USER GUIDE

EKNIcalde
Tecnología en calderería
 WARNING

IMPORTANT RECOMENDATION FOR EXTRACTOR

MAINTENANCE

 We recommend that in the first weeks of the extractor

operation the chain tightness is checked every 15
days. This procedure is explained i our instruction
manual in the section “front assembly of the extractor”.

 The tightening operation requires very little time,

whereas the life span of the extractor is considerably
increased.

2
 EKNIcalde
Tecnología en calderería

TEKNICALDE S.L.
GUARANTEE CERTIFICATE

CERTIFICATE: Nr. 4.257

THAT THE EQUIPMENT WHOSE DETAILS ARE LISTED

BELOW MEETS THE QUALITY STANDARDS, TO CUSTOMER
REQUIREMENTS, FOR APPROVAL.

- MODEL: TR-2”-450

- DRAWING Nr.: IM1811280

- CAPACITY MAIN TANK (Litres): -

- MANUFACTURING / ORDER: 394279

- LEAK TIGHTNESS TESTED: Ok

- OPERATION AND SETTING

TESTED: Ok

APPROVAL QUALITY MANAGER

DATE: 02/09/19

3
 CONTROL SHEET DOC. 8.2.4/2
CHIP CONVEYOR
CLIENT: SERIAL Nr.: DRAWING Nr.: DATE:

ERLO 4.257 IM1811280 28-07-19

FEATURES OF MOTORS VOLTAGE: FREQUENCY:
THREE-PHASE 220/380V 50/60Hz
MOTOR TECNOTRANS POWER HP 0,5

L1 2.515 TYPE OF BELT CHARNELAS

L2 3.615 CONVEYING SPEED ~3 m / min
H 1.090 PAINT Ok
H1 180 RUNNING IN (minimum 24 h) Ok
B 554 LEAK CONTROL Ok
C 450

RUNNING TEST
Consumption motor Ok
Testing of pins Ok
Operation cooling pump -
Sealing Ok
Control of coolant flowing to pump compartment -

4
 EC DECLARATION OF CONFORMITY

José Ramón Araolaza, in capacity of Managing Director of

TEKNICALDE, S.L.
Apartado 103
Albitxuri ,16

Tfnos. (943) 74.74.00

Fax (943)74.74.13
20870 Elgoibar (Guipúzcoa)

Hereby states that the swart extractor

Type: TR-2”-450

Serial Number: 4.257

Manufacturing date: 2.019

Complies with the Safety Directive for machines 2006/42/CE and its
modiffications and additions.

The follow norms have been taken into account during desing and construction:

UNE-EN ISO 13850:2016

UNE-EN 60204-1:2007

UNE-EN ISO 12100:2012

UNE EN ISO 14120:2016

Elgoibar, 02/09/19

Fdo .: Alejandro Sotés

5
 USER GUIDE

MODEL TR-2”-450

SERIAL NUMBER 4.257

MANUFACTURING YEAR 2.019

POWER 0,5 CV

VOLTAGE 220/380 V

FREQUENCY 50 / 60 Hz

6
 GENERAL NORMS

For safety reasons as well as to obtain a correct machine operation, the

following recommendation should be read carefully:

 Read this manual befare machine instauation.

 Check that the machine dimensions correspond with its new siting,
before proceeding to its installation.

 The electrical connection should be performed as described in the

chapter INSTALLATION.

 Check that all machine functions are in working order before proceeding
to its definite start-up.

 lts use should be conform with the technical features for which it was
meant.

 Keep away from the moving parts of the machine and keep a safe
distance in general from the machine. Make sure access to the machine
is made easy for maintenance and repair operations.

 Do not remove any mechanical safety component.

 Do not remove electrical safety components, nor modify their operation.

 Do not leave tools, devices or any other object on the moving chain, or
places near to avoid anything falling on top of it..

 Only authorised and speciahised staff has access to the electrical

zone.

 It is stricthy prohibited to use air pressure on or near the machine as

this might lead to chain failure due to swarf accumuhation ion the rotating
guides.

7
 TABLE OF CONTENTS

General information

1. MACHINE DESCRIPTION
1.1 ARCHITECTURE
1.2 FUNCTIONS. USES TO WHICH THE MACHINE IS PUT
1.3 TECHNICAL FEATURES

2. INSTALLATION
2.1 LOADING AND UNLOADING
2.2 INSTALLATION
2.3 SAFETY DISTANCE
2.4 ELECTRIC CONNECTION
2.5 CONTROL OF OPERATION

3. OPERATION
3.1 OPERATION DIAGRAM
3.2 CONTROL PANEL
3.3 INTEGRATION WITH THE MACHINE INTERFACE

4. MAINTENANCE
4.1 LUBRICATION
4.2 CLEANING

5. SAFETY
5.1 SAFETY MEASURES

6. ASSEMBLY DRAWINGS. COMPONENTS

8
1. MACHINE DESCRIPTION

9
1.1 ARCHITECTURE

It concerns a “continuous swarf extraction” system which can be adapted

to “metal cutting” machines or a group of machines, which is generally called a
Chip conveyor.

Basically it is made up of the following:

 a platework housing fitted with slides for the sliding of

 a sprocket chain of meshing hinges at the end of the housing on two

rotating
pinions, of which one is driven by a

 a motor-reducer, which provides the chain with a continuous movement

as
is the case with an endless belt.

The extractor can be defined in two zones:

 Swarf collection point. The housing with its open top leaves the chain
uncovered so that the swarf falls directly on the chain.

 Swarf discharge point. At this point with usually an upward ramp, the
housing covers the chain. It is the endmost point where the driving wheel
is connected to the motor-reducer, and where the swarf is discharged by
inversion of the position of the chain. The purpose of the higher
discharge position with respect to the loading position of the swarf is to
facilitate the separation of the coolant from swarf.

The housing has two outlets at the bottom for the coolant which is returned
to the coolant tank of the machine.

Optionally, the extractor is also available with a coolant tank and pump.

Nonetheless, the extractor has a sealed construction so that leaking of

coolant is impossible.
10
1.2 FUNCTIONS. USES TO WHICH THE MACHINE IS PUT

The function of the extractor is to extract swarf generated during the

machining process and dispose of it outside the machine.

With swarf is understood that it obtained through so-called metal stock

removal processes: cast iron, steel and its alloys, light metals (aluminium,
bronze, etc.). Regarding their size, they should be small shavings and never
exceed 400 mm. in length.

Therefore, using this extractor for non-metallic swarf generated by cutting of

wood, plastics, polycarbonates, resins, graphite, etc. is considered as incorrect
use.

As the following components used are articulated, neither the slideways,

nor the articulations themselves can be completely sealed off from the entry of
chippings. That is why the extractors have been designed with a swarf
collection surface and a displacement speed to be able to extract the maximum
volume of swarf produced by the machine. Therefore it is necessary that the
extractor is in continuous operation so that an accumulation of swarf on the
chain is avoided. The heaped up swarf on the machine should be manually
pushed at regular intervals towards the extractor.

It is considered incorrect use to have the extractor stopped and wait for it to
fill up with swarf befare switching it on.

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 1.3 TECHNICAL FEATURES

GENERAL FEATURES

Motor power (CV) 0,5

Reduction ratio 1/15
Driving torque (Nm)
Chain displacement speed (m/min)

HOUSING

Thickness chain protection plate (1)1 (mm) 2

Thickness housing plate (mm) 3
Dimensions sliding guides (mm) 48x8
Dimensions separator tube (mm) Ø60x3
Dimensions separator rim (mm) 50x10

CHAIN

Type of hinge TC-2”

Pitch (mm) 50.8
Shaft diameter (mm) Ø12.5
Sliding wheels diameter (mm) Ø32

TRANSMISSION

Driving gear
Pitch (mm) 50.8
Number of teeth 8
Rear gears
Pitch (mm) 50.8
Number of teeth 8
Bearings 6002Z
Transmission shaft diameter (mm) Ø35
Transmission shaft bearing UCP-207

COOLANT TANK

Motor pump
Power (Kw)
Flow (l/min)
Tank contents (l)

WEIGHT

Net weight (kg)

1) Numbers in parenthesis correspond to the numbered references of the

dimension drawing.
12
2. INSTALLATION

13
2.1 LOADING AND UNLOADING

The machine can be provided with or without packing. In either case, the
maximum admissible load of the lifting devices, cables or chains used for
machine handling must exceed the maximum weight of the machine.

SAFETY DURING TRANSPORT

Not complying with the following safety norms may result in

personal harm or in damage to the machine.

 There should never be any people positioned under the load!

 Lift the machine smoothly, avoiding any abrupt movements.

 If the machine is going to be transported by truck, fasten it securely to

the loading surface.

 Use lifting devices with a lifting force exceeding the machine weigh.

14
  When lifting the machine, hook the cables to the for that purpose
provided lifting components in such a way that the machine is well
balanced.

2.2 INSTALLATION

Once the extractor is installed in its correct position, set the height of it
by means of the setting bolts of the supporting legs until the loading area of the
chain is in horizontal position and rested on the machine structure.

2.3 SAFETY DISTANCE

The part of the extractor that extends from the machine (ramp and
unloading part), the user should provide an area free of any obstacles of at least
50 cm. so that any maintenance operations or repairs may be carried out
without any major problems, and a free access is created to the emergency
stop and the control panel.

2.4 ELECTRIC CONNECTION

If the extractor is not fitted with a control box, its operation should be
integrated with that of the machine, in which case it will be necessary to connect
the driving motor and, if fitted, the coolant pump motor.

In case the extractor is fitted with a control box for its independent
operation, link it to the mains with a three-phase + earth connection. Power
supply: 380V - 50 Hz (refer to 4.2 electric diagram).

To check the correct order of the phases proceed as follows: press the
push-button ON, and check whether at the loading area the chain moves
towards the unloading area of the extractor. If this is not the case, reverse the
phases.

2.5 CONTROL OF OPERATION

If the extractor is not fitted with its own control panel, check the correct
performance of all operations (refer to 3.1 Operation diagram), before initial use.

15
3. OPERATION

16
3.1 OPERATION DIAGRAM

For an efficient performance of the operation, as well as to guarantee an

extended life span and durable reliability, the extractor should be in continuous
operation (in ON position) at the same time as the machine itself. The red push-
button (mushroom type) stops the machine, and serves at the same time as an
“emergency stop”. When pressed alI operations of the extractor are cancelled.
This push-button has an interlocking system, so that it is necessary to slightly
rotate it to “unlock” it to initiate all extractor operations once again.

When problems with the swarf extraction arise, either because of

clogging up due to accumulation of swarf, or because of swarf particles present
on the slideways, this can be solved by means of the INVERSION function,
which inverses the chain movement so that the problem can easily be solved.
The chain should be stopped before being able to perform the INVERSION
function.

It the extractor is fitted with a coolant tank and motor pump, it is

recommended lo integrate the start button on the control panel of the machine
as its operation is dependent on the production process of the machine and not
with the operation of the extractor. However, it you wish to fit the starting button
on the control panel of the extractor, its operation is independent from the
extractor operation and can only be cancelled when the “emergency stop”
push-button is pressed.

3.2 CONTROL PANEL

If extractors are fitted with a control panel it is made up of the following

controls:

PM IN SERVICE push-button. It starts the chain to extract swarf and

discharge it.

PI INVERSION push-button of chain movement

 use only when strictly necessary, in case of clogging
of chain, and with small movements!!!

PP Stop push-button for both ON and INVERSION functions. At the

same time it serves as the EMERGENCY STOP.

17
 H1 Backlit push-button of TEMPERATURE FAILURE MOTOR

3.3 INTEGRATION WITH THE MACHINE INTERFACE

If the extractor is supplied without a control panel, then it is the user’s or

the machine manufacturer’s duty to provide the aboye mentioned item.

We suggest an operation mode as described above should be

anticipated as a minimum.

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4. MAINTENANCE

19
4.1 LUBRICATION

Driving shaft bearing Fui with 2 cm3 of lubricant, type XBCEA 2 ISO/TR
3498- 1986 yearly

Reducer Life-long lubrication

Bearings Life-long lubrication

4.2 CLEANING

Depending on use and accumuiated dirt, clean chain at regular intervals

in the following way: remove the protection of the discharge area, run the chain
and clean it with a brush.

Thoroughly clean the chain, the slides and the inside of the housing once
a year. The chain should be disassembled for this purpose:

 remove the protection from the ramp and the discharge area.

 slacken the driving shaft after having “marked” the correct tension
position.

 extract a union shaft chain link beyond the discharge area.

 switch on the chain and it will come out of the housing in its entire length.

 clean the chain, the slides and the inside of the housing.
Reassembly of the chain.

 insert several chain links in the discharge area by the upper slide.

 star the chain in INVERSION direction until the entire chain is inserted in
the slides.

 join the two links with their union shaft and fir the protections.

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5. SAFETY

21
5.1 SAFETY MEASURES
In accordance with the MACHINE DIRECTIVE 89/392/EEC, and its
amendments, and especially with the recommendations on safety specified in
the Appendix 1, during the design phase special attention has been paid to the
technical standards and specifications for the design specified in the UNE-EN
ISO 12100-1:2004 and UNE-EN ISO 12100-2:2004 norms, complying with all
generally considered technical rules, in such a way that the user does not run
any risk provided that the machine is handled in a correct manner.

 Transport, handling and installation

 The machine will be provided with suspension components with a

capacity far exceeding the weight of the machine.

 Do not position yourself nor any other person, below the load when its
suspended in the air!

 Use lifting devices (cranes, chains, etc.) with their maximum capacity
exceeding the machine weight.

 Before running the machine, make sure there are not any tools or
devices on the chain.

 t the part of the extractor outside the machine, the chain is protected
with firm safety guards. They can only be moved with the help of
tools.

 Operation

 Do not lean on the chain when it is in movement.

 The user should impede or obstruct access to the loading area,

depending on the machine type.

 The driving motor is fitted with a protection against overloading. If the

operation is integrated with that of the machine, this protection should
be prepared for.

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  The machine is provided with an “emergency stop” push-button.
Access to this should be unblocked.

 At the part of the extractor outside the machine, the chain is

protected with firm safety guards. They can only be moved with the
help of tools.

 Rotating components are protected with fixed safety guards.

 Maintenance, cleaning and repairs

Whenever possible, carry these operations out with the machine 0FF.

 When periodically cleaning the chain (refer to chapter 4), run machine
until links are uncovered and stop machine again. When one part is
cleaned start the machine again until another group of links remains
uncovered, stop machine again and proceed to cleaning; follow this
order until the entire chain is cleaned, making sure that during the
cleaning periods the machine is stopped.

 The use of safety gear, safety goggles, gloves, etc., is strongly

recommended because of the continuous presence of metallic
particles.

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6. ASSEMBLY DRAWINGS. COMPONENTS

24
FRONT ASSEMBLY EXTRACTOR

25
 FRONT ASSEMBLY EXTRACTOR

No. Nomenclature

1 Motor reducer

2 Bolt M-12x40

3 Nut M-12

4 Bolt M-12 x 100 (tensor)

5 Nut M-12

6 Bracket UCP-207

7 Bolt M-12x45

8 Nut M-12

9 Nut M-12

10 Bolt M-12 x 100 (tensor)

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COMPOSITION CHAIN AND REAR SHAFT ASSEMBLY

27
COMPOSITION CHAIN AND REAR SHAFT ASSEMBLY

No. Nomenclature

1 Fin Right/Left - 2”

2 Rear shaft tare

3 Chain shaft Ø12,5

4 Rear shaft Ø35

5 Spring washer l-62

6 Spring pin Ø4x20

7 Pinion 2” Z-8

8 Bracket-Rear shaft Ø35

9 Spring pin Ø6 x 50

10 Bearing 6.007- ZZ

11 Spring washer 1-62

12 Links - Pitch 2”

13 Revolving roller Ø32 x 16

14 Hinge - Pitch 2” Ø12

15 Extractor housing - 3 m/m thickness

28
FRONT PART ASSEMBLY EXTRACTOR

29
 FRONT PART ASSEMBLY EXTRACTOR

No. Nomenclature

1 Bracket UCP-207

2 Safety bolt bracket UCP

3 Retainer flange bracket UCP

4 External protection bracket UCP

5 Key 8 x 8 x 55

6 2’-Z8 pinion

7 Front shaft Ø35

8 Spring washers E -35

9 Key 8 x 8 x 100

10 Housing - Motor reducer

30