DAGII - Operating Manual

DAG II Vacuum device for shredder modules Operating Manual

Giesecke & Devrient

Hinweis Die in dieser Dokumentation enthaltenen Informationen, Kenntnisse und Darstellungen betrachten G&D/GAO/KRÄMER als ihr alleini-ges Eigentum, sie sind daher STRENG VERTRAULICH zu behandeln. Die Dokumentation bzw. die darin enthaltenen Informationen, Kenntnisse und Darstellungen dürfen ohne die vorherige schriftliche Zustimmung von G&D/GAO/KRÄMER weder vollständig noch auszugsweise, direkt oder indirekt Dritten zugänglich gemacht, veröffentlicht oder anderweitig verbreitet werden. Die Geltendmachung aller diesbezüglichen Rechte, insbesondere für den Fall der Erteilung von Patenten, bleiben der Firmengruppe Giesecke & Devrient vorbehalten. Die Übergabe der Dokumentation begründet keinerlei Anspruch auf eine Lizenz oder Benutzung. Warenzeichen Andere Produktnamen, Firmennamen und Bezeichnungen in diesem Handbuch können Warenzeichen oder eingetragene Warenzei-chen anderer Firmen sein und werden in diesem Handbuch nur in erklärender Weise und ohne Absicht zur Rechtsverletzung erwähnt. Vorbehalt Die in dieser Dokumentation gemachten Angaben stellen keine zugesicherten Eigenschaften dar. Note The information or material contained in this document is STRICTLY CONFIDENTIAL and any recipient of this document shall not disclose or divulge, directly or indirectly, this document or the information or material contained herein without the prior written consent of G&D/GAO/KRÄMER. All copyrights, trademarks, patents and other rights in connection herewith are expressly reserved to the Giesecke & Devrient group of companies and no license is created hereby. Trademarks Other product names, company names and descriptions in this manual may be registered trademarks from other companies. These are only used in this manual for explanatory purposes and any misuse is unintended. Disclaimer The information in this documentation does not represent any guaranteed characteristics. Technische Änderungen vorbehalten / Technical changes reserved. Systemlieferant Supplier of system Giesecke & Devrient Prinzregentenstraße 159 D-81677 Munich Germany Unternehmensbereich Banknotenbearbeitungssysteme Currency Automation Division Euckenstraße 12 D-81369 Munich Germany

Hersteller DAG II Manufacturer DAG II G. H. Krämer GmbH & Co. KG Schulstrasse 57 Postfach 1162 35301 Grünberg

Diese Maschine erfüllt die Sicherheitsanforderungen der einschlägigen EG-Richtlinien und hält die EN-Normen, wie in der EG-Konformitätserklärung angegeben, ein. This machine meets the safety requirements of the relevant EC directives an complies with the EN standards as listed in the EC Declaration of Conformity.

Service Hot Line Tel. 0180 531 37 32 Fax x49 89 4119-4410 © 1998 GAO/KRÄMER Printed in Germany Ausgabedatum / Date of issue 11/98

Artikelnummer / Part no. 207943 00 1

Contents Operating Manual DAG II

Contents

General safety information Chapter 1 Correct use ...................................................................................................................... 1-1 Incorrect use.................................................................................................................... 1-1 Safety information for maintenance and repair of the vacuum device ...................... 1-2 Safety rules ...................................................................................................................... 1-2 EC Conformity ................................................................................................................. 1-2

Description of product Chapter 2 Introduction ..................................................................................................................... 2-1 Symbols used .................................................................................................................. 2-1 General note .................................................................................................................... 2-2 Specification of the vacuum device .............................................................................. 2-3 Scope of supply............................................................................................................... 2-3 Basic equipment.............................................................................................................. 2-4 Area of application, construction, mode of operation................................................. 2-4 Data on the specification plate ...................................................................................... 2-4 Technical specifications / device overview .................................................................. 2-5

Installation Chapter 3 General quality of the installation room........................................................................ 3-1 Weather influences ......................................................................................................... 3-2 Dimensions of the installation room ............................................................................. 3-2 Exhaust air and waste heat ............................................................................................ 3-2 Interface to the banknote processor ............................................................................. 3-3 Transport piping for shreddings.................................................................................... 3-4

Putting into operation Chapter 4

Change of collecting bags and maintenance Chapter 5 Safety information........................................................................................................... 5-1 Change of the collecting bag ......................................................................................... 5-1 Maintenance intervals..................................................................................................... 5-2 Cleaning of the filter bag ................................................................................................ 5-3

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DAG II Operating Manual Contents

Renewing of the filtering bag ........................................................................................ 5-3 Adjustment of the filling level control .......................................................................... 5-4

Malfunctions Chapter 6 General ............................................................................................................................ 6-1 Vacuum device malfunctions ........................................................................................ 6-1

Assembly of spare parts and wear parts Chapter 7 General ............................................................................................................................ 7-1 Preface to safety............................................................................................................. 7-1 Device design ................................................................................................................. 7-2 Switchbox........................................................................................................................ 7-3 Power pack...................................................................................................................... 7-3 Fuses and relays ............................................................................................................ 7-3 Filling level control......................................................................................................... 7-3 Terminal switch .............................................................................................................. 7-3 Fan ................................................................................................................................... 7-4 Motor................................................................................................................................ 7-4 Impeller............................................................................................................................ 7-4 Steering roller / pedestal roller..................................................................................... 7-4 Rubber gasket................................................................................................................. 7-4

Anhänge / Appendix A-1 Maßskizzen / Dimension sketches................................................................................ A-3 Schaltpläne / Wirering diagramms................................................................................ A-5 EG-Konformitätserklärung............................................................................................. A-9 Ersatz- und Verschleißteiliste / Spare parts and Wear parts listing .......................... A-11

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General safety information Operating Manual DAG II

Chapter 1 General safety information

Warning Non-observance of the following safety information may lead to physical injury and damage to the vacuum device. Always follow the general safety and accident prevention rules in addition to those set forth in this manual!

Correct use The device may only be used to vacuum dry shredder material and

may not be used in open air. Incorrect use No liquids or aggressive gases, lightly inflammable and explosive

dusts and powders or glowing particles (e.g. smoulder spots) shouldbe vacuumed. The application of the vacuum device to lacquer sprayis prohibited.

Safety information • The vacuum device may only be commissioned and maintained

after these operating instructions have been read and understood.• The vacuum device may only be used in the manner described in

these operating instructions. • The owner must ensure

1. that the people involved with the operation and maintenance ofthe equipment are thoroughly familiar with all safety information and rules and follow them accordingly.

2. that the vacuum device is only used in safe operating condition.• The vacuum device may not be used without the appropriate

protective and safety equipment. • If a removal of the safety features will be necessary, authorized

personnel only are allowed to carry out the removal. Immediatelyafter the maintenance the safety features must be checked.

• The vacuum device is not to be deployed on machine tools onwhich the occurrence of effective ignition sparks or smoulder spotsshould be anticipated.

• Attention must be paid to ensure that the vacuumed medium isstored exclusively in undamaged collecting bags.

• Attention has to be paid to ensure that the connecting cable is notdamaged by being driven over, jerking, crushing or other similar actions. The connecting cable must be inspected regularly for da-mage and aging.

• The vacuum device may not be operated if one or more parts (e.g.cable, plug) are damaged and the functioning is not faultless andthere is visible or anticipated damage.

• Electrically powered vacuum devices of the Type DAG II may only be connected by using the plugs specified for the purpose - in ac-cordance with VDE 0623 (EN 60 309 -2; 1992).

• The plug is to be inserted into the socket after the vacuum device

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DAG II Operating Manual General safety information

is in its place of deployment. • After use and prior to relocating the vacuum device to a new place

of the deployment and prior to maintenance, cleaning or the repla-cement of moving parts, the plug must be removed from the so-cket.

• Do not reach into rotating or moving parts. • Attention must be paid to the electrical conductivity (earthing) of

the transport ducts.

Safety information for maintenance and repair of the vacuum device

• Maintenance tasks may only be performed by appropriately instructed staff.

• Adjustments, troubleshooting and repairs may only be performed by trained people or appropriately instructed staff.

• Before maintenance or repair work is carried out: 1. Switch off the master switch. 2. Secure the master switch against being accidentally switched

on. 3. Remove the network plug from the socket. 4. Check that none of the parts are under (electrical) power.

• Work on parts and equipment that are under power is not allowed.• Engagement in power leading equipment is allowed only for

authorized personnel. Otherwise there may be hazard of electric shock.

• Only approved, original spare parts may be used for maintenanceand repairs.

Safety rules The owner of the vacuum device is responsible for ensuring that it

is properly installed and maintained. If the vacuum device is used outside Germany, the safety rulesapplicable in that country must be followed in addition to those setforth in these operating instructions. If such applicable rules demandthat steps be taken which go beyond the rules applying in Germanyor these instructions, then these must be complied with before thevacuum device is used.

EC Conformity

The vacuum device with CE symbol is compliant with the guidelinesset forth in the EC declaration of conformity (see appendix) whenused for the purposes and in the manner described in these operating instructions.

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Description of Product Operating Manual DAG II

Chapter 2 Description of product Introduction These operating instructions contain important information for the

safe operation of the vacuum device. They contain essential information for the necessary maintenance work, give help in the event of malfunctions, and contain information about spare parts. The operating instructions must always be available to staff at the place the vacuum device is used. The operating instructions should be consulted for the following tasks:

• Operation, including rectification of faults and system care • Maintenance (Maintenance, inspections, repairs) • Commissioning

The vacuum device may only be used after the operating instructions have been read and understood. The operating instructions are an ideal supplement to existing national rules concerning safety and environmental protection.

Symbols used These operating instructions contain essential safety information and tips which are indicated by the following symbols:

This symbol and the keyword below it indicates information concerning danger. Non-compliance with these instructions may be hazardous to health or lead to physical injury. If the symbol is followed by the keyword Danger it indicates a direct danger to the life and health of people. If the symbol is followed by the keyword Warning it indicates a possible danger to the life and health of people. If the symbol is followed by the keyword Caution it indicates a possibly dangerous situation that may lead to light or slight injury.

Warning: Remote-controlled system - may start without warning.

Danger - High Voltage! This symbol warns of potentially lethal voltage. It refers to tasks that may only be carried out by trained electricians.

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DAG II Operating Manual Description of Product

Attention! This symbol indicates warnings. The non-observance of these warnings may lead to damage or destruction of parts of the pneumatic module.

This symbol indicates information and tips.

It is, however, equally important to follow the instructions concerning transport, installation, operation and maintenance that have no special emphasis, and to comply with the technical specifications (in the operating instructions, product documentation and on the machinery itself) in order to avert malfunctions which, directly or indirectly, may lead to serious injury or material damage. Qualified staff are people who by virtue of their training, experience and knowledge of the respective standards, provisions, safety rules and operating conditions, have been given responsibility to carry out the required activities and in doing so to recognise and avert possible dangers.

General note For reasons of scope and due to the many possible variations, these operating instructions do not contain every detail and can, inparticular, not take into account every operational constellation orstate of maintenance. Should you require further information, or should particular problems occur that are not covered in full detail in these instructions, then please contact the maker for the necessary information. We expressly state that the content of these operating instructions does not constitute part of an earlier or existing agreement, promise or legal relationship, nor is it intended to change any of the above. All obligations derive from the respective purchase agreement, which also contains the complete and sole valid warranty text. The contractual provisions contained therein are neither extended nor limited by these operating instructions.

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Specification of the vacuum device

• Heavy industrial specification for heavy duty deployment. • Suitable for all climatic zones for deployment in buildings. • Ready to plug-in device incl. switchbox, mounted on casters. • Double collection unit for shredder material with manual swit-

ching. • Continuous operation with interchangeable collector switching. • Synchronised operation with charging collection units in parallel. • Lacquer finished, Color: pebble grey RAL 7032.

The basic dimensioning of the double vacuum devices DAG II are identical and differ only in the sizes of the types DAG II - 75 and DAG II - 110 by the size of the reduction joint on the suction side ofthe fan DN 120/80 mm, or DN 120/100 mm. The necessary electrical supply of the DAG II is by means of flexible cable (VDE,UL) with CEE plug (3-phase devices), or protected con-tact plug (single phase devices), with a length of 10 m. As signal cable a data line (VDE,UL) with a (9 pin) data connector is used toconnect it to the banknote processor. For the different banknote processing machines two types of signalcables are used: Control type 300/1000: with 4-terminals, Length: 30 m and Control type 3000/2000: with 4 terminals, Length: 40 m. The deployment of two "One way collecting bags" for shreddings, leads to a capacity per bag of ≈ 190 l (in synchronous operation ≈ 380 l per every DAG II). This approximates to 19,000 BN – 21,500 BNwhich is equals to a weight of approx. 17 kg - 20 kg*), depending on numbers deployed (in synchronous operation about 38,000 BN –43,000 BN per DAG). *) In case of normed BN: Format 150 mm x 75 mm, Thickness 80 µm, Paper 80 g/m² The filter bag of the DAG II is made of a polyester needle-loomed felt. The designation of the filter material is PE 7527 ASEP. With a diameter of 500 mm of the bag, the filter surface is 1.6 m2.

Scope of supply • Subframe on 4 casters. • Fan completely installed in the sound insulation cabin. • With integrated control board. • Tubular silencer. • 10 m power connection cable with plug. • 30 m (controller 300/1000), or. 40 m (controller 2000/3000)

signal cable. • 2 collecting bags for shreddings mounted on the subframe each

with a capacitive proximity switch as level indicator as well as aswitch shutter (with inductive proximity switch as end switch) andwith adjustable filter bag supports.

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Basic equipment • 2 filter bags, Length: 1200 mm or 900 mm, DN 500 mm, Material: Polyester needle-loomed felt

• 6 collecting bags for DN 500 mm The device is supplied completely assembled, however, withoutfilter and collecting bags mounted.

Area of application, construction, mode of operation

NOTE: the electrical machinery with which these operatinginstructions are issued are parts of high-voltage installations, assemblies and appliances. They are mainly designed for industrialapplications in accordance with rules referred to on specificationplates and in certificates, purchase documentation, and catalogue(eg,: ”VDE 0530, ”IEC34-1”).

Accordingly, the safety information in these operating instructionsrefers chiefly to the procedures to be followed for correct use in anindustrial environment. Any additional national, local or system-specific rules and requirements must also be taken into account. However, the vacuum device is also used in non-industrial areas, ie, in trade and office areas. If in such cases (or in special industrial applications) the safety measures taken in accordance with the documentation and specification plates is not sufficient due to special rules or provisions, then the owner of this machinery must ensure compliance with such special rules and provisions (eg, by ordering special models of the machinery, fitting additional safety equipment, appropriate installation, etc.).

Data on the specification plate

Typ G&D DAG II-__/____ Ident. No. __________ Baujahr 1998 Serial No. ______ Luftvolumenstrom ____ m³/h Max. Pressung ____ kPa V~ AC _ * ___ N Hz __ VA _____ A ____ Translation:

Type G&D DAG II-__/____ Ident. No. __________ Year made 1998 Serial No. ______ Air volume flow _____ m³/h Max. pressure _____ kPa V~ AC _ * ___ N Hz __ VA _____ A ____

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Technical specifications / device overview

Type: DAG II 55 Ident. No. Type of control (ISS/BPS) DimensionsLength Depth Hight *) Weight *) Final height with filtering bag sup-ports draged out complete Max. sound pressureacc. to DIN 45 635 Vacuum performanceVolume flow (maximal) Underpressure (maximal) Transportation fanDrive motor Type of rotor (DN in mm) Electrical connection DAG IIOperating/Mains voltage Frequency Power consumption Power intake Heat flow(cos ϕ = 0,9)

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

[dB/A]

[m³/h]

[kPa]

[mm]

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

[W]

55/1000 50 Hz

158770 011

300/1000

1890 730

2370 172

69

400

1,4

EAMR 71 G 280

230 50

550 3,4

500

55/1000 60 Hz

158771 011

300/1000

1890 730

2370 172

69

400

1,4

EBS 71 K2 280

115 60

550 ²)

500

²) Data will be detected at first after device is manufactured

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

[dB/A]

[m³/h]

[kPa]

[mm]

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

[W]

75/1000 50 Hz

156737 011

300/1000

1890 730

2370 175

70

660

1,8

K21R 80 K2340

400 50

750 1,2

700

75/1000 60 Hz

156739 011

300/1000

1890 730

2370 175

²)

660

1,8

K21R 80 K2280

208 60

750 ²)

700

75/2000 50 Hz

156738 011 3000/2000

1890 730

2370 175

70

660

1,8

K21R 80 K2 340

400 50

750 1,2

700

75/2000 60 Hz

156741 0113000/2000

1890 730

2370 175

²)

660

1,8

K21R 80 K2280

208 60

750 ²)

700


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

[dB/A]

[m³/h]

[kPa]

[mm]

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

[W]

110/1000 50 Hz

156742 011

300/1000

1890 730

2370 176

70

800

1,6

K21R 80 G2340

400 50

1100 1,6

1000

110/1000 60 Hz

156744 011

300/1000

1890 730

2370 176

²)

800

1,6

K21R 80 G2280

208 60

1100 ²)

1000

110/2000 50 Hz

156743 011 3000/2000

1890 730

2370 176

70

800

1,6

K21R 80 G2 340

400 50

1100 1,6

1000

110/2000 60 Hz

156745 0113000/2000

1890 730

2370 176

²)

800

1,6

K21R 80 G2280

208 60

1100 ²)

1000


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Type: DAG II 150 Ident. No. Type of control (ISS/BPS)

150/1000 50 Hz

156746 011

300/1000

150/1000 60 Hz

156748 011

300/1000

150/2000 50 Hz

156747 011 3000/2000

150/2000 60 Hz

156749 0113000/2000

DimensionsLength Depth Hight *) Weight *) Final height with filtering bag sup-ports draged out complete

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

1890 730

2370 185

1890 730

2370 185

1890 730

2370 185

1890 730

2370 185

Max. sound pressureacc. to DIN 45 635

[dB/A]

71

²)

71

²)

Vacuum performanceVolume flow (maximal) Underpressure (maximal)

[m³/h]

[kPa]

1200

1,85

1200

1,85

1200

1,85

1200

1,85

Transportation fanDrive motor Type of rotor (DN in mm)

[mm]

K21R 80 S2

365

K21R 80 S2

340

K21R 80 S2

365

K21R 80 S2

340

Electrical connection DAG IIOperating/Mains voltage Frequency Power consumption Power intake

[V]

[Hz] [VA] [A]

400 50

1500 2,4

208 60

1500 ²)

400 50

1500 2,4

208 60

1500 ²)

Heat flow(cos ϕ = 0,9)

[W]

1400

1400

1400

1400


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Installation Operating Manual DAG II

Chapter 3 Installation

General quality of the installation room

The installation room must be dry and have a level floor. If locatedoutside a solid building should possess a solid construction on allsides to protect the vacuum device against weather influences. In any event there should be exhaust openings in the room structure to let out the transport-air volume for shredder material suctioned off the currency processor.

Attention! If the installation room is cooler than the banknote processing room by more than 15°C, the suction line must be fitted with a back pressure valve in order to prevent a convective streaming back of the cold air into the banknote processing room during the standstill of the vacuum device.(Used only on basis of special discussion.)

Note If the piping of the vacuum device crosses areas with temperatures more than 15°C colder than the banknote processing room, the pi-ping must be heat insulated (building contractors work).

Caution At the door entry to the installation room of the vacuum device (possibly the whole room of currency processing if the vacuum device is installed there too) a warning sign “Fire, Open Light and Smoking prohibited“ should be fitted.

Danger! Installation of the vacuum device in surroundings with hazard of explosion is prohibited.

Caution The vacuum device should be inspected daily to detect damages. Damages of the filter bag and the collecting bag should be searched for in particular. This inspection has especially to be organized by the user if the vacuum device will be operated in a detached installation room without surveillance.

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DAG II Operating Manual Installation

Warning! If inspection of the vacuum device can not safely be organized by the user and without sufficient ventilation of the installation room, it may become possible in case of trouble and under most disadvantageous circumstances (e. g. a damage of a collecting bag followed by a free blowing of shreddings into the installation room) to reach a lower ignition limit of the shreddings-air-mixture. In this case hazard of explosion is possible. If inspection of the vacuum device can not safely be organized by the user it is strictly recommended to install a surveillance device for hazards (e. g. dust, smoke, fire, etc.) by the user. If non of the above named action will be carried out the operation of the vacuum device inside the meant room is prohibited.

Weather influences The vacuum devices may not be exposed to the influence of high airhumidity (relative humidity not above ϕ ≤ 80 %), splash water, rain, snow, etc.

Dimensions of the installation room

The installation room should be sized such that the vacuum devicecan be accessed from at least two sides (free space approx. 0.8 m),without impairing the pipework layout. Changing the collecting bagsshould be possible in a simple manner and without hindrance. Recommended minimum size is 8 m². Given this also full collectingbags can be stored for the interim period until removal. The room should have a height of 2.5 m.

Exhaust air and waste heat

The air exit of the installation room must be able to accommodate thetransport air volume suctioned off, depending on the type of the va-cuum device. A part of the waste heat can de discharged using the exhaust air withcertain types of banknote processing machines. This quantity of heatis then transmitted to other parts of the buildings and the plant.

Attention! The room temperature in the installation room may not exceed ap-prox. 45 °C. The fire protection regulations applicable at the place of installation must be observed (building contractors' performance).

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Installation Operating Manual DAG II

Interface to the banknote processor

Switching On and Off: The banknote processing machine controls the function of the va-cuum device via the signal cabling. A software signal (generated onlyin a certain shredder mode) is transferred free tension to the vacuumdevice. If the main switch of the vacuum device is switched on, thiswill start it automatically.

Warning: Remote-controlled system - may start without warning. If the software signal discontinues, the vacuum device stops automa-tically.

Note If several banknote processing machines are connected to an DAG II, then the signal connections are connected in parallel on the DAG II: Each interface switches the DAG II separately. Filling level control: A capacitive filling level control in every collecting bag reports to the banknote processing machine without tension via the signal cable that the admissible filling level of the bag is reached and that it must be changed. On switching, only the filling level control of the bag in use is evaluated. (In synchronised operation both filling level control-lers are evaluated.)

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DAG II Operating Manual Installation

Transport piping for shreddings

For the transport of the shreddings a suitable pipe system (withsmooth internal surface, pressure resistant against a vacuum of ap-prox. on ca. 2 kPA) must be installed. The alternate use of completely flexible piping is permitted. Connections to the banknote processing machine must be rendered flexibly. The use of a tube or cable channel for the signalling cable isrecommended. The flexible connections should incorporate a steel wire. This wire shall be stripped and bent at the respective ends in such a manner that it can form a conducting connection (earthing) between the banknote processing machine, pipe system and vacuum device.

Attention! The distance to the of the banknote processing machine may not exceed the equivalent to 25 m pipe length. (In case of applying internally smooth piping in a straight line the equivalent length is the actual length. Bends, fittings and flexible tubes have their respective equivalent lengths which in terms of pressure loss exceeds their geometrical lengths. Inclusion of such components in the piping shortens the ap-propriate equivalent distance to the banknote processing machine.

Vacuum device Cross section of pipe connection DAG II - 55 dia 80 mm DAG II - 75 dia 100 mm

DAG II - 110 dia 120 mm DAG II - 150 dia 150 mm

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Putting into operation Operating Manual DAG II

Chapter 4 Putting into operation

Note Examine the vacuum device prior to commissioning for damage in transit.

Caution Read operating instructions Prior to commissioning the vacuum device must be connected to the pipework and the signal cable in line with the conditions of installation and operation. Following this, the electrical supply (socket provided by constructor) is to be connected. The appropriate instructions of the local utility supplier must be observed.

Danger - High Voltage! (Only for three-phase devices) After the initial switching on of the device at the installation site the rotational direction of the fan must be inspected. (Filter and collecting bags must be inflated.) The vacuum device is supplied from works with rotation set in the right direction. If applicable, the direction of rotation should be changed by an ex-pert in the supply net. Two phases - L1, L2 or L3 - are to be chan-ged in the power supply).

Attention! Operation of the vacuum device is only permitted with installed filter and collecting bags. If this is not observed, all warranty for damage to the device is excluded. 1. Pull filter bags over the upper rim of the samplers (pay attention to

correct positioning!) and affix to the sampler by means of the spring clasp.

2. Raise filter bag supports to the appropriate height and fix by me-

ans of winged screw. 3. Pull collecting bags over the lower rim of the samplers below the

rear clasps and fix by means of spring clasps (attention should be paid to airtight seating!).

4. Connect signal cable with banknote processing machine to be pla-

ced under suction. 5. Connect flexible transport piping to banknote processing machine

(attention should be paid to airtight positioning).

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DAG II Operating Manual Putting into operation

6. In order to prevent static charges the steel spirals in the flexible transport piping should be connected conductively between pipe-work, banknote processing machine and vacuum device (compare Chapter 3: Transport piping for shreddings).

7. Selection of the collecting unit (1, 2 or 1+2) by appropriate setting

of the lever on the switchover. 8. Insert plug to the ( protected) socket provided. 9. Switch on main switch.

Device is ready to function!

Warning: Remote-controlled system - may start without warning. The on-going operation runs fully automatically in conjunction with banknote processing.

Note In case of no demand for operation of the vacuum device by the cur-rency processor for a long period the vacuum device should be swit-ched off line by the main switch.

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Change of collecting bags and maintenance Operating Manual DAG II

Chapter 5 Change of collecting bags and maintenance

Safety information Maintenance work may only be performed by appropriately instructed or trained people.

CAUTION The vacuum device must be stopped whenever covers or safety features are removed for maintenance work, as described in these operating instructions. The covers and safety features must be refitted straight after the work has been completed.

Danger - Risk of Injury! Follow the procedure described below for all maintenance work. Never disregard a single safety measure! You otherwise risk injury through restart, electrical shock or flying parts. Before all maintenance work: 1. Switch off the master switch and secure it against accidentally

being switched on. 2. Pull plug out of the socket. 3. Check that none of the system parts are under (electrical) power. 4. Remove the necessary covers for the maintenance task. After completing maintenance work: 1. Replace all covers previously removed. 2. Check that no-one is still working on the pneumatic module before

switching it back on.

Change of the collecting bag

1. During operation of the DAG II the change-over flap should be turned to the (empty) bag which is not to be changed. In the syn-chronous operation mode the vacuum device should be switchedoff.

Warning! Breathing of dusts may be hazardous to health or lead to physical injury. In case of appearance of larger amounts of dust while chan-ging the collecting bags (depending on the soiling of the currency) a protective mask for breathing should be used. 2. The filter bag should be tapped in its entirety to release the majori-

ty of the adhering shreddings and dust. Wait while the dust settles. 3. The spring clasp of the collecting bag should be released and the

collecting bag removed.

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DAG II Operating Manual Change of collecting bags and maintenance

4. Close and stove away collecting bag. 5. Pull new collecting bag over the lower rim of the sampler. The ed-

ge of the bag should extend over the spring clasp by 2-5 cm. Close spring clasp carefully and check that the collecting bag is correctly positioned.

6. Switch on again vacuum devices with synchronous (parallel run-

ning collecting bags) operation

Maintenance intervals The maintenance intervals given in the table refer to averageoperating conditions. Shorter intervals may be necessary underextreme conditions. The installation room should be regularly (once every week) cleaned of dust and shredder material. Accumulation of dust and shreddings on the vacuum device should be removed once every three month at the latest. In this interval the vacuum device should also be inspected for signs of visible damage.

Maintenance intervals according to use

Daily Weakly Monthly yearly Control of the collecting bags

for airtightness and damage X

Check power and signal cab-ling for mechanical damage

X

Check quiet running of the fan X Clean filter bags thoroughly X Clean entire equipment X Check rubber gasket of the

switch-over flap from the inside after removing filter bag

X

Change filter bag and dispose it in line with local regulations

X

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Change of collecting bags and maintenance Operating Manual DAG II

Cleaning of the filter bag

The filter bag should be cleaned at regular intervals. Given averageuse of the vacuum device on five working days per week, cleaningonce per week is recommended. At the latest the bag must be clea-ned when the filter bag becomes hard on being inflated (insufficientairflow).

Attention! The filter bag comprises of a special porous filter cloth which may not be washed. If washed it looses its filter properties. Therefore dry cleaning by tapping and a subsequent vacuum cleaning of the inside surface is recommended. Never use compresed air for cleaning. Breathing of dusts may be hazardous to health or lead to physical injury. Procedure 1. Tap the mounted filter bag on its entire length to ensure that dust

and shreddings detach and drop into collecting bags. 2. Undo spring clasp of the filter bag. 3. At the sampler undo the fixing screw of the filter bag support and

lower filter bag support. 4. Remove filter bag from filter bag support and vacuum clean the in-

ternal surface of the filter bag. 5. Pull filter bag again over the upper rim of the sampler. Subse-

quently close spring clasp carefully and check that filter bag is po-sitioned correctly.

6. Finally raise filter bag support again until the filter bag is stretched

out without tension and tighten the fixing screws.

Renewing of the filtering bag

After one year of regular use the filter bag should be renewed. If thebag is inflated hard after cleaning during operation (insufficient air-flow) it should be replaced earlier.

Attention! A filter bag which has become airtight may lead to a blockage of the pipework as the shredder material is no longer transported. The moni-toring of the vacuum device of the banknote processing machine sig-nals.

11/98 5 - 3

DAG II Operating Manual Change of collecting bags and maintenance

Adjustment of the filling level control

The overfilling of the bags should be prevented by the two capacitiveproximity switches of the type KD 5022. The sensitivity of the capaci-tive proximity switches can be adjusted by means of the worm screwswhich are situated on the top side and depends on the shredded ma-terial which is to be transported by vacuum. Once set, the sensitivityremains the same and should only be adjusted in case of need, or ifthe shredded material is changed. Procedure: 1. Adjust height of the capacitative proximity switch KD 5022 in the

collecting bags in such a manner that the full bags may be closed for replacing without excessive dust.

2. The centre of the capacitative proximity switch KD 5022 determi-

nes the filling level of the collecting bags and may be set by un-doing or relocating the supporting screws.

3. For setting the sensitivity of the shredded material, the collecting

bags should be removed. 4. The action of the capacitative proximity switch is tested by holding

a handful of loose shreddings in front of the switch. 5. A distance of 10 cm should activate the contract which may also

be checked by means of an LED located on the side of the worm-screw.

6. If this not the case, the activation distance of the switch can be inc-

reased by turning the screw right and reduced by turning it left. 7. A final control of the switching sensitivity is carried out under ope-

rating conditions, during which the collecting bags is remounted.

5 - 4 11/98

Malfunctions Operating Manual DAG II

Chapter 6 Malfunctions

General The tables on the following pages give information about the possible causes of system messages and the action to be taken.

Caution A Troubleshooting work may only be performed by appropriately instructed or trained people.

Vacuum device malfunctions

Cause Action

Vacuum device does not start

Plant is deactivated because of a malfunction via the cutoff switch. No release via banknote proces-sor. No tension Power line damaged Cutoff switch Q 11 is activated Main switch is out of order

Eliminate malfunction Search for malfunction in the banknote processor Examine and reset cutoff switch Search for malfunction at the banknote processor and the sig-nal line. Check main fuse. Replace supply cable. (see cutoff switch activated) Replace main switch.

No or low transportation fan output

Wrong rotational direction Clogging of the pipes Clogging of the vacuum device collecting bag overfilled Filter bag dirty

Repole supply Locate and remove blockage Change collecting bag and in-spect proximity switch thoroughly. Clean or change filter bag.

Cutout Q1 actuated Cutoff switch is set wrongly Motor is overloaded by: Wrong voltage Single phase running with three-phase motor

Set cutoff switch Ensure correct voltage Check fuses in front of cutoff. do not use automatic cutoff

Cutout F10 actuated Defective part in supply net Fault in control circuitry

Switch off plan, replace part Find and eliminate fault

11/98 6 - 1

DAG II Operating Manual Malfunctions

Material leakage on chan-ging collecting bag

Change-over flap not in terminal position Rubber gasket of the switch-over is not airtight

Set change-over flap in terminal position, remove any remnant residual shreddings Change rubber gasket.

Material leakage at collec-ting bag

Collecting bag not correctly positi-oned Collecting bag damaged

Inspect bag fastenings and tigh-ten belts Replace collecting bag

Material leakage at filter bag

Filter bag not correctly positioned Filter bag damaged

Inspect bag fastenings and tigh-ten belts Replace filter bag

Strong vibrations and noi-ses from the sound pro-tected booth

Wheel out of balance or damaged Motor bearings damaged

Replace wheel Replace motor

"Full" sign on the switch-board stays on

Sensitivity of the capacitative pro-ximity switch for measuring filling level is excessive Terminal switch on the switchover flap in false position or defect

Reset sensitivity Adjust terminal position switch by means of the rings or replace.

6 - 2 11/98

Assembly of spare parts and wear parts Operating Manual DAG II

Chapter 7 Assembly of spare parts and wear parts

General Preface to safety

The following pages provide a secure overview in respect of the secure assembly of spear and wear parts. The vacuum device DAG II should be inspected regularly. In this context the entire fan casing and the impeller. The vacuum device DAG II may only be maintained by suitably trai-ned staff. The functioning of the vacuum device DAG II is only warranted with original spare and wearing parts. Attention should be paid to the careful connecting of the supplycable to the power supply, i.e. it should not be crushed or bent atacute angles. The power supply line must be inspected at regular intervals for damage and signs of aging and if it is not in a perfectcondition it should be replaced immediately. As replacement cablethe cable type VDE 0 165 must be used. Replacement of the electrical connections as well as all otherelectrical components may only be carried out by qualified experts. Prior to cleaning, maintaining, replacing or removing of moving partsthe safety switch of the motor should be switched off and safeguar-ded against being switched on by cutting off the vacuum device from the supply net. Coverings and opening the device DAG II or dismantling pipe con-nections is only permitted in a cut-off state. During works in pro-gress the device is to be safeguarded against being switched on. In cases of unequal wear or baking on of material an imbalance mayoccur which may destroy the motor bearings. If imbalance is foundor there are substantial symptoms of wear in the part of the impellerwhich is in contact with material a replacement is necessary. In dismantling and mounting of the impeller the shaft must not beexposed to impacts. In all cases a dismantling and mounting deviceshould be used. Prior to connecting up the motor it should beestablished manually whether the impeller does not touch the ca-sing of intake side. After completing all maintenance and repair work attention must bepaid to the fact that the vacuum device DAG II may only be opera-ted with the pipework attached. Furthermore the correctness of therotational direction of the impeller must be inspected.

11/98 7 - 1

DAG II Operating Manual Assembly of spare parts and wear parts

Device design

7 - 2 11/98

Assembly of spare parts and wear parts Operating Manual DAG II

Switchbox 1. Open the lever at the sound insulation cover to remove the side. 2. Disconnect motor power and earthing cable. 3. Disconnect and pull out the supply points provided in the box

(supply net, control cable, filling level monitor and terminal positi-on switch as well as earthing).

4. Undo four fixing screws on the switchbox and lift off switchbox. 5. Position new switchbox and affix it in the reverse order and re-

connect.

Power pack 1. Disconnect and pull out the cable of the net supply G 10. 2. Undo and remove defective power pack from the rack. 3. Insert new pack and fasten. 4. Reconnect pack with the cable in accordance with the wiring dia-

gram (cf. appendix A-5 to A-7) and fasten terminals.

Fuses and relays Dismantling of the fuses and relays is executed in the same stepsas for the power pack.

Filling level control 1. Remove pipe piece preceding the distribution box between thetwo samplers by undoing connecting straps.

2. Open distribution box and disconnect defective filling level con-trol.

3. Open spring clasp of the collecting bag and remove the bag in acareful manner and seal it without dust.

4. Undo fixing screws on the filling level control and after removingthe connecting cable from the terminal lugs remove the defective component.

5. Mount new filling level control in the same position and reconnect to the terminal lugs and thread in the leads into the switchbox

6. Shorten connecting cable to the appropriate length and cover bysleeves prior to reconnection accordance with the wiring dia-gram.

7. Close distribution box and remount pipe piece in front (pay atten-tion to airtight fitting)

8. Set filling level control (cf. page 5-4)

Terminal switch 1. Remove pipe piece preceding the distribution box between thetwo samplers by undoing connecting straps.

2. Open distribution box and disconnect defective terminal switch. 3. Undo the 2 fixing screws of the terminal switch and remove

switch. 4. Mount a reconnect new terminal switch in the same position and

thread connecting cable into the switchbox. 5. Shorten connecting cable as appropriate and cover by sleeves

prior to reconnecting in accordance with the wiring diagram. 6. Close distribution box and remount pipe piece in front (pay atten-

tion to airtight fitting)

11/98 7 - 3

DAG II Operating Manual Assembly of spare parts and wear parts

Fan To change the motor or the impeller the fan must be completelydismantled first. Suction-side connection of the vacuum device DAG II is to be sepa-rated, the motor must be disconnected in the terminal box and thecomplete unit must be lifted at the subframe.

Motor 1. Pipe connection straps are to be undone below the silencer and

the silencer must be turned to side. 2. Undo the four clasps of the sound insulation and lift off half of the

sound insulation cover from the subframe. 3. Undo the four screws in the lid of the stationary part of the sound

insulation cover and remove it. 4. Open terminal box and pull out the cables from the loosened

lugs. 5. Undo four screws on the motor support. 6. Lift fan from subframe and put it on its side. 7. Undo domed cap nuts on the fan motor base and pull fan casing

from the motor mounting. 8. Undo screw M 8 from the shaft and pull the impeller off the motor

shaft. 9. Remove the motor plate by undoing the four screws at the motor

flange. 10.The assembly of the new motor and the new fan takes place in

reverse order. However, attention should be paid to the identicalpositioning of the motor plate at the motor flange.

Impeller In changing the impeller the same steps 1-8 must be carried out as

for the change of the motor. After removing the defective impeller and mounting the new impeller the assembly takes place in inverse order.

Steering roller / pedestal roller

Replacing the steering and pedestal rollers is done by loosening therespective fastening screws on the subframe For this the entire vacuum device DAG II should be slightly lifted with a lifting platform.

Rubber gasket 1. Replacing the silicon rubber gaskets on the switch-over flap is done from within by the primary collector no. 1.

2. The PE collecting bag and the filter bags must be unstrapped sothat the switch-over flap can be accessed.

3. Undo the countersunk hexagonal screws of the flap. 4. Remove covering of the flap and replace worn silicon rubber

gaskets. 5. New silicon rubber gaskets to be cut (using old rubber gaskets

with 1-2 mm oversize as templates) and inserted on the internalcentering plate.

6. Affix new silicon rubber gaskets by means of the cover and tigh-ten the six countersunk hexagonal screws.

7 - 4 11/98

Appendix Betriebsanleitung / Operating Manual DAG II

Anhänge / AppendixA

11/98 A - 1

DAG II Betriebsanleitung / Operating Manual Appendix

Maßskizzen / Dimension sketches

A - 2 11/98


11/98 A - 3


Schaltpläne / Wirering diagramms

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11/98 A - 7


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EG-Konformitätserklärung

11/98 A - 9


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Ersatz- und Verschleißteiliste / Spare parts and Wear parts listing

Gültig für / Valid for:

Alle / all DAG II 115V/208V/230V/400V 50Hz/60Hz mit Änderungsindex / with modification status ∗∗∗∗∗∗ 011, ab / from 11/98

Ersatzteile / Spare parts

Stk no.

Artikelnr. Part No.

Benennung

Name

1 205565 000 Gummilippe für Umschaltklappe Silikon DN120DAG II - 55 / 75 / 110

Rubber gasket for switch-over flap, Silikon DN120, DAG II - 55 / 75 / 110

1 209088 000 Gummilippe für Umschaltklappe Silikon DN150DAG II - 150

Rubber gasket for switch-over flap, Silikon DN150, DAG II - 150

2 205564 000 Lenkrolle LE-VE 160R Caster wheel LE-VE 160R 2 205563 000 Bockrolle B-VE 160R Pedestal wheel B-VE 160R 1 110596 000 Erdtrennklemme Earthing insulating terminator 1 110316 000 Motorentstörung Interference suppressor for electric motor 1 124969 000 Schaltschütz 24VDC 50/60Hz Contactor 24VDC 50/60Hz 1 124268 000 Hauptschalter 25A Main switch 25A 1 127644 000 Sicherungsautomat 0,5A Automatic cut-out 0,5A 1 194393 000 Lampenkappe Gelb Lamp cap yellow 1 125245 000 Glühlampe 24V 1,2W Bulb 24V 1,2W 1 110439 000 Glassicherung M 500mA Glas fuse M 500mA 2 141513 000 Füllstandswächter (kapazitiv) IFM KD-5022 Filling level gauge (capacitive) IFM KD-5022 1 194394 000 Näherungsschalter (induktiv) IFM IN-5251 Approximation switch (inductive) IFM IN-5251 4 207972 000 Relaisklemme DEK-REL-G24/21 24 VDC Relay terminal DEK-REL-G24/21 24 VDC 1 205557 000 Ventilatorlaufrad DAG II -

55 / 75 (60Hz) / 110 (60Hz) DN 280 Impeller DAG II - 55 / 75 (60Hz) / 110 (60Hz) dia 280

1 205558 000 Ventilatorlaufrad DAG II - 75 (50Hz) / 110 (50Hz) / 150 (60Hz) DN 340

Impeller DAG II - 75 (50Hz) / 110 (50Hz) / 150 (60Hz) dia 340

1 205559 000 Ventilatorlaufrad DAG II - 150 (50Hz) DN 365 Impeller DAG II - 150 (50Hz) dia 365 1 205549 000 Motor für DAG II-55 230V 50Hz Electric motor for DAG II-55 230V 50Hz 1 205548 000 Motor für DAG II-55 115V 60Hz Electric motor for DAG II-55 115V 60Hz 1 205550 000 Motor für DAG II-75 400V 50Hz Electric motor for DAG II-75 400V 50Hz 1 205551 000 Motor für DAG II-75 208V 60Hz Electric motor for DAG II-75 208V 60Hz 1 205553 000 Motor für DAG II-110 400V 50Hz Electric motor for DAG II-110 400V 50Hz 1 205554 000 Motor für DAG II-110 208V 60Hz Electric motor for DAG II-110 208V 60Hz 1 205555 000 Motor für DAG II-150 400V 50Hz Electric motor for DAG II-150 400V 50Hz 1 205556 000 Motor für DAG II-150 208V 60Hz Electric motor for DAG II-150 208V 60Hz 1 205547 000 Netzteil 230V 50-60Hz / 24 VDC 1A Power pack 230V 50-60Hz / 24 VDC 1A 1 205546 000 Netzteil 208V 60Hz / 24 VDC 1A Power pack 208V 60Hz / 24 VDC 1A 1 205545 000 Netzteil DAG II-55 115V 60Hz / 24 VDC 1A Power pack DAG II-55 115V 60Hz / 24 VDC 1A 1 207600 000 Motorschutzschalter 2,5A DAG II-75 (50Hz) Prot. mot. circ. break. 2,5A DAGII-75(50Hz) 1 191957 000 Motorschutzschalter 2,5-4A DAG II -

75 (60Hz) / 110 (50Hz) / 150 (50Hz) Protec. mot. circuit breaker 2,5-4A DAG II - 75 (60Hz) / 110 (50Hz) / 150 (50Hz)

1 200607 000 Motorschutzschalter 4-6,3A DAG II- 55 (50Hz) / 110 (60Hz) /150 (60Hz)

Protec. mot. circuit breaker 4-6,3A DAG II - 55 (50Hz) / 110 (60Hz) /150 (60Hz)

1 202252 000 Motorschutzschalter 6,3-10A DAG II-55 (60Hz) Prot. mot. circ breaker 6,3-10A DAG II -55 (60Hz)2 205769 000 Zeitrelais MT-6 AV (Steuerung 2000/3000) Timing relay MT-6 AV (2000/3000 control)

Verschleißteile / Wear parts

Stk no.

Artikelnr. Part No.

Benennung

Name

2 194074 000 Filtersack Filtering bag 2 121557 001 Auffangsack für Shreddings (Transparent) Collecting bag for shreddings (transparent)

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DAGII - Operating Manual

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