Conversion instruc- Inflatable side seal

tions
DFML-8000, DFML-10000 (-Ex)

DFML-67197-1-1-en_US-1311
Original Operating instructions

Copyright
All rights reserved.
Any duplication of these Operating instructions in any manner, either in whole or in
part, is not allowed without express permission from Bühler AG.

Technical progress
Bühler AG reserves the right to make modifications due to technical progress up to
the time of delivery.
 Table of contents

1 Important information ............................................................................................ 4

1.1 Scope of validity ....................................................................................................... 4
1.2 Supporting documents ............................................................................................. 4
1.3 Contact ..................................................................................................................... 4
1.4 Personnel qualification ............................................................................................. 5
1.4.1 Mechanics ................................................................................................... 5
1.4.2 Electricians.................................................................................................. 5
1.4.3 Welders ....................................................................................................... 5
1.5 Explanation of the warning instructions.................................................................... 5

2 Safety....................................................................................................................... 6
2.1 Designated use ........................................................................................................ 6
2.2 Technical condition ................................................................................................... 6
2.3 ATEX ID.................................................................................................................... 6
2.4 Personnel qualification ............................................................................................. 6
2.5 Protection against unexpected start-up .................................................................... 6
2.6 Protective devices .................................................................................................... 7
2.7 Safety signs.............................................................................................................. 7
2.8 Safe work environment............................................................................................. 7
2.8.1 Slipping and stumbling hazard .................................................................... 7
2.8.2 Aspiration .................................................................................................... 7

3 Parts needed ........................................................................................................... 8

3.1 Mechanics conversion.............................................................................................. 8
3.2 Pneumatics conversion ............................................................................................ 8
3.3 Electrical system conversion .................................................................................... 8

4 Conversion.............................................................................................................. 9
4.1 Preparing the installation location............................................................................. 9
4.2 Converting the mechanics........................................................................................ 9
4.3 Converting the pneumatics..................................................................................... 12
4.4 Converting the electrical system ............................................................................ 14

5 Decommissioning ................................................................................................ 16
5.1 Removing ............................................................................................................... 16
5.2 Disposal.................................................................................................................. 16

6 Spare parts ............................................................................................................ 17

6.1 Ordering spare parts............................................................................................... 17
6.2 Ordering instructions .............................................................................................. 17
6.3 Spare parts identification ........................................................................................ 17
6.4 Spare parts lists ...................................................................................................... 18
6.4.1 DFML-11964-001 Inflatable side seal ....................................................... 18

Bühler AG
Seitendichtung aufblasbar DFML-67197-1-1-en_US-1311
Table of contents 3
 1 Important information

1.1 Scope of validity

Type Usable volume [dm3]

DFML-8000, -8000-Ex 8000
DFML-10000, -10000-Ex 10000

1.2 Supporting documents

Designation Identification number

High-speed mixer DFML-8000, DFML-10000 DFML-66309-6
Spare parts catalog DFML-8000 DFML-8062-x
Spare parts catalog DFML-10000 DFML-8063-x

1.3 Contact
■ Address questions to the appropriate branch office or subsidiary of the
manufacturer.
■ Have the Operating instructions at hand.

Bühler AG
Customer Service Grain Processing
CH-9240 Uzwil, Switzerland
Phone: +41 71 955 30 40
Fax: +41 71 955 33 05
[email protected]

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
4 Chapter 1 Important information
1.4 Personnel qualification
1.4.1 Mechanics
Personnel that work on mechanical devices must be technically trained or have
completed training provided by the manufacturer.

1.4.2 Electricians
Personnel that work on electrical devices must be technically trained or have
completed training provided by the manufacturer.

1.4.3 Welders
Personnel that carry out welding work on equipment must be technically trained.

1.5 Explanation of the warning instructions

DANGER
Type and source of danger.
Danger will result in death or serious injury.
 Actions for protecting against danger.

WARNING
Type and source of danger.
Danger can result in death or serious injury.
 Actions for protecting against danger.

CAUTION
Type and source of danger.
Danger can result in injury.
 Actions for protecting against danger.

NOTICE
Type and source of danger.
Danger can result in property damage.
 Actions for protecting against property damage.

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
Chapter 1 Important information 5
 2 Safety

2.1 Designated use

This machine is intended exclusively for processing foodstuff or feed components.

■ Always use the machine in compliance with its intended use.

■ Always operate the machine in accordance with these Operating instructions.

2.2 Technical condition

If the machine is operated in defective condition, the safety, function and availability
are impaired.

■ Never operate the machine unless it is in proper technical condition.

■ Always comply with the maintenance plan.
■ Always use the original spare parts as listed in the Spare parts catalog.
■ If the operating behaviour of the machine changes, check the machine for
faults.
■ Remedy all faults immediately.
■ Never carry out unauthorized conversions or modifications to the machine.

2.3 ATEX ID
The ATEX ID indicates the conditions required for integrating the machine into an
Ex zone or connecting the machine to an Ex zone.

■ Observe the identification plate.

2.4 Personnel qualification

Unqualified personnel cannot identify risks and thus are subject to greater dangers.

■ Always assign the activities listed in these Operating instructions to technically

qualified personnel.
■ The owner / operator must ensure that the personnel comply with the locally
valid regulations and laws pertaining to safety and safety-conscious work.
■ The owner / operator must assign responsibilities and tasks and inform
personnel of these assignments. Give keys and passwords to authorized
personnel only.

2.5 Protection against unexpected start-up

If the machine starts unexpectedly, people who are working at the machine can be
seriously injured.
■ Set the safety switch to "0" and lock it.
■ Remove the key and keep it with you.

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
6 Chapter 2 Safety
2.6 Protective devices
If protective devices are ineffective, this poses a danger to people.

■ Before operating the machine, always verify that all protective devices are
effective.

2.7 Safety signs

If safety signs are not visible or legible, this poses a danger to people.

■ Replace safety signs that are not visible or legible.

■ Do not remove or cover up safety signs.

2.8 Safe work environment

2.8.1 Slipping and stumbling hazard
Slipping and stumbling hazards can result in serious accidents.

■ Always keep walkways, grips, steps, railings, platforms and ladders free of
grease, oil, and other dirt.
■ Never climb or walk on the machine and do not use it for storage. Use the
provided steps and platforms only.
■ Wear non-skid safety shoes.

2.8.2 Aspiration
Gases and dust are health hazards and can lead to dangerous situations when the
machine is in operation.

■ Always leave ventilation units running when the machine is in operation and do
not remove them.

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
Chapter 2 Safety 7
 3 Parts needed

3.1 Mechanics conversion

Item Part No. C Designation Number

01 DFML-11964-001 Inflatable side seal 2
02 DFML-11965-001 Filler plate 2
03 DFML-12192-001 Filler plate 0.5 mm 4
04 UXB -26002-014 PERMABOND sealing compound 2

3.2 Pneumatics conversion

Item Part No. C Designation Number

01 UXR -56207-062 Pneumatic hose D6, length 0.3 m 2
02 UNR -56207-014 Pneumatic hose D10, length 10 m 1
03 UXS -16014-027 GOK pressure regulator 1.0 bar 1
04 UNS -39110-041 Pressure switch 0.2 to 2.0 bar 1
05 UNN -24037-009 Screw-in connector G¼" D10 5
06 UNN -24037-244 Plug-in connector T D10 4
07 UNN -24037-289 Reducer D10 D6 2
08 UNN -24037-204 Plug-in connector D10 2
09 UNS -16245-032 Roller lever valve G¼“ 1
10 DFML-12253-001 Holder to limit switch/valve 1
11 UNN -10008-064 Hexagon head screw M4x40 2
12 UNN -12016-002 Locknut M4 2
13 UNN -14000-090 Washer 2
14 UNS -53003-003 Silencer 1

3.3 Electrical system conversion

Item Part No. C Designation Number

2
01 UNE -30100-053 Electric cable 3x1 mm , length 10 m 1
02 UNE -32201-101 Clamp (344, 345, 346) 2
03 UNE -32202-511 Ground terminal 1
04 UNE -32206-011 Closing plate 1

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
8 Chapter 3 Parts needed
4 Conversion

4.1 Preparing the installation location

■ Space requirements, floor openings, bearing surfaces and floor loads are in
accordance with separate planning documents.
■ Block the assembly area from unauthorized access.
■ Secure the surrounding area, e.g. remove any items that could cause someone
to stumble etc.
■ Allow sufficient clearance for performing installation and set-up tasks.

4.2 Converting the mechanics

1. Open the gate and remove the covers of the consoles.
2. Remove the screws (2) and cover plate (1).

Fig. 4.1

3. Remove the seal (3) and filler plate (4).

Fig. 4.2

4. Install a new seal with filler plate. Lay the filler plate (5) with the beveled
edge (A) on the seal holder (6).

IMPORTANT
Do not damage the plug of the sealing profile (B).

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
Chapter 4 Conversion 9
 Fig. 4.3

IMPORTANT
Inspect the seals without using compressed air.

5. Align the seal:

Clean the sealing profile using a rag and open and close the gates 3 to 4 times.
6. Check the seal for wear points.
□ The seal is allowed to rub against the gates only slightly.
□ Use a 0.5 mm filler plate to shim where the seal rubs against the gates too
much.
7. Drill a ø14 mm through-hole (7) in the stand above the reinforcement plate for
the compressed air connection.
□ Drill the through-hole at the same height as the separation connection so
that you can insert the pneumatic hose through the stand without any
bends.
□ Drill the through-hole on the left or right as needed.

Fig. 4.4

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
10 Chapter 4 Conversion
 IMPORTANT
Do not drill the sealing profile.

8. Drill the sealing profile at the designated spot (C) using a ø3 mm drill.

Fig. 4.5

9. Screw in the separation union (8) through the aluminum profile until it is
centered in the sealing profile.

Fig. 4.6

10. Seal: Pull the silicon hose D 16 over the separation union and pneumatic hose
and insert it in the stand through the ø14 mm through-hole.
11. Use a sealing compound to seal the cover plate facing the stand and seal
holder.
12. Screw the cover plate into place.
13. Install the covers of the consoles and close the gate.

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
Chapter 4 Conversion 11
 4.3 Converting the pneumatics
1. Connect the separation connections of the seals using a pneumatic hose D6
(L = 20 cm).
2. Connect the other end of the pneumatic hose D6 to the pneumatic hose D10
using a reducer and a plug-in connector.
3. Disconnect the pneumatic hose at the locking cylinder (close position) and
install a T-piece.
4. Attach the GOK pressure regulator to D10 with 2 screw-in connectors G¼".
5. Install a T-piece at the connection to the pressure regulator.
□ On one side of the T-piece, install the pressure switch with angle swivel
union.
□ Install additional T-piece on opposite side.
6. Install roller lever valve (1).

Fig. 4.7

7. At the roller lever valve install a silencer and 2 screw-in connectors G¼“.

Fig. 4.8

8. On the other side, distribute the pneumatic hose D10 on both side seals using a
T-piece.
9. Make sure that the roller lever valve is actuated when the locking cylinder is
closed.
□ Side seals are inflated.

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
12 Chapter 4 Conversion
Fig. 4.9 Pneumatics conversion

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
Chapter 4 Conversion 13
 4.4 Converting the electrical system
1. Integrate the pressure controller (D) into the terminal box according to the wiring
diagram.
2. Accept the signal into the installation control system.

Fig. 4.10

Legend for Fig. 4.11

Item Description
01 EMERGENCY STOP: Supplied by the customer in accordance
with locally applicable codes and regulations
1 Hinge switch, lock-out device (first access door)
2 Safety switch, safety device for openings (first access door)
1A Hinge switch (second access door)
2A Safety switch, safety device for openings (second access door)
S3 Limit switch, operator’s side gate open
S4 Limit switch, back side gate open
S5 Limit switch, operator’s side gate closed
S6 Limit switch, back side gate closed
S1 Limit switch, interlock system of left side, gates unlocked
S2 Limit switch, interlock system of right side, gates unlocked
S7 Limit switch, interlock system of left side, gates locked
S8 Limit switch, interlock system of right side, gates locked
D Pressure controller, side seal inflatable
Y4 Compressed air supply
Y1a Solenoid valve, opening gates
Y1b Solenoid valve, closing gates
Y2 Solenoid valve, unlocking gates
02 Motor temperature monitor (posistor)

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
14 Chapter 4 Conversion
Fig. 4.11

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
Chapter 4 Conversion 15
 5 Decommissioning

5.1 Removing
When decommissioning the machine (for overhaul, dismantling or disposal
purposes), disassemble it by following the installation steps in reverse order.

■ Before beginning the disassembly work, the person in charge must obtain the
instructions for safe disassembly from the manufacturer.
■ The machine may be disassembled only in observance of all accident
prevention measures and only by trained personnel. These personnel must be
familiar with all relevant safety precautions.

5.2 Disposal

Dispose of the machine and its components in accordance with your locally appli-
cable codes and regulations.
■ Sort and dispose of metal parts by type of metal.
■ Dispose of electric motors properly.
■ Dispose of electronic parts properly.
■ Dispose of plastic pieces properly.

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
16 Chapter 5 Decommissioning
6 Spare parts

6.1 Ordering spare parts

Stocking a supply of spare and wear parts is an important prerequisite for the
machine to remain up and running. Always use original spare parts as listed in the
Spare parts catalog. Spare parts from third-party providers can have an adverse
affect on the operating behavior of the machine and on safety.

6.2 Ordering instructions

Incomplete information in spare parts orders can result in incorrect deliveries.

An order for spare parts must include the following information:

■ Machine number
■ Subassembly number or ordering code number
■ Designation
■ Quantity
■ Motors: Manufacturer and motor number
■ Gears: Manufacturer and gear number

In cases of uncertainty, please send a dimensioned drawing and a description.

6.3 Spare parts identification

Code [C] Meaning

V1 Wear part
■ Parts that wear during normal operation.
■ Parts that have to be replaced one or more times within a year.
E1 Very critical spare part
■ Parts that can cause the entire machine to fail if they fail or
become defective.
■ Parts that are safety-related.
E2 Problematic spare part
■ Parts that can greatly limit the functionality of the machine if they
fail or become defective.
■ The machine may continue to be operated for a short time.
E3 Normal spare part
■ Parts that can slightly limit the functionality of the machine if they
fail or become defective.
■ The machine may continue to be operated for a longer time.

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
Chapter 6 Spare parts 17
 6.4 Spare parts lists
6.4.1 DFML-11964-001 Inflatable side seal

Fig. 6.1

Item Part No. C Designation Number

01 DFML-11960-001 E1 Sealing holder 1
02 DFML-11961-001 E1 C-profile 1
03 DFML-11963-001 V1 Profiled seal 1
05 UNN -24045-153 E3 Separation union 1
06 UNN -16018-013 Blind rivet AL MG 3 D 4x12 7
07 UNN -10503-022 Tension plate bolt D 3.5x12 2
08 UXR -56646-009 Silicon hose D 16/12x300 mm 1

Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
18 Chapter 6 Spare parts
 Bühler AG
Inflatable side seal DFML-67197-1-1-en_US-1311
Chapter 6 Spare parts 19
Bühler AG
CH-9240 Uzwil, Schweiz
Telefon +41 71 955 11 11
Telefax +41 71 955 33 79
www.buhlergroup.com