DIAMOND Retractable Rodding Robot Model SPRAYROD-R

2004-12-21 2 1 (23) DIAMOND Retractable Rodding Robot Model SPRAYROD-R

2004-12-21 2 2 (23) Table of contents 1 TECHNICAL DESCRIPTION...4 1.1 MAIN DETAILS...5 1.2 COMPONENTS DESCRIPTION...5 1.2.1 Pneumatic cylinder...5 1.2.2 Cutting Head...6 1.2.3 Gun inclinator...6 1.2.4 Locking device...6 1.2.5 Liquor gun holder...6 1.2.6 Materials...6 1.3 CONTROL SYSTEM...6 1.3.1 Electrical arrangements...6 1.3.2 Air hoses...7 1.3.3 Control Cabinet...7 2 INSTALLATION...8 2.1 DIAMOND SPRAYROD-R...8 2.1.1 Installation...8 2.1.2 Adjusting the stroke...9 2.1.3 Centering the Cutting Head...10 2.1.4 Positioning of the liquor gun...11 2.1.5 Retracting the liquor gun and rodder...12 2.1.6 Adjusting liquor gun position...13 2.2 AIR SYSTEM...14 2.2.1 Control Cabinet...14 2.3 CONTROL SYSTEM...14 2.3.1 Timer...14 3 OPERATING INSTRUCTIONS...14 3.1 ELECTRICAL ARRANGEMENTS...14 3.1.1 Main switch...14 3.1.2 Timer...14 3.1.3 Push button for manually activation...14

2004-12-21 2 3 (23) 4 SAFETY REGULATIONS...15 4.1 GENERAL SAFETY RULES...15 4.2 SAFETY...15 5 TROUBLE SHOOTING...16 5.1.1 If a SPRAYROD-R is out of operation, possible reason:...16 5.1.2 If a spray gun is insufficiently cleaned:...17 5.1.3 Dismounting the SPRAYROD-R...17 6 REPLACEMENTS...18 6.1 REPLACEMENT OF THE CUTTING HEAD...18 6.2 REPLACEMENT OF BUSHINGS...18 6.3 REPLACEMENT OF CYLINDER...19 7 PERIODIC CLEANING...19 7.1 KEEPING SLIDE CLEAN...19 8 Recommendation for liquor gun.. 20

2004-12-21 2 4 (23) TECHNICAL DESCRIPTION DIAMOND SPRAYROD-R System normally includes: 1 4 5 Fig. 1 2 3 1. SPRAYROD-R 2. Control cabinet with timer and circuit breaker 3. Hoses set 4. Liquor gun holder 5. Boiler attachment plates

2004-12-21 2 5 (23) 1.1 Main details DIAMOND SPRAYROD- consists of the following parts (Fig.2). Fig. 2: Retractable Spray rod 1 3 5 2 1. Pneumatic cylinder 2. Cutting heat 3. Liquor gun inclinator 4. Locking device 5. Liquor gun holder 4 1.2 Components description 1.2.1 Pneumatic cylinder DIAMOND SPRAYROD-R is equipped with a double-acting 63 mm diameter cylinder. The cylinder stroke is variable, but the standard is 400mm.

2004-12-21 2 6 (23) 1.2.2 Cutting Head The Cutting Head is made of DOMEX 024 BOR, a boron alloyed, hardened spring steel with high heat resistance. The Cutting Head is of flexible type. 1.2.3 Gun inclinator The inclinator is used to positioning the liquor gun in an angle between 20 to + 20 degrees to optimize the efficiency. 1.2.4 Locking device A locking device with two positions is used to guarantee that the retractable spray rod is in a safe working position. 1.2.5 Liquor gun holder The liquor gun is attached and secured in place by the Liquor gun holder. 1.2.6 Materials The main parts of DIAMOND SPRAYROD-R; mounting plate, robot arm, robot arm plate and rod are made of hot-galvanized steel The surface layer is min 20 µm. Bushings are made of PTFE, reinforced with stainless steel powder to increase the wear resistance. 1.3 Control system 1.3.1 Electrical arrangements From the main power supply a cable may be connected to the control cabinet, where it provides the solenoids with current. Optional voltages can be used; 220VAC, 110VAC or 24VDC. The operator handles programming/ time settings etc. for current timer interval. Instructions for the timer can be found in the appendix.

2004-12-21 2 7 (23) 1.3.2 Air hoses The air hoses distribute air from the control cabinet to the cylinders. The hoses are high temperature resistant. Incoming air to the valve inside the control cabinet is taken care of by the end user. 1.3.3 Control Cabinet Fig. 3: Control Cabinet 1.3.3.1 Cabinet description The control cabinet is made of stainless steel; dimensioned 240x240x150 mm and in a waterproof design, protection class IP66. The cabinet is equipped with a 1/4 ball valve with self-ventilation to turn off air when working with SPRAYROD-R, a timer for adjustment of the activation time of the SPRAYROD-R, terminals, main switch, power on indication lamps and a push button for manual activation of the spray rod. CAUTION FOLLOW THE SAFETY INSTRUCTIONS IN CHAPTER 4 BEFORE ANY WORK IS PERFORMED IN THE CONTROL BOX. ONLY AUTHORIZED PERSONNEL MAY OPEN THE CABINET.

2004-12-21 2 8 (23) 2 Installation 2.1 DIAMOND SPRAYROD-R Before the SPRAYROD-R may be installed, the mounting location and the liquor gun have to be well cleaned. 2.1.1 Installation Installation can be done during operation, under condition that necessary safety measures carefully are followed and that safety equipment is worn. Fig. 4: SPRAYROD-R Fig. 5: Mounting collar Boiler attachment plates The SPRAYROD-R is mounted on the Boiler attachment plates, which are welded to the boiler wall. These are to be fully welded to boiler either by client or supplier. DANGER! IF WELDING IS NOT PROPERLY DONE, THERE IS A RISK OF THE EQUIPMENT FALLING OUT OF PLACE, INCLUDING THE LIQUOR GUN.

2004-12-21 2 9 (23) 2.1.2 Adjusting the stroke The stroke is to be completed at the widest part of the splash plate (spoon). To ensure that the SPRAYROD-R is able to complete its stroke, there are two different adjustment options. This may be done as follows: 1. Move the Cutting Head backwards and forwards on the rod 2. Push the Cutting Head and rod backwards or forwards by loosening the 2 screws holding the cylinder against the robot arm (see Fig. 6). Fig. 6: Stroke Adjustment

2004-12-21 2 10 (23) 2.1.3 Centering the Cutting Head Center the Cutting Head using the four spring-loaded screws 1 4, as shown on Fig.7. Follow the instructions in table 1. Fig.7: Spring-loaded screws Table 1: Tighten adjustment SCREW N0. ROD DIRECTION 1 Inclined down right 2 Inclined down left 3 Inclined up right 4 Inclined up left

2004-12-21 2 11 (23) 2.1.4 Positioning of the liquor gun The gun can be positioning in an angle from 20 to +20 degrees in relation to the horizontal. Release the locking lever (Fig.8) and adjust the liquor gun turning the positioning lever (Fig.9) until desire angle is reached, then re-tighten the locking lever. Fig. 8: Inclinator Locking lever Fig. 9: Positioning lever

2004-12-21 2 12 (23) 2.1.5 Retracting the liquor gun and rodder. DANGER! BEFORE RETRACTING THE UNIT ENSURE THAT THE BLACK LIQUOR FLOW IS TURNED OFF 2.1.5.1 Pull out retracting device from liquor firing position 1. Unlock rear lock pin by turning handle 180 degrees and put it in open position. 2. With left hand, pull front lock ball and with right hand pull out liquor gun and holder until it reaches the rear position lock. Fig. 10 Rear lock pin locked Rear lock pin unlocked 3. The liquor gun holder can be locked in its outermost position by pulling it out until rear lock engages. This keeps the unit in place while service or change of liquor gun is done. Fig. 11 Rear position lock

2004-12-21 2 13 (23) 2.1.5.2 Inserting retracting device into liquor firing position Release the rear position lock by pressing the lock plunger slightly. Push the unit to the work position, until it locks. Fold down the rear lock pin. DANGER! BE SURE THAT RETRACTING DEVICE IS FIRMLY LOCKED AND THAT BOTH LOCK-PINS ARE ENGAGED, BEFORE BLACK LIQUOR IS TURNED ON 2.1.6 Adjusting liquor gun position To change position the end stop must be moved (Fig.12 andfig.13.) 1. Release the 2 screws. 2. Move end stop forward or back as needed. Fig 12 End stop positions available Fig 13 End stop

2004-12-21 2 14 (23) 2.2 Air System 2.2.1 Control Cabinet The control contains a pneumatic valve to supply the cylinder. The control cabinet is mounted on a profiled tube close to the liquor gun, either on the boiler wall or placed loose on either platform or concrete floor. 2.3 Control system 2.3.1 Timer A timer unit mounted on a mounting rail inside the control cabinet controls the system. This is used to set the active- and pause- time for the cylinder movement. 3 Operating instructions 3.1 Electrical arrangements 3.1.1 Main switch The main switch placed on the cabinet front is used to connect and disconnect the power supply. An indication lamp will light when the power supply is turn on. 3.1.2 Timer The timer consists of a 3 digits display, showing the function and time period and two potential free change over contacts. There are 3 potentiometers on the front used for adjusting the active time (about 2 sec.) and pause time (about 8min.). Timer instruction see appendix 1. 3.1.3 Push button for manually activation If you would like to activate the SPRAYROD-R manually, you can push the button on the control cabinet s front door. The SPRAYROD-R will then perform a stroke, assuming that the button keeps pressed until the stroke is fully performed. Then release the button and the cutting head will return to its home position. The push button overrides to pre-set values on the timer. This procedure can be repeated several times, the pre-set values of the timer will not be affected.

2004-12-21 2 15 (23) 4 Safety regulations Special attention should be given to safety texts introduced with a warning symbol (triangle) followed by a cue word. DANGER: indicates imminent risk that WILL result in serious or lethal injury if the warning is not heeded. WARNING: indicates risk or hazardous action that MAY result in serious or lethal injury if the warning is not heeded. CAUTION: indicates risk or hazardous action that MAY cause personal injury or damage to property if the warning is not heeded. 4.1 General safety rules Only personnel who are trained for it are allowed to use the equipment. The equipment may only be used for the purposes described in this document. Read all instructions carefully and follow them. Report all damage and defects immediately. Do not operate the equipment until all faults have been rectified. Make sure that all warning signs and safety labels are posted, clean and fully legible Always wear safety protection equipment when working on the SPRAYROD-R. 4.2 Safety If work is to be done on the SPRAYROD, first close the valve under the control cabinet and turn the power off by setting the main switch on OFF position. DANGER! NO WORK SHOULD BE PERFORMED WITHOUT FIRST HAVING CLOSED THE CABINET S VALVE AS WELL AS TURNING OFF THE POWER SUPPLY. If dismounting of silencers on the control cabinet s underside are done, please notice that the noise level exceeds 90 db if the equipment is put into operation without these. DANGER! ALWAYS USE PRESCRIBED PROTECTION EQUIPMENT DETAILS CLOSE TO BOILER WALL AS WELL AS LIQUOR GUN OPENING CAN BE VERY HOT

2004-12-21 2 16 (23) 5 Trouble shooting We recommend having the following spare parts to be kept in stock: Cylinder Cutting Head Bushings Silencer (must be inspected / changed at least twice per year) 5.1.1 If a SPRAYROD-R is out of operation, possible reason: An air hose to the cylinder could have come loose. Replace it if needed The SPRAYROD-R could have got stuck The cylinder gaskets can be broken The ball valve under the control cabinet can be closed The solenoid valve in the control cabinet can be defect Debris in the air system can have caused blocking of the solenoid The power supply may be switched off The air supply may be switched off The timer can be defect

2004-12-21 2 17 (23) 5.1.2 If a spray gun is insufficiently cleaned: rod sleeve is non-centered the rod sleeve is worn out the stroke is not long enough the bushings are worn out activation time in timer to short 5.1.3 Dismounting the SPRAYROD-R Follow the safety regulations in chapter 4 Start with turning off the air supply. Then, turn off the air to the control cabinet by turning the ball valve and break the power supply by setting the main switch to 0. Remove the spray gun. Loosen the hoses on the cylinder and remove the nuts keeping the SPRAYROD-R in place. Lift out the SPRAYROD-R if necessary. DANGER! BE CAREFUL WHEN LIFTING OUT THE SPRAYROD-R. LIQUOR FROM THE BOILER CAN BE SPREAD OUT THROUGH OPENING. IF YOU ARE TAKING THE ROBOT FOR SERVICE, MAKE SURE THAT THE OPENING IS COVERED WITH A PLATE. Please be careful when manually cleaning so you do not damage any exposed tubes.

2004-12-21 2 18 (23) 6 Replacements 6.1 Replacement of the Cutting Head Follow the safety regulations in chapter 4 When the cutting head is worn out it has to be replaced. Replacement can be done while liquor gun is in operation. Turn off SPRAYROD-R. Loosen screws and nuts and change the Cutting Head. Turn on SPRAYROD-R. Check that cutting head is centered. CAUTION! NUTS TYPE METAL LOCK MUST BE USED, NOT THE ONES WITH PLASTIC INSERTS. 6.2 Replacement of bushings Follow the safety regulations in chapter 4 If the bushings on the rod are too worn, it will result in that the rod will become too much play. Start with dismounting the SPRAYROD-R according to chapter 5.1.3. The Cutting Head has to be removed before replacement of the bushings. Loosen the screws on the mounting forks (see 2.1.3 on page 10) and pull the rod. The bushings can easily be removed manually. If necessary, also replace the expanding pins, which hold the bushings. It can sometimes be necessary to grind the bushings, which can bear against the weld, also the sharp corners, so that the rod easily moves back and forward. Note Make sure that the rod runs smoothly, before remounting the SPRAYROD-R.

2004-12-21 2 19 (23) 6.3 Replacement of cylinder Follow the safety regulations in chapter 4.1 Loosen the four screws holding the cylinder in its place and pull the cylinder straight backwards, so that the locking nut on the cylinder rod, is able to loosen. Thereafter, the cylinder rod shall be unscrewed from the rod, to loosen the cylinder. When mounting a new cylinder, the cylinder rod shall first be tightened down to the bottom in the pipe, which is welded on the rod, followed by: CAUTION! UNSCREW THE CYLINDER ONE TURN BEFORE THE LOCKING NUT IS FIXED AGAIN. 7 Periodic cleaning 7.1 Keeping slide clean If the slide or any other parts get fouled by black liquor, we recommend rinsing the unit with warm water at appropriated occasions. CAUTION! BE CAREFUL TO NOT INJECT WATER INTO THE LIQUOR PORT DURING LIQUOR FIRING.

2004-12-21 2 20 (23) 8 Recommendation for liquor gun To ensure that the liquor gun is placed in the correct postion at all times, we recommend that end user welds a guide pin to the bottom of the liquor gun. The guide pin then fits into the guide hole under the liquor gun holder and ensures that liquor gun is correctly placed with respect to length in-out of boiler and in the horisontal plane. Place the liquor gun in the holder and ensure that the cutting head reaches the widest place of the liquor gun splash plate. Then make a mark through the guide hole on the liquor gun pipe. On that mark a pin is to be welded. Guide hole Guide pin welded to liquor gun

2004-12-21 2 21 (23) Appendix

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