allfi 952000 User manual

Operating manual
Abrasive Hopper
952000, 952800, 952900, OM-952500, BO-952900; IWE-952900,
Operating manual
ALLFI AG - Riedenmatt 1 –CH-6370 Stans
Phone: [phone] - Fax: [phone]
E-Mail: [email protected] - http://www.allfi.com
July 2022
952800
952000
OM-952500
952900

General
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ALLFI Abrasive Hopper 22.12.2022
Scope of application
The present operating manual is valid for ALLFI Abrasive Hopper:
➢952000 Abrasive Hopper 1300 kg
➢952800 Abrasive Hopper 100 kg
➢952900 Abrasive Hopper 1300 kg
➢OM-952500 Abrasive Hopper 1000 kg, 230V
➢BO-952900 Abrasive Hopper 1300 kg RAL 7016
➢IWE-952900 Abrasive Hopper 1300 kg RAL 9002
The descriptions are not necessarily shown with all available options. Function and execution with
mounted options is done in the same way & manner.
The following options are available:
➢952156 230V-Option
➢040056 Y-distributor for supplying two abrasive dosing units
➢Colors RAL 5003, other colors on request

General
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ALLFI Abrasive Hopper 22.12.2022
Table of Contents
1General............................................................................................................................................ 6
Information on use of the operation manual............................................................................ 6
Scope of delivery..................................................................................................................... 6
Warranty claim......................................................................................................................... 6
Target group............................................................................................................................ 6
Warranty claim......................................................................................................................... 7
Life cycles of the machine ....................................................................................................... 7
2Safety............................................................................................................................................... 7
Declaration of symbols ............................................................................................................ 7
Intended use............................................................................................................................ 8
Inadmissible use...................................................................................................................... 8
Information signs on the machine............................................................................................ 9
Foreseeable misapplication..................................................................................................... 9
Residual risks ........................................................................................................................ 10
Safety installations................................................................................................................. 10
Personal protection equipment.............................................................................................. 10
Qualification of the staff......................................................................................................... 11
Special safety instructions..................................................................................................... 11
2.10.1 Transport, assembly, commissioning............................................................................ 11
2.10.2 Operation....................................................................................................................... 11
2.10.3 Cleaning, maintenance, servicing.................................................................................. 11
2.10.4 Decommissioning, disassembly, disposal..................................................................... 11
Duties of the ownwe .............................................................................................................. 11
Duties of the staff................................................................................................................... 11
3Product description........................................................................................................................ 12
General function of the machine............................................................................................ 12
Structure................................................................................................................................ 12
3.2.1 Abrasive Hopper 1300 kg, 952000................................................................................ 12
3.2.2 Abrasive Hopper 100 kg, 952800.................................................................................. 13
3.2.3 Abrasive Hopper 1300 kg, 952900................................................................................ 13
3.2.4 Abrasive Hopper 1000 kg, OM-952500......................................................................... 14
3.2.5 Pressure vessel ............................................................................................................. 14
3.2.6 Control/pneumatics........................................................................................................ 15
Technical data ....................................................................................................................... 15
3.3.1 Type plate...................................................................................................................... 15
3.3.2 Dimensions and weights Abrasive Hopper 952000, 1300 kg........................................ 16
3.3.3 Dimensions and weights Abrasive Hopper 292800, 100 kg.......................................... 16
3.3.4 Dimensions and weights Abrasive Hopper 952900, 1300 kg........................................ 17

General
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ALLFI Abrasive Hopper 22.12.2022
3.3.5 Dimensions and weights Abrasive Hopper OM-952500, 1000 kg................................. 18
3.3.6 Mechanics...................................................................................................................... 18
3.3.7 Data and connected loads pneumatics ......................................................................... 19
3.3.8 Electrical connection values .......................................................................................... 19
Limits for operation and storage............................................................................................ 19
Accessories / options / wear parts......................................................................................... 19
4Transport, packaging and storage................................................................................................. 20
Lifting and transporting.......................................................................................................... 20
4.1.1 Abrasive Hopper 952000, 952900, OM-952500........................................................... 21
4.1.2 Abrasive Hopper 952000............................................................................................... 21
4.1.3 Abrasive Hopper 100 kg, 952800.................................................................................. 22
Packing.................................................................................................................................. 22
Disposal................................................................................................................................. 22
Storage.................................................................................................................................. 22
5Installation and Mounting............................................................................................................... 22
Requirements for the staff to be performed........................................................................... 22
Requirements for the installation site .................................................................................... 23
Mounting the machine........................................................................................................... 23
5.3.1 Fixing to the floor.......................................................................................................... 23
5.3.2 Potential equalization..................................................................................................... 23
5.3.3 Connect compressed air................................................................................................ 23
5.3.4 Electrical supply............................................................................................................. 24
5.3.5 External emergency stop............................................................................................... 24
5.3.6 Connect the sand hose.................................................................................................. 24
6Commissioning.............................................................................................................................. 24
Requirements for the staff to be performed........................................................................... 24
Adjusting the pressure regulators.......................................................................................... 24
Fill abrasive hopper with sand............................................................................................... 25
6.3.1 Abrasiv Hopper, 95200, 952900, OM-952500............................................................... 25
6.3.2 Abrasiv-Hopper 100 kg, 952800.................................................................................... 25
Switch on the machine .......................................................................................................... 25
Switch off the machine .......................................................................................................... 25
7Operation....................................................................................................................................... 25
Requirements for the staff to be performed........................................................................... 25
Notes for safe operation ........................................................................................................ 25
Warning and error messages (LED strip).............................................................................. 26
7.3.1 Service display............................................................................................................... 26
7.3.2 Sand level monitoring in hopper.................................................................................... 26
7.3.3 Sand level monitoring in pressure vessel...................................................................... 27

General
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ALLFI Abrasive Hopper 22.12.2022
7.3.4 Differential pressure too little......................................................................................... 27
Operating and display elements............................................................................................ 27
Refilling the hopper with sand ............................................................................................... 28
7.5.1 Abrasive hopper, 952000, 952900, OM-952500........................................................... 28
7.5.2 Abrasive hopper 100 kg, 952800................................................................................... 29
8Maintenance and servicing............................................................................................................ 29
Requirements for the staff to be performed........................................................................... 30
Regular maintenance ............................................................................................................ 30
Condensed water................................................................................................................... 30
Replace filter in pressure vessel............................................................................................ 30
Replace pinch valve .............................................................................................................. 31
8.5.1 Abrasive Hopper 952800, 952900, OM-952500............................................................ 31
8.5.2 Abrasive Hopper 952000............................................................................................... 31
Replace level sensor of pressure vessel............................................................................... 31
Replace level sensor off hopper............................................................................................ 32
Replace ball valve.................................................................................................................. 32
8.8.1 Abrasive hopper 952800, 952900, OM-952500............................................................ 32
8.8.2 Abrasive Hopper 952000............................................................................................... 33
Reset of the machine............................................................................................................. 33
9Troubleshooting............................................................................................................................. 34
Requirements for the staff to be performed........................................................................... 34
Malfunctions and troubleshooting.......................................................................................... 34
10 Decommissioning/Deinstallation/Disposal................................................................................. 35
Requirements for the staff to be performed........................................................................... 35
Decommissioning .................................................................................................................. 35
Deinstallation......................................................................................................................... 35
Disposal................................................................................................................................. 35

General
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ALLFI Abrasive Hopper 22.12.2022
1 General
Information on use of the operation manual
The present operation manual is part of the product. It must be read and understood by all the persons
working with the Abrasive Hopper before operating. The manual must be stored within spitting dis-
tance as well as always accessible to the persons, working with the Abrasive Hopper.
Should you have any questions regarding the content of the manual, please contact the manufacturer
directly.
ALLFI AG - Riedenmatt 1 –CH-6370 Stans
Phone: [phone] - Fax: [phone]
E-Mail: [email protected] - http://www.allfi.com
Scope of delivery
The individual parts contained in the shipment can be gathered from the set list in the appendix A
(technical drawing and part list). Upon receipt, the shipment has to be checked for integrity. Possible
detected defectives must be reported immediately to the manufacturer.
Warranty claim
The ALLFI AG grants warranty for the shipped parts as followed:
➢Material- and manufacturer faults of 12 months from date of delivery or
➢Defects within the first 2’000 hours of operation
Following spare parts are excluded from the warranty:
oSieve
oPinch valve
oBall valve
oFilter
oSilencer
oSensors for level monitoring
Target group
These operating instructions are intended for the following personnel:
➢Installation staff
➢Machine operators
➢Maintenance staff

Safety
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ALLFI Abrasive Hopper 22.12.2022
Warranty claim
ALLFI AG rejects any claims for liability on the part of the manufacturer for damage to property and
personal injury, as well as operational malfunctions resulting from non-compliance with these operat-
ing manual.
This includes, for example, damage as a result of:
➢Inadmissible use of the abrasive hopper.
➢Inadequate maintenance
➢Disregard of operating instructions
➢Chemical or electrolytic influences
➢Use of non-original parts, original spare parts or original accessories
➢Unauthorized modification
➢Untrained or insufficiently trained personnel
Ignoring these instructions is at the sole risk and liability of the operator. ALLFI AG is also not liable for
any loss of production.
Life cycles of the machine
The machine goes through the following life cycles:
➢Transport
➢Assembly
➢Operation
➢Maintenance
➢Disassembly
➢Disposal
2 Safety
The waterjet cutting technique involves dangers. Poorly instructed users can cause damage to prop-
erty and personal injury due to incorrect behavior. Read and follow the instructions in this operating
manual to operate this machine safely. Do not carry out any independent conversion measures or re-
pairs on the unit.
Declaration of symbols
This operating manual contains important notes and symbols, which are to be considered and fol-
lowed. These are:

Safety
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ALLFI Abrasive Hopper 22.12.2022
DANGER
Points to a danger situation. If not avoided, death or heavy injuries are the
consequence.
WARNING
Points to a danger situation. If not avoided, death or heavy injuries could
be the consequence.
CAUTION
Points to a danger situation. If not avoided, light or medium body injuries
could be the consequence.
NOTE
Points to a danger situation. If not avoided, light or medium body injuries
could be the consequence.
Danger symbol without key word: Additional notes
Intended use
The abrasive hopper is used to convey sand for abrasive waterjet cutting. The abrasive hopper must
be firmly screwed to the floor and may only be used completely assembled. Grounding, potential
equalization and sand hose must be connected. The cover must always be in place during operation.
Sand quantity up to 2000g/min. Filling can be done with 25kg bags or 1000kg big bags (except
952800). When filling with big bags, they must not be placed on the abrasive hopper. The max. filling
height is the top edge of the hopper so that the lid can be placed properly. Only dry sand mesh 60 to
250 may be used. The technical limit values must always be observed.
Inadmissible use
As an inadmissible use of the abrasive hopper counts amongst others:
➢The use of any abrasive other than sand.
➢Any mixing of additives to the sand.
➢Excessive stress on the abrasive hopper (e.g. air pressure > 8bar).
➢Exceeding the permissible limits of use (see technical data, chap.3.3),
➢Any structural changes to the abrasive hopper.

Safety
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ALLFI Abrasive Hopper 22.12.2022
➢Any change to the software.
➢Operation of the abrasive hopper without it being screwed to the floor.
➢Operation of the abrasive hopper without the lid in place.
➢Operating the abrasive hopper without it being grounded or the potential equalization con-
nected.
➢Placing a non-empty big bag on the abrasive hopper.
➢Operating the abrasive hopper with dismantled or deactivated technical protective devices
(e.g. pressure relief valves).
➢Operating the abrasive hopper without the sand hose being connected on both sides and se-
cured with clamps.
➢Use of abrasive sand finer than mesh 250 or coarser than mesh 60.
All further from the intentional application deviating applications of the abrasive hopper are inadmissi-
ble. Should you have questions, please contact the manufacturer directly.
ALLFI AG - Riedenmatt 1 –CH-6370 Stans
Phone: [phone] - Fax: [phone]
E-Mail: [e-mail] - http://www.allfi.com
Information signs on the machine
Info panel “Message signals “
This adhesive is applied to the terminal box of the abrasive hopper. With its help, the operator can bet-
ter interpret the message signals of the LED strips.
Message signals (LED-Strips)
Continuous System not switched on
1 x Interval Warning Service required
2 x Interval Warning filling quantity abrasive hopper →sensor
3 x Interval Fault filling quantity pressure vessel →sensor
4 x Interval Fault differential pressure (Pdiff < 2,5 Bar)
Foreseeable misapplication
The machine must not be used for purposes other than those for which it is intended. The following
foreseeable misuses are not permitted:
➢Overfilling the hopper so that the lid cannot be placed properly.
➢Placing a non-empty big bag on the hopper.
➢Abrasive hopper not screwed onto the floor.
➢Operating the abrasive hopper when the lid is not placed on the hopper.

Safety
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ALLFI Abrasive Hopper 22.12.2022
Residual risks
The residual risks listed below are to be reduced by the owner/operator of the abrasive hopper by
means of the following measures:
Operation
phase
Damage
Danger
Reason
(possible) measures
Operation
Physical
injuries
Leakage of
compressed air
and or sand un-
der pressure
Deflagration
from open
end of the
conveying
hose
Operate abrasive hopper only com-
pletely assembled
(incl. cover)
Do not open the hose coupling un-
der pressure
Wear protective glasses when
working on the system
Secure sand hose with clamps
Vent closed
or clogged
Never close the vent
Test the vents during regular func-
tion tests
Replace filter on pressure vessel
according to instructions
(see 8.4)
Wear protective glasses when
working on the system
Filling the
Abrasive
hopper
Physical
injuries
Crushing of
limbs during fill-
ing of the abra-
sive hopper
lack of safety
distance
Do not step under suspended loads
Keep your distance
Train personnel
Safety installations
Emergency stop: The machine is switched off. If the emergency stop is wired to the higher-level sys-
tem, the entire system is switched off.
Hopper cover: Must always be placed on the hopper during operation..
Safety devices that are not always functional or can be bypassed pose a risk to the
operator. The owner must ensure that they are in working order at all times.
Personal protection equipment
The Owner must offer his staff following protection equipment while he’s working:
Ear protector against:
➢Noise emissions

Safety
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ALLFI Abrasive Hopper 22.12.2022
Wear protection glasses against:
➢Fluids, sand and dust particles
➢Flying fragments
Hand guards against:
➢Sharp edges of components
➢Intrusion of micro particles into the skin
Inhalation protection against:
➢Dust particles, micro particles and spray mist
Qualification of the staff
The abrasive hopper may only be operated and maintained by certified, trained staff.
Special safety instructions
2.10.1 Transport, assembly, commissioning
•Transport strictly as described under 4.1
•Observe the requirements for the installation site (see 5.2)
2.10.2 Operation
•Do not step under suspended loads (big bag)
•Wear protective equipment during filling of sand (see 7.5)
2.10.3 Cleaning, maintenance, servicing
•Before any manipulations on the machine:
Switch off the abrasive hopper system and depressurize the compressed air line.
2.10.4 Decommissioning, disassembly, disposal
•Close ball valve
•Disconnect abrasive hopper from compressed air and power supply
Duties of the owner
•Regular maintenance
•Carry out safety instructions
•Carry out trainings
Duties of the staff
•Read and follow the operating instructions
•Wear necessary protective equipment

Product description
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ALLFI Abrasive Hopper 22.12.2022
3 Product description
General function of the machine
The abrasive hopper is used to convey abrasive sand for abrasive waterjet cutting. The abrasive is
stored in the abrasive hopper (contents see 3.3). The sand enters the pressure vessel through a pinch
valve which is periodically opened and closed. From there it is conveyed by compressed air (max. 5
bar) through a hose into the storage container of the abrasive dosing unit. For trouble-free operation,
the carried air in the abrasive feeder must be able to escape without pressure via a vent.
CAUTION
The vessel vent of the abrasive feeder must be sufficiently large and al-
ways open, otherwise the vessel may burst.
Structure
3.2.1 Abrasive Hopper 1300 kg, 952000
Naming
Piece
Item no.
Cover
1
952011
Hopper with
frame
1
952009
Sight glass
1
952913
Sieve insert (in-
side the hopper)
1
952030
Capacitive sensor
2
032008
Control
1
952921
Pressure vessel
assembly
1
952020
Bolt anchor
4
000346

Product description
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ALLFI Abrasive Hopper 22.12.2022
3.2.2 Abrasive Hopper 100 kg, 952800
3.2.3 Abrasive Hopper 1300 kg, 952900
Naming
Piece
Item no.
Cover
1
952826
Funnel and frame
1
952801
Sieve insert (inside the
funnel)
1
952831
Capacitive sensor
1
032008
Control 400
1
952821
Pressure vessel assem-
bly
1
952822
Bolt anchor
4
000346
Naming
Piece
Item no.
Cover
1
952926
Hopper with frame
1
952901
Control plexi
1
952943
Sieve insert (inside
the hopper)
1
952930
Capacitive sensor
1
032008
Control
1
952921
Pressure vessel as-
sembly
1
952822
Bolt anchor
4
000346

Product description
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ALLFI Abrasive Hopper 22.12.2022
3.2.4 Abrasive Hopper 1000 kg, OM-952500
3.2.5 Pressure vessel
For OM-952500, 952800, 952900 for 952000
Naming
Piece
Item no.
Cover
1
952131
Hopper with frame
1
952128
Control plexi
1
952943
Capacitive sensor
1
032008
Sieve insert (in-
side the hopper)
1
952129
Control
1
OM-952521
Pressure vessel
assembly
1
952822
Bolt anchor
4
000346
Naming
Piece
Item no.
Ball valve G1"
1
040003
fitting G1"
1
040144
Pinch valve
1
030129
Push-in fitting
G1/4-6
2
030286
Filter
1
030327
Washer M12
1
000403
Quick exhaust
1
030287
Reducer
D-1/4I-1/2A
1
040022
Pressure vessel
1
952124
Capacitive sensor
1
032008
Coupling with noz-
zle 16mm
1
040057
Claw coupling
AG1/2"
1
040059

Product description
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ALLFI Abrasive Hopper 22.12.2022
3.2.6 Control/pneumatics
Electrical diagrams see appendix
Cover of control box
control box open
Technical data
3.3.1 Type plate
The type plate is fixed on the outside of the control box or inside on the lid.
Naming
Piece
Item no.
Emergency stopS3
1
032171
Switch/Light S1/S2/P1
1
032105
Solenoid valve K1/K2
1
030288
Filter control valve
1
030289
Pressure control valve
1
030290
Differential pressure
sensor
1
032329
PLC LOGO!
1
032027
Fuse slow blow
250V 1.6A
1
032183
Condensate drain
1
Coupling plug
KS4-1/4-A
1
030230
Silencer
1
030272

Product description
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ALLFI Abrasive Hopper 22.12.2022
3.3.2 Dimensions and weights Abrasive Hopper 952000, 1300 kg
Height: 1854 mm
Width: 870 mm
Depth: 870 mm
Empty weight: approx. 140 kg
Operating weight full: approx. 1440 kg
Filling quantity abrasive hopper: approx.1300 kg
3.3.3 Dimensions and weights Abrasive Hopper 292800, 100 kg
Height: 1100 mm
Width: 597 mm
Depth: 618 mm
Empty weight: approx. 65 kg
Operating weight full approx. 165 kg
Filling quantity abrasive hopper: approx. 100 kg

Product description
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ALLFI Abrasive Hopper 22.12.2022
3.3.4 Dimensions and weights Abrasive Hopper 952900, 1300 kg
Height: 1801 mm
Width: 870 mm
Depth: 870 mm
Empty weight: approx. 140 kg
Operating weight full: approx. 1440 kg
Filling quantity abrasive hopper: approx. 1300 kg

Product description
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ALLFI Abrasive Hopper 22.12.2022
3.3.5 Dimensions and weights Abrasive Hopper OM-952500, 1000 kg
Height: 1645 mm
Width: 880 mm
Depth: 880 mm
Empty weight: approx. 140 kg
Operating weight full: approx. 1140 kg
Filling quantity abrasive hopper: approx. 1000 kg
3.3.6 Mechanics
Flow rate : 0 to approx. 2.000 g/min (with abrasive hose inner-Ø=16mm, L=20m)
Abrasive hose connection: Hose nozzle for hose D=16mm
Temperature min./max.: 0 / +50°C
Emission sound pressure level: less than 70 dB(A)
NOTE
To prevent the formation of condensation, large temperature fluctuations
should be avoided as far as possible.

Product description
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ALLFI Abrasive Hopper 22.12.2022
3.3.7 Data and connected loads pneumatics
Pressure vessel: Volume approx. 6.5 dm3
Max. allowed pressure 6 bar
Compressed air supply Pressure: 6 bar bis 10 bar
Quality compressed air must be dry and oil-free
Air consumption 5 bis 25 nL/min (depending on sand
consumption and delivery pressure)
air connection: Plug nipple quick coupling Ø 6mm
Pinch valve P1: Control pressure: 6 bis 8 bar
Pressure vessel P2: Operating pressure: 1 bis 5 bar
Differential pressure P1 - P2: min. 2,5 bar
3.3.8 Electrical connection values
Supply voltage: 24 VDC (21,6V –26,4V)
230 VAC, als Option mit integriertem Netzteil
Power consumption: approx. 20W
Limits for operation and storage
The limits of the machine according to the Machinery Directive are defined in chapter 2 Safety and
chapter 3.3 Technical data.
Accessories / options / wear parts
Article:
230V option
Y-distributor
Hose electrically conductive
[In metres]
Article no:
952156
040056
040141
Function:
Supply 230VAC
instead of 24VDC
For supply of two
abrasive feeder
As connection to the
abrasive feeder

Transport, packaging and storage
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ALLFI Abrasive Hopper 22.12.2022
Article:
Sensor
Sinter filter
pinch valve
Article no:
032008
030327
030129
Function:
Level sensor for
Abrasive hoppers and
pressure vessel
Venting
pressure vessel
Shut off
pressure vessel
Article:
Hose sleeve
Ball valve G1"
Upgrade kit differential
pressure
Article no:
030134
040003
952922
Function:
Replacement sleeve for
pinch valve
Shut off hopper
Retrofit of differential pressure
monitoring for older abrasive
hopper
4 Transport, packaging and storage
Lifting and transporting
DANGER
Ensure that NO ONE is under or near the abrasive hopper during transport.
1 Difference pres-
sure switch
1 Connection cable
1 SD card
2 T-piece
0.5m Hose Ø4