with appropriate media and chemicals supporting the process
2) turn on the main switch
3) set the timer and adjust the process speed
4) press START button ( machine will start after two seconds)
5) After starting the machine, add workpieces to the working chamber

7 TECHNICAL INSPECTIONS
The trough vibratory machine should be subjected to some technical inspections described in this instruction
manual, and if necessary, to repairs. The decision of the necessity of immediate repair is made as a result of a
technical survey conducted together with the personnel (or when submitted by the operator). It is advised to do
repairs by means of the exchange of the damaged elements or units. A rigorous following of the established service-
repair system will allow to maintain the machine in a high technical efficiency.
All the service- repair activities must be conducted after previous stoppage of the machine and turning off the
electric power!
The base for estimating the number of the working hours of the machine are the recordings done in the “Trough
vibratory machine, type WR60 Service Book”.

There are the following types of technical inspections and repairs:

1. Daily technical inspection- DTI
2. Temporary technical inspection- TTI done every 1000 working hours
3. Running repair - the term as well as the kinds of repairs are not planned forward
4. Major repair- done after 15 000 working hours.

7.1 DAILY TECHNICAL INSPECTION DTI

The aim of the daily technical inspection is to prepare the round vibratory machine for doing the everyday
tasks efficiently. The inspection is done by the machine operator.

DTI inspection includes:

1. Cleaning the outer part of the machine with clean cloth,
2. Checking the sealing of working chamber
3. Check the correctness of outlet’s lock
4. Check the correctness of lock of the water valve
5. Check the work of all the control buttons before starting to operate on the machine,
6. Tighten all loose screws and caps.

7.2 TEMPORARY TTECHNICAL INSPECTION TTI

This kind of inspection should be done by a machine operator every 1000 work hours of the machine. All the
maintenance and repair work should be done by the personnel previously trained in a given type of the
machine.

As a part of the inspection TTI the following activities from the DTI inspection must be done and additionally:

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 1. Wipe the chamber with a plastic chips (black) to get rid of the slippery chamber
2. Check the condition of electrical wiring,
3. In case of leakage of fluid - exchange water drain valve (recommended regeneration at AVALON),
4. In case characteristic spiral motion deteriorates, adjust the machine (recommended regulation at
AVALON).

7.3 MAJOR REPAIR

As a part of this inspection it is recommended to do the repair in AVALON.

7.4 EMPTING THE WORKING CHAMBER

2 4

1. Plug blocker
2. Draining hole
3. chamber plug
4. Plug blocker knob

 A dedicated separator or container for fittings should be placed under the discharge opening.
 Slightly loosen the knob (4) and then take off the blocker(1).
 Caution, after removing the plug (3), the load will start flowing out of the discharge opening.
 Pull the chamber plug(3) out
 Turn on the machine until the entire load leaves the working chamber.
 Put the plug into the draining
 Place the blocker (1)
 Tighten the knob(5) firmly.

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8 COMMON PROBLEMS AND FAILURES
ERRORS MESSAGE APEARS ON TIMER TA-040

Display Content Cause Corrective action

Err1

Fluid level sensor

Fluid container is empty Fill up the liquid container
error

Err2

Inverter error Inverter error See relevant inverter alert

ERRORS MESSAGE APEARS ON FREQUENCY INVERTER

Display Content Cause Corrective action

-LV-
1. Check if the power voltage is
Voltage too low correct;
1. Power voltage too low;
when stopped 2. Check the position of
2. Emergency switch pressed.
emergency stop button
3. Consult with the supplier.

-OH-
The inverter is
overheated when 1. Detection circuit malfunction; 1. Improve the ventilation
2. Ambient temperature too high conditions;
stopped or bad ventilation. 2. Consult with the supplier.

OH-C
The inverter is 1. Inverter temperature is too high
overheated during 3. Improve the ventilation
or bad ventilation;
conditions;
running 2. Temperature sensor error or
4. Consult with the supplier.
circuit malfunctions.

OL1

Motor overload 1. Motor failure 1. Consult with the supplier

OL2

Inverter overload Motor failure Consult with the supplier

LU-C
1. Check if the power voltage is
Voltage too low 1. Power voltage too low;
correct;
2. Power voltage varies widely
during operation 2. Check the position of
(fluctuates)
emergency stop button
3. Emergency switch pressed.
3. Consult with the supplier.

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9 ELECTRIC SYSTEM DIAGRAM

CZD Open door sensor SA Emergency switch

CZP Fluid level sensor SP Motor Direction Switch
F Inverter TA040 Timer
K1,k1 Connector W Varistor AS-12M
LED Start-Stop light WG Main switch
M1 Electric motor X1.1,2...5 Clamps on terminals
M2 Dosing pump X2 Main motor socket
P START/STOP button X4 Fluid level sensor socket
R Frequency regulation potentiometer

10 EVALUATION OF SAFETY AND WORK CONDITIONS

10.1 INTRODUCTION

10.1.1 THE AIM OF DRAWING-UP

Work on the assessment of the round vibratory machine type WR60 as far as Industrial Safety is concerned, have
been conducted in order to pass The CE Declaration of Conformity with the 2006/42/WE Directive as well as
with the Polish Harmonized Standards regarding Industrial Safety.
The structure of the device has been analyzed with regard to construction conformity with the current law and
with the effectiveness of the security system as well as the probability of a risk.

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 10.1.2 LEGAL BASE
Product is compatible with the following laws, directives and regulations:
 European Parliament and European Council 2006/42/WE of 17 May 2006 the laws of the Member States
relating to machinery;
 European Parliament and Council Directive 2014/30/EU 26 February 2014 the laws of the Member States
relating to electromagnetic compatibility;
 European Parliament and Council Directive 2014/35/UE of 26 February 2014 on the harmonization of
laws relating to electrical equipment designed for use within certain voltage limits;
 Decree of the Minister of Economy of 21 October 2008 Dz. U. Nr.199 poz.1228 dated 7 November 2008
on essential requirements for the machines;
 Regulation of the Minister of Economy of the 30.10.2002 Dz. U. Nr. 191 pos.1596 dated 18 November
2002 before commissioning the unit;
 The Act of 13 April 2007 on electromagnetic compatibility. (Dz.U.Nr. 82, pos. 556);
 Regulation of the Minister of Economy of 2 February 2016 on essential requirements for electrical
equipment (Dz. U. Nr. 2016, poz.806);
 Act on general product safety Acts U. No .229 pos.2275 dated.12.12.2003r. as amended Dz. U. Nr. 35 pos
.215. dated.12.01.2007r.;

and with the following standards:

 PN-EN 60204-1:2018-12 Safety of machinery. Electrical equipment of machines. General requirements.;

 PN-EN 547-1+A1:2010 Safety of machinery – Human body measurements – Part 1: Principles for determining the
dimensions required for openings for whole body access into machinery;
 PN-EN ISO 12100:2012 Safety of machinery - General principles for design – Risk assessment and risk reduction;
 PN-HD 60364-4-41:2017-09 Electrical installations in buildings. Protection for safety. Protection against electric
shock.;
 PN-EN ISO 14120:2016-03 Safety of machinery – Guards – General requirements for the design and construction
of fixed and movable guards;
 PN-EN 981+A1:2010 Safety of machinery - System of auditory and visual danger and information signals.;
 PN-EN ISO 14118:2018-05 Safety of machinery – Prevention of unexpected start-up.;
 PN-EN ISO 12100-2012 Safety of machinery- Part 1- Principles of risk assessment.;
 PN-EN ISO 13850:2016-03 Safety of machinery – Emergency Stop – Design properties.;
 PN-EN ISO 4413:2011 Hydraulic drives and control - General principles and safety requirements for systems and
their components.
procedures:
 Testing program;
 Procedure for inspection and testing;
 Validation of the product

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10.2 RISKS DESCRIPTION

Accident and health risk may be caused by the following noxious and dangerous agents occurring with the work
connected with operating the machine.

 Service-repair works
 Electric shock

10.2.1 MEANS OF PROTECTION AGAINST RISKS

After the inspection of the machine, it has been proved that the producer has used the following means of
protection against risks:

 A worker operating the round vibratory machine has the opportunity of a visual control of the working
area. Taking into consideration the technology of work and the scale of the risks, the operator comply
certain health requirements and undergo a special training in order to get machine operating
qualifications. The access to moveable driving elements is limited by a still shield.
 All the service- repair activities must be conducted after previous stoppage of the machine and turning
off the power supply.
 The solutions regarding the construction of the work stand of the operator, the control buttons
workspace meet the requirements of the Polish norms in this matter.
 The electrical system meets the safety requirements against the electric shock.

10.2.2 FUTHER NOTICE AND RECCOMMENDATIONS

The user is obliged to:

 Before admitting an employee to operate the machine, the employer is due to train them in safe machine
operation and inform of the occupational risk connected with operating the machine.
 Work out an operation and industrial safety instruction and make it available to the employee.

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11 THE GUARANTEE CERTIFICATE

Producer:

AVALON MACHINES SP. Z O. O.

UL.GRUNWALDZKA 38
84-351 NOWA WIEŚ LĘBORSKA
POLAND
gives a one-year guarantee on:
WR60 Trough vibratory machine
Manufacturing number..................

We guarantee a failure-free work of the machine under the condition of following all the requirements included
in the hereby operating instruction.

In the guarantee period we provide free repairs of the defects caused by hidden manufacturing flaws.

The user loses the right to free repairs in case of: using the machine at variance with its destiny, disassembly or
modification of the machine without the producer’s permission, mechanical damage caused by the user or during
the transport.

stamp and signature

of the seller

date: ____________

Number of the Description of the repair Date and stamp of the service
repair

The producer reserves the right to introducing changes in construction without including them in the operating instruction.

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