allfi Abrasive Feeder 2.0 User manual

Operating and maintenance instruction
Abrasive Feeder 2.0
Operating and maintenance instruction
ALLFI AG - Riedenmatt 1 –CH-6370 Stans
Tel.: [phone] - Fax: [phone]
E-Mail: [email protected]om - http://www.allfi.com
May 2021

General
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Scope of application
This installation and maintenance manual is valid for the following abrasive feeder
➢951400
➢FP-951400
➢TE-951400
➢WO-951400
The descriptions are shown with all options. Function and execution without mounted options are car-
ried out in the same way.
Adapter plates for most common motors are available on request. Please simply send a request with
details of the exact motor type to [email protected]m

General
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Table of contens
1 General............................................................................................................................................ 5
Information on use of the operation and maintenance instruction....................................... 5
Scope of delivery ..................................................................................................................... 5
Warranty claim........................................................................................................................ 5
Disclaimer................................................................................................................................ 5
2 Security............................................................................................................................................ 6
Declaration of symbols............................................................................................................ 6
Intended use............................................................................................................................ 6
Inadmissible usage .................................................................................................................. 6
Residual risks........................................................................................................................... 7
Safety installations .................................................................................................................. 8
Personal protection equipment .............................................................................................. 8
Qualification of the staff.......................................................................................................... 8
3 Structure and function of the abrasive feeder................................................................................ 9
Structure.................................................................................................................................. 9
Function................................................................................................................................. 10
Accessories ............................................................................................................................ 10
4 General technical data .................................................................................................................. 11
Delivery rate sand 80 mesh................................................................................................... 11
5 Installation and commissioning .................................................................................................... 12
Installing the abrasive dosing system.................................................................................... 12
Connecting hoses .................................................................................................................. 13
Electrical connection ............................................................................................................. 13
5.3.1 Mounting the connector housing.................................................................................. 14
6 Uninstalling.................................................................................................................................... 14
7 Maintenance.................................................................................................................................. 15
Belt replacement................................................................................................................... 15
Cleaning after backflow recoil or sand accumulation ........................................................... 16
8 Options .......................................................................................................................................... 17
Level Sensor........................................................................................................................... 17
Check Valve Sensor................................................................................................................ 18
9 Faults and Troubleshooting........................................................................................................... 20
10 Recycling.................................................................................................................................... 20

General
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11 Data sheets................................................................................................................................ 21
Linearer Servo Controller ...................................................................................................... 21
Linearer Servo Controller connection diagram ..................................................................... 22
11.2.1 Control with 0 - 10V voltage (standard)........................................................................ 22
11.2.2 Control with potentiometer (optional) ......................................................................... 22
Level Sensor........................................................................................................................... 23
Control Unit........................................................................................................................... 24
Back-flow Sensor ................................................................................................................... 25
Appendix A –Technical drawing and parts list (shipped with the product)

General
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1 General
Information on use of the operation and maintenance instruction
This operation and maintenance instruction is a key part of the product. The information in this manual
is mandatory and must be read and understood by all the persons before operating with the pneumatic
valve 2.0. The manual must be stored in distance as well as always accessible to the persons, working
with the abrasive feeder 2.0.
Should you have any questions regarding the content of the manual, please contact the manufacturer
directly.
ALLFI AG - Riedenmatt 1 –CH-6370 Stans
Tel.: [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 of 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:
➢Belt
➢Geared Motor
➢Ball bearings
➢Sensors
➢Seals / O-Rings
Disclaimer
ALLFI AG refuses any claims of liability (material damages, physical injury, as well as disruption of op-
eration), that are a result of disregarding this operating and maintenance instruction.
For example the damage as a consequence of:
➢Inadmissible application of the abrasive feeder 2.0
➢Defective maintenance
➢The disregard of operation instructions
➢Chemical and electrolytical influences
➢Use of parts, spare parts or accessory from a third-party manufacturer
➢Arbitrary modifications
➢Not or insufficiently trained staff
The disregard of all these instructions happens on exclusive risk and exclusive responsibility of the cli-
ent. The ALLFI AG is not liable for any production downtimes.

Security
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2 Security
Declaration of symbols
This operating and maintenance instruction manual contains important notes and symbols, which are
to be considered and followed. These include:
DANGER
Danger emphasizes operating and service procedures that if not avoided,
may lead to death or serious personal injuries.
WARNING
Warnings emphasize operating or service procedures, or conditions that
can result in serious personal injury or death.
CAUTION
Cautions emphasize operating or service procedures, or conditions that
can result in equipment damage or impairment of system operation. If not
avoided, light or medium body injuries could be the consequence.
NOTE
Notes provide additional information that can expedite or improve operat-
ing or service procedures.
Danger symbol without key word: Additional notes
Intended use
The abrasive dosing is used for dosing sand for abrasive water jet cutting. Sand quantity 50 to
1000g/min. Filling must be carried out with a abrasive hopper which conveys the sand into the inter-
mediate container without pressure. The dosing unit may only be used completely assembled and
must be permanently mounted on the machine. All hoses must be connected. Only dry sand mesh
from 60 to 250 may be used as abrasive.
Inadmissible usage
The inadmissible usege of the dosage includes, but is not limited to, the following:
➢Use of any abrasive other than sand
➢Any admixture of additives to the sand

Security
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➢Excessive strain of the dosage
➢Exceeding the permissible limit values
➢Any modifications of the feeder
➢Operation of the dosing in dismantled or disabled technical protective devices (e.g. the plexi-
glass disc)
The uses listed below are also considered inadmissible if there are no suitable technical protective
measures to protect the operator, other groups of persons, the machine components themselves or
the environment:
➢Cutting materials whose processing releases harmful, aggressive or explosive substances in
the form of dust, microparticles or gas.
Likewise, all other uses of abrasive dosing that deviate from the intended use are considered inad-
missible. If you have any questions or concerns, please contact the manufacturer directly.
ALLFI AG - Riedenmatt 1 –CH-6370 Stans
Tel.: [phone] - Fax: [phone]
E-Mail: [email protected] - http://www.allfi.com
Residual risks
The manufacturer and/or operator of the machine where the abrasive feeder 2.0 is built in, has taken
every precautionary measure possible to reduce residual risks, as far as possible reasonably practica-
bly.
Operation
phase
Damage
Danger
Reason
(possible) measures
Operation
Physical inju-
ries
Liquids or sand
leaking under
high pressure
Back-flow or sand
jam due to clogged
cutting head
Operate abrasive
feeder only completely
assembled
Keep a safe distance
Protective walls as a
technical protective
measure
Vent closed or
blocked
Never close the vent
Only use hose with in-
ner diameter adapted
to the connection
piece.
Do not bend the hose
Protective walls as a
technical protective
measure
Intrusion of
limbs into the ro-
tating belt
Missing protective
glass
Operate abrasive
feeder only completely
assembled

Security
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Safety installations
The manufacturer or the operator of the full machine, which the arbrasive feeser 2.0 is built in, has en-
sured the following safety arrangements:
➢Protective devices against leaking liquid or sand
➢Emergency stoppage to immediately shut down the operating machine.
➔Active: Manually triggered by operator
➔Passive: Automatically triggered by:
oNon-return or sand accumulation (option 951401)
Danger for the operator will arise if safety protections are not functionally, not
followed or evaded anytime. The operator has to ensure the functionality of the
safety protections anytime.
Personal protection equipment
The operator must offer his staff following protection equipment while he’s working:
Ear protector against:
➢Noise emissions
Wear protection glasses against:
➢Fluids 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 feeder 2.0 may only be operated and maintained by certified, trained staff.

Structure and function of the abrasive feeder
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3 Structure and function of the abrasive feeder
Structure

Structure and function of the abrasive feeder
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Function
The abrasive feeder 2.0 is used for dosing sand for abrasive water jet cutting. Sand is transported
from the abrasive hopper into the container via a hose with the use of compressed air. The transported
air escapes via the vent. This must always be open, otherwise the container may burst. If required, a
hose can be connected to the venting nozzle. The dosage is performed by means a of special belt.
The quantity is controlled by the motor speed and is almost linear to the belt speed. The standard di-
rection of rotation is clockwise. This allows sand quantities of up to approx. 650 g/min to be achieved.
With the direction of rotation to the left, sand quantities of up to approx. 1000g/min are possible. In the
event of a sand backflow, the backflow preventer prevents the water-sand mixture from entering the
dosing housing. Without tools, the backflow preventer can be separated from the housing and cleaned
and dried with compressed air.
As an option, a sensor is available which detects a backflow as well as a sand jam. Another option is
the level sensor. This detects a too low sand level in the container. Both sensors can be used for a
warning message and or machine stop.
Accessories
Article:
Back-flow sensor
Level Sensor
Hose
Electrically conductive
Article no:
951401
951402
040141
Function:
Signals a water-sand
back-flow or a sand jam
Signals a level too low in
the sand container
For feeding sand from the
abrasive hopper

General technical data
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4 General technical data
Height: 410mm
Width: 94mm
Depth: 144mm (depending on motor)
Empty weight: approx. 2 kg; without linear servo controller (LSC)
Usable sand volume: 400 ml
Dosing quantity: clockwise rotation: 50 - 650g/min
counterclockwise rotation: 80 - 1000g/min
Connection sand inlet: Hose connector Outer Ø 16mm
Connection Ventilation Hose: Hose connector Outer Ø 16.7mm
Hose Sand outlet Inner-Ø 6,4mm, Outer-Ø 9,6mm (2.5m included)
Max. motor speed 6300min-1
Gear ratio 60:1
Max. Pulley speed 105min-1
Further technical data such as connection dimensions can be found in the technical drawing in Appen-
dix A.
Data sheets for sensors & linear servo controller see chapter 11.
Delivery rate sand 80 mesh
General characteristic curve Only valid for Maxon motor

Installation and commissioning
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5 Installation and commissioning
Installing the abrasive dosing system
The four M6 threads marked green at the bottom or on the back can be used to mount the dosage on
the cutting system.
For mounting the servo controller see chapter 11.1 and separate operating instructions.
General installation tip:
➢For an first installation, follow the corresponding subchapters step by step
➢Only operate the dosing unit completely assembled
➢Electrical components may only be connected by qualified personnel

Installation and commissioning
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Connecting hoses
•Green dot:
Connection for the sand inlet from the Abrasive
Hopper.
Secure the hose with a clamp.
•Red dot:
Connection for venting.
In the event of a malfunction of the abrasive hop-
per, an air-sand mixture can escape.
Install a hose that is adapted to the size of the con-
nection, sloping down and kink-free so that no jam-
ming can occur.
The connection must not be closed, other-
wise the vessel may burst.
•Blue dot:
Connection to the abrasive cutting head for the
dosed sand. Install the supplied hose in a sloping
position and as short as possible in order to avoid a
jam. The direction of the connection can be se-
lected by turning the black non-return valve.
Electrical connection
The connection of the Maxon motor module is pre-installed, the counterpart is connected as explained
in chapter 5.3.1.
For the connection of the Linear Servo Controller and the connection with the motor see chapter 11.
The direction of rotation of the motor can be selected with the corresponding polarity.
Clockwise rotation: sand quantities from 50 - 650 g/min
Left turning: sand quantities from 80 - 1000g/min

Uninstalling
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5.3.1 Mounting the connector housing
1
Strip 3 mm of insulation from both cable ends and
twist both copper ends.
Insert the socket contact including the yellow seal
with the " ERGOCRIMP" pliers
crimping,
with die for Ergo basic hand pliers
use.
Operate the pliers as far as they will go.
Use 1.0 mm crimping position!
Observe alignment of motor and connector hous-
ing during crimping!
2
Mount the socket housing,
red cable + at terminal 1
and
black cable - at terminal 2
Retract until it clicks.
3
Check that the cables are firmly seated by pulling
on them gently.
6 Uninstalling
•- Switching off the abrasive hopper
•- Remove hose from abrasive cutting head
•- Empty the container completely by switching on the dosing system
•- Remove remaining hoses and electrical connection.
•- Disconnect any existing sensors as well.
•- Unscrew the dosing unit, do not damage the sand container.

Maintenance
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7 Maintenance
Belt replacement
A good belt condition is a prerequisite for correct operation of the feeder system. In case of slippage,
damage (cracks) or after 2000 operating hours, it is recommended to replace the belt.
•Remove the motor assembly (pos. 4) from the housing.
•Loosen nut (marked red) two turns while simultaneously holding the hexagon socket screw
(green).
•Sliding the unit in the direction of release
•The belt is now slackened and can be changed.
•Push the unit up to the stop and tighten in direction
•Tighten the lock nut (marked red) while holding the hexagon socket screw (green).
•Install the motor assembly (pos. 4) in the housing.
tighten
loosen

Maintenance
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Cleaning after backflow recoil or sand accumulation
If a jam on the abrasive cutting head has caused a backflow or sand build-up, the backflow preventer
must be cleaned with compressed air and dried.
•Stop machine (high pressure pump &
abrasive hopper)
•If necessary, prepare a container to col-
lect the sand.
•Remove the hose from the abrasive cut-
ting head.
•Hold the black backflow-preventer valve
with your fingers at the green dot and
pull it out of the aluminium housing with
simultaneous turning and pulling move-
ments (red arrow).
•If necessary, collect sand with container
•Detach the drip tray using a screw-
driver.
•and extend upwards
•Blow out and dry Backflow-preventer
valve
•Also check if the aluminium housing is
dry and not clogged. If necessary, clean
and dry here as well.
•Assemble everything in reverse order
as follows
•Check whether the sheet is clicked in
correctly

Options
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8 Options
Level Sensor
The level sensor signals a too low level in the sand container. The signal can be used for a warning
message and or machine stop.
The sensor is attached to the container with the supplied double-sided adhesive tape and is con-
nected to the Control Unit. After installation, the sensor sensitivity must be set on the Control unit of
the abrasive dosing system (Picture left).
HINT
Damage to property due to incorrect assembly
The power amplifier is IP40 certified. It is not protected against water in any form.
See also data sheets chapter 11.
Therefore:
Place this component in a place protected from water & steam. Alternatively, it
can be mounted in a waterproof box.
HINT
Install cables properly
Lead the sensor cable to the sensor in an arc without tension. Also make sure
that the cable to the control cabinet is long enough in all positions.

Options
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1
1. Cut off the side tabs from the sensor.
2
2. Glue double-sided adhesive tape
onto the container at the point where
the sensor is to be fixed. Height see
picture left
3. Press the sensor onto the adhesive
tape The connection cable must
be on the left side and point-
ing downwards so that the
crosses, marked red in the top left
picture, are in contact with the adhe-
sive tape
4. Connect the sensor to the Control
unit (plug)
5. Connect the control unit to the cutting
system (see operating instructions
supplied)
6. Adjust the sensitivity on the Control
unit (see operating instructions sup-
plied)
Check Valve Sensor
The Check Valve sensor signals a water sand non-return or a sand jam. The signal can be used for a
warning message and or machine stop.
In addition to the sensor, the scope of delivery includes the screws for fixing to the drip tray as well as
the cable for potential equalization.
HINT
Do not set the sensor to teach mode
The sensor was already configured for the application before delivery. If the sen-
sor is incorrectly set to teach mode, smooth operation can no longer be guaran-
teed. If it is unintentionally taught, contact Allfi Service.

Options
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HINT
Install cables properly
Lead the sensor cable in an arc to the sensor so that sufficient cable length is
available when removing the non-return unit. Also make sure that the cable to the
switch cabinet is long enough in all positions.
HINT
Mounting the sensor in the correct position
When mounting, the crosshairs on the sensor must point in the direction of the
black backflow preventer, otherwise the sensor will not function.
Correct assembly
Wrong assembly
The sensor cable can be guided to the left or
right.
The drip tray must be electrically connected to
the motor plate using the cable supplied.
For screw torque and electrical connection, re-
fer to the operating instructions supplied.

Faults and Troubleshooting
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9 Faults and Troubleshooting
Depressurize high-pressure, water and compressed air lines before any trouble-
shooting.
Fault
Possible causes
Correction
Dosage tank does not fill with
abrasive sand
Sponsor does not support ade-
quately or not at all
Switching on or adjusting the
conveyor
Connection line between con-
veyor & dosing blocked or in-
terrupted
Clean or check the connecting
hose.
Air pressure in supply line for
dosing
too high (max. 3 bar)
Incorrect air pressure setting
on maintenance unit
Set the air pressure at the
maintenance unit to max. 3
bar.
Water/sand mixture repels or
accumulates in backflow pre-
venter
Focusing tube, nozzle, mixing
chamber, hose and / or back-
flow preventer blocked.
Clean the focusing tube, noz-
zle, mixing chamber, hose and
non-return valve.
The dosage container is over-
filled.
Sand outlet at venting from
Too high air pressure at the
abrasive conveyor
Adjusting the air pressure on
the abrasive conveyor cor-
rectly
Refill device on abrasive con-
veyor does not fill properly
Check abrasive conveyor
Container of abrasive conveyor
is almost empty
Filling sand
Overpressure in abrasive con-
tainer
Vent blocked at expansion
tank
Expose vent
Power supply for drive inter-
rupted
power supply
ensure
Drive motor defective
Replace drive motor
Servo controller defective
Linear Replace servo controller
Dosage does not promote
abrasive agent
Control loop failed
Control loop from potentiome-
ter or CNC
10 Recycling
The Abrasive feeder 2.0 is made of metal and plastic. All the metal parts can be recycled. The elec-
tronic- & plasticparts are to be professionally recycled as per local specifications.