Manual type: User manual Date issued:

Machine Type：

ZC Number：

Project：

Contact: ANDRITZ Feed Technologies

Division: Machine documentation
Contact: ANDRITZ Feed Technologies
Division: Machine documentation
Machine responsible: Engineering
Glentevej 5-7
6705 Esbjerg, Denmark
Phone: +45 7216 0300
Fax: +45 7216 0301
www.andritz.com
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PCF COOLERS
MANUAL

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PCF COOLER PAGE 2
OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

INDEX

Description Page No

General Instructions 3

Introduction 4

Safety Instructions 5-8

Operating Principle 9

Residence Time 9-11

Operation Sequence 12-13

Product Bed Depth 13

Reciprocating Table Stroke Setting 14-17

Weights / Lifting 18

Electrical 19-20

Maintenance 21-23

- Lubrication 21
- Start-Up Checks 22
- Maintenance (Conditioned) 23

Trouble Shooting 24

Final Observations 25

Movable Rotating Sensors 26

Fire Damper and Thermostat (option) 27

Rotary Distributor (option) 28-31

Level Rake(option) 32-34

Electrical Diagram and Drawing

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

GENERAL INSTRUCTIONS

These installation, operating and maintenance instructions are for use by competent
personnel responsible for the operation and control of machines and plant.

It is of vital importance that these instructions are handed to these persons.

Erection and Installation:

Erection and installation of Andritz Feed and Biofuel machines and spare parts must be executed
only by persons skilled for this task. Persons charged with operation of the machines should be
made familiar with all instructions and directions before commencing operation.

Safety Instructions and Rules:

Observance of the safety instructions and directions contained in these operating instructions will
prevent accidents. They should be read thoroughly and strictly followed.

Cleaning and Maintenance:

Adequate cleaning and maintenance are essential to preserve the good condition and ensure an
extended working life of your machines and plant.

Cleaning and maintenance are only to be executed by competent, qualified personnel familiar with
the detailed instructions supplied with the machines.

Guarantee:

Any negligence or failure to observe the operating, maintenance and safety instructions could result
in accidents and / or damage to the machines and equipment. Any such accidents are not covered
by normal guarantee and the supplier cannot be held responsible for them.

Andritz Feed and Biofuel reserve the right to modify machines or equipment in conformity
with our policy
of continuous innovation and improvement.

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

INTRODUCTION

The Andritz Feed and Biofuel range of Counterflow Coolers are designed primarily for the cooling
of animal feedstuffs. However, they are also well suited for applications within other industries.

Andritz Feed and Biofuel are always pleased to consider and advise upon their application.

The AFB Counterflow Cooler is of robust and compact construction, with mild steel sides and
discharge grid.

Counterflow Cooler top is manufactured from Cromweld 3CR12 stainless steel as is the inlet
airlock. Bottom discharge hopper is manufactured from mild steel.

As an option, the Counterflow Cooler can be supplied manufactured in stainless steel throughout or
other materials to suit the application.

Please consult AFB Sales Office for details.

Before installing and operating the Counterflow Cooler it is recommended that the operating and
maintenance manual is read so that the principles of operation are clearly understood.

AFB COUNTERFLOW COOLERS, WHEN CORRECTLY INSTALLED AND

MAINTAINED, WILL GIVE MANY YEARS OF TROUBLE FREE OPERATION AND
SERVICE.

AFB RECOMMEND THAT REGULAR SERVICE VISITS BY THEIR SERVICE

ENGINEERS WILL ASSIST IN ACHIEVING TROUBLE FREE OPERATION. SERVICE
CONTRACTS MAY BE NEGOTIATED, PLEASE CONTACT US ON:-

TEL: (44) 1482 825119 FAX: (44) 1482 839806

SHOULD YOU HAVE ANY QUESTIONS NOT ANSWERED BY THIS MANUAL, OR

WISH TO DISCUSS ANY OPERATIONAL PROBLEMS, PLEASE DO NOT HESITATE
TO CONTACT US, WE ARE ONLY TO PLEASED TO HELP.

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

SAFETY INSTRUCTIONS

The PCF Counterflow Cooler is a very safe machine is operated and maintained with proper care.
Keeping the machine in its good and safe condition is the User’s responsibility.

The PCF Counterflow Cooler is a machine fitted with rotating parts and in which high temperatures
will occur. Operation, maintenance, cleaning, servicing and similar work on the Cooler is to be
done exclusively by experienced and competent personnel.

Never allow any incompetent person to work at the machine !

ELECTRICAL SYSTEM

AFTER WIRING UP, CHECK PERFORMANCE OF ALL

MICROSWITCHES.

For the electrical interlock connections see the circuit diagrams supplied with the machine.

Electrical interlock connections of AFB Counterflow Coolers should be made as per AFB’s
instructions.

AFB cannot accept any responsibility for failures or consequences caused by electrical connections
which differ from AFB’s instructions.

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
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SAFETY INSTRUCTIONS(cont’d)

1. Before any maintenance and operation the following section should be read and understood by
all personnel responsible for its operation.

2. Safety devices fitted to the Counterflow Cooler must never be tampered with or isolated or by-
passed or removed.

3. Safety devices fitted to the Counterflow Cooler should be checked on a weekly basis and
records maintained.

4. Safety signs shown on Pages 3, 4 and 5 are displayed on the Counterflow Cooler and must not
be removed. Should during operation after a period of time they become damaged, they should
be replaced.

5. Unless air system checks are being conducted, isolate and lock-off all electrical supplies before
maintenance work is commenced. If the Counterflow Cooler system fails, the cause must be
identified and the system made safe before maintenance continues.

6. Isolate and lock-off all electrical supplies before opening the inspection door. Should the
Counterflow Cooler control system be linked to a computer controlled or similar automatic start
up or running system, the start up system should be run to prove isolation.

7. The Counterflow Cooler must not in any way be altered adjusted or modified other than
described in this manual or with AFB written approval.

8. Inspection and maintenance must only be carried out by competent persons appointed by the
user.

9. All local and national regulations, including those on labour and safety, must be observed at all
times.

10. All operators must have had sufficient training to ensure that they can manage any situation that
may arise during the operation and maintenance of the Counterflow Cooler.

11. If any personnel detects an irregularity or does not agree with the safety measures taken the
owner and site safety representative must be informed.

12. The workplace must be kept clear of obstructions.

13. Adequate safety measures must be taken to prevent explosion hazard.

14. Do not remove any guards whilst the Counterflow Cooler is in operation.

15. Do not tamper with the hydraulic power pack.

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
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SAFETY INSTRUCTIONS (cont’d)

16. Do not clean motors with flamable products.

17. Isolate and lock-off all electrical supplies before removing any guard. Should the Counterlow
Cooler control system be linked to a computer controlled, or similar, automatic start up or
running system, the start up system should be run to prove isolation.

It the Counterflow Cooler system fails, the cause must be identified and the system made
safe before maintenace continues.

18. Do not operate the Counterflow Cooler with any guard removed.

19. Do not operate the Counterflow Cooler with a damaged guard.

20. Always wear the appropriate protective equipment, if in doubt check with the plant supervisor.

21. Any dust leaks must be repaired immediately.

SAFETY WARNINGS

WARNING !

Hazardous voltage and moving parts can

cause severe injury or death. Turn off power
and lock out before servicing.

WARNING !
Discharge grid moves without warning and
can cause severe injury – keep hands away
when in operation !

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PCF COUNTERFLOW COOLER – SINGLE DECK

SAFETY WARNINGS (cont’d)

WARNING !
Moving parts can cause severe injury.
Lock out power before entering !

WARNING !
Dust hazard can injure lungs – wear mask.
Turn off to remove exhaust vent !

WARNING !
Rotating parts can cause severe injury!
Lock out power before inspecting !

WARNING !
Avalanche hazard.
Do not open when loaded !

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

OPERATING PRINCIPLE

INTRODUCTION

As the machine title states, it operates on a true counterflow principle. In this application the flow of
product opposes the flow direction of the cooling media. This has a number of advantages, the main
ones being detailed below :

1. As the cooling air is drawn through the product bed it contacts the cooler product first and
warms as it progresses through the product bed. Due to this action there is an even temperature
gradient across the product bed; thus also aiding the heat transfer characteristics. Therefore, hot
product is contacted by warm air thus minimising temperature shock and possible subsequent
product degredation.

2. Discharge only starts once a pre-determined product bed depth is reached. This depth is variable
to suit the product being cooled. Thus, by altering the position of the working level probe
different products may be cooled with the minimum of production downtime. Note that
multiple sensors may be fitted, their selection being via the associated control system.

3. Maintenance is reduced due to the few moving parts.

RESIDENCE TIME

The residence time required for a product in the cooler is influenced by the following factors:-

- quality of product being cooled;

- temperature of product being cooled;
- size of the product being cooled;
- ambient cooling air temperature;
- ambient air humidity;
- moisture level of the product being cooled.

For thorough cooling, the product must cool throughout its section. If it does not, there is a
possibility of the retained heat generating moisture through condensation in product storage.
Moisture thus generated can cause bacteria and mould growth and may inhibit product discharge
from storage bins.

Because of these factors product being discharged from the Counterflow Cooler should be regularly
checked and the residence time altered as appropriate.

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

RESIDENCE TIME (cont’d)

Cooled temperature based on 5 degrees Celsius (41 degrees Fahrenheit) above ambient.
Cooling capacity based on 4 to 7.2mm (5/32" to 9/32") of density 0.64kg/dm3 (40lb/cubic foot).
Residence time is 15 minutes for normal selection purposes for the section size stated. For pellets
of greater diameter or alternative product sections a different residence time may be required.

IF IN DOUBT PLEASE CONSULT UNIVERSAL MILLING TECHNOLOGY

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

DETAIL OPERATION PRINCIPLE

The Counterflow Cooler consists of a steel bunker (B) into which is fed the product to be cooled.
Product is fed into the bunker through an airlock (A) mounted on the top cover. Product entering
the bunker (B) is evenly spread across the reciprocating table (L) through contact with the spreader
(F). As the bunker (B) fills, the product bed depth will gradually increase until it reaches the
working level probe. This probe may be a capacitance probe or Roto-Bin-Dicator subject to the
contract.

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

OPERATION SEQUENCE

1. With the selection switch set to auto and table in the closed position, the bunker fills until the
working level probe is reached. This actions the discharge cycle for a period of time which is set
by timer TR3.

2. The table (L) starts the discharge mode.

3. The cylinder (K) out-strokes until it makes the open position switch PS2, (or PS3 depending on
product size).

4. Once made switch PS2 (or PS3) returns the cylinder to the closed position where it remains for
a dwell period which is set by timer TR1.

Timer TR1 is adjustable in the range 1.5 and 30 seconds, which is determined by the discharge
rate required by the product being cooled.

5. The reciprocation of the bed continues with the TR1 dwell until the discharge cycle is complete
i.e. as set by TR3 and the bed returns to it's closed position.

6. The bunker continues to fill until the working level is reached and the discharge cycle repeats.

NOTE:

If the bunker continues to fill above the working level probe, a high level probe is reached
which activates an alarm.

Auto Dwell Timer TR1 is adjustable in the range of 1.5 and 30 seconds
Auto Discharge Timer TR3 is adjustable in the range of 10 and 200 seconds
Empty Timer TR2 is adjustable in the range of 1.5 and 30 seconds

By adjusting the timer TR1 the discharge capacity may be changed, typically as follows:-

- 1.5 sec. - high capacity discharge (i.e. more strokes of reciprocating table in a given time period)

- 30 sec. - low capacity discharge (i.e. less strokes of reciprocating table in a given time period)

The second timer, TR3, allows discharge to continue after the working level probe has been cleared.
Once set this timer prevents the frequent interruption of operation due to the discharge operating for
a pre-determined time.

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PCF COUNTERFLOW COOLER – SINGLE DECK

DETAIL OPERATION PRINCIPLE (cont’d)

To one side of the bunker (B) is a flanged opening to accept the ductwork for the fan. The cooling
air is drawn through the baffles (M) and up through the product.

Where the fan ductwork is attached to the Counterflow Cooler a damper flap is fitted which may be
adjusted as required to alter the air flow through the product bed.

The principle previously described continues automatically until the flow of warm product ceases.
At this point the control switch on panel needs to be changed from auto to empty. The cycle will
continue without the delay of product reaching the working level probe, the discharge rate being
governed by timer TR2, rather than TR1 as is the case on Auto. This is so that the empty cycle can
be carried out at a slower rate if required.

When the product has been discharged there will still be some left on the reciprocating table. This is
overcome by pressing the clean-out button which effects one full stroke of the reciprocating table.

The clean-out button has to be manually operated.

PRODUCT BED DEPTH

As previously noted, the product bed depth is controlled by a working level probe which, subject to
contract, may be either a capacitance probe or Roto-Bin-Dicator.

When fitted with a capacitance probe adjustment is straight forward as follows:-

- Loosen the screw securing the lower capacitance probe bracket then slide the probe to the
desired position. Tighten the fixing.

When fitted with a Roto-Bin-Dicator it is necessary to enter the top bunker. Before entering ensure
that all safety procedures have been followed and that the electrical control system is fully isolated.

Once satisfied with safety arrangements proceed as follows :-

- At the end of the Roto-Bin-Dicator shaft is fitted an impeller shaped blade secured by two
clamping screws. Loosen the clamping screws and slide the blade to the desired position then
tighten the screws.

When fitted with Roto-Bin-Dicators it is recommended that at least two working level probes are
fitted so that downtime due to adjustment is minimised.

When setting the working level probe check that it is not above the high level warning probe.

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PCF COOLER PAGE 14
OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

HIGH LEVEL PROBE

As with the working level probes either capacitance or Roto-Bin-Dicators may be fitted.

The high level Roto-Bin-Dicator is pre-set and will only require minor adjustment. Before entering
the top bunker to adjust it ensure that all safety procedures have been followed and that the
electrical control system is fully isolated.

Once satisfied with safety arrangements proceed as follows :

- At the end of the Roto-Bin-Dicator shaft is fitted an impeller shaped blade secured by two
clamping screws. Loosen the clamping screws and slide the blade to the desired position then
tighten the screws.

When a capacitance probe is fitted as high level it should be adjusted to a height above the working
level probe to ensure material cannot back-up into the airlock.

Adjustment is straight forward as follows:-

- Loosen the screw securing the higher capacitance probe bracket then slide the probe to the
desired position. Tighten the fixing.

RECIPROCATING TABLE STROKE SETTING

Fitted inside the drive box unit ( item K, page 10 ) are the proximity sensors that control the
reciprocating table stroke. These are labelled PS1, PS2, PS3, PS4 and PS5.

Sensor 1 should be adjusted so that it operates when the reciprocating table is fully closed, i.e.
hydraulic cylinder fully retracted. See page 16 "A".

Sensor 4 should be adjusted so that it operates when the reciprocating table is fully open, i.e.
hydraulic cylinder fully extended. See page 16 "C".

Sensors 2 and 3 are adjustable to suit the product being cooled and control the extent of table
opening. See page 16 "B".

Adjustment of any sensor position is straight forward as each sensor is fitted to its own bracket. The
bracket is slotted to allow adjustment. To adjust, loosen the fixings on the relevant bracket, slide
bracket to its desired position then tighten the fixings.

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PCF COOLER PAGE 15
OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

RECIPROCATING TABLE STROKE SETTING (cont’d)

1. Supply Tank
2. Ball Valve
3. Strainer
4. Gear Pump
5. Bell Housing
6. Coupling
7. Motor
8. Bell Housing Gasket
9. Lid Gasket
10. Level Gauge
11. Breather
12. Manifold
13. Relief Valve
14. Solenoid Control Valve
15. Solenoid Control Valve
16. Hose
18. Cylinder Lower Deck
20. Gauge
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PCF COOLER PAGE 16
OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

RECIPROCATING TABLE STROKE SETTING (cont’d)

Sensor Function

PS1 Cylinder fully retracted - Lower Deck Closed

PS2 Product sensor (adjustable) - Lower Table Oscillates between PS1 & PS2
PS3 Product sensor (adjustable) - Lower Table Oscillates between PS1 & PS3
PS4 Product sensor (adjustable) - Lower Table Oscillates between PS1 & PS4
PS5 Cylinder fully outstroked - Lower Deck Cleaning Stroke

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

RECIPROCATING TABLE STROKE SETTING (cont’d)

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

TRANSPORT AND INSTALLATION

Before installation, read the safety instructions, Pages 4-7. Installation is straight forward and
should present no major problems proving the guidelines given below are followed.

MECHANICAL

The Counterflow Cooler should be fixed to a foundation designed to accept the weight of the unit
plus the maximum product holding capacity. This data is given in Table 1 below using a product
density of 0.63kg/dm3 (40lb/cubic foot).

WEIGHTS

Cooler Type Machine Weight (Empty) Loaded

Single Deck Single Deck
PCF 005 12.7 kN 25 kN
PCF 010 16.5 kN 41.5 kN
PCF 015 24 kN 61 kN
PCF 020 32 kN 80 kN
PCF 030 40 kN 100 kN
10 N (Newton) = 1 kgf

1. Weights include the rotary valve.

As there are few moving parts there are no dynamic loads to be considered.

2. Filled with pellets with a bulk density of 0.63 kg/dm3

3. Weights of exhaust fans, cyclones and centrifugal separators depend on their specific types.

LIFTING

When lifting the Counterflow Cooler it must only be lifted by the lifting
brackets fitted. The sling or chain used being in-line with the lifting bracket.
All lifting brackets must be used during a lift.

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PCF COOLER PAGE 19
OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

ELECTRICAL

The Counterflow Cooler can be supplied with a number of variants, with respect to installation for
the control system. Of these the two most common are:-

1. control panel
2. chassis mounted unit

- Both these variants are fully wired and tested on assembly prior to despatch.

- Should the customer elect to supply their own panel AFB. cannot accept responsibility for any
electrical faults that may occur in service.

- Fitted to the Counterflow Cooler are two junction boxes; one situated on the drive box unit
(item 15 page 14-01-a), the other adjacent to the door in the front panel of the top bunker
assembly.

- Inside each junction box is a diagram showing the connection points.

- Product level sensors are not wired to a junction box.

- Wiring should be carried out in accordance with the wiring diagram on the following page.

- The door safety switch must be wired into the Counterflow Cooler starting circuit such that in
the event of the door being opened the Counterflow Cooler stops operating immediately. There
is no alternative to this wiring.

- The working level probe should be wired into the control circuit as shown on the wiring
diagram on the following page.

- The high level probe should be wired in so that when activated the feed to the machine
producing the product to be cooled is stopped. Once the probe has cleared then feed may be
re-started.

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

ELECTRICAL WIRING DIAGRAM

BOTTOM COOLER
DISCHARGE GRID

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

MAINTENANCE

Adequate maintenance will help to keep the Cooler in good condition and reduce any failure
probability.

LUBRICATION

1. Hydraulic Power Pack and Reciprocating Table Hydraulics

Hydraulic power pack reservoir is filled to the correct level and with the correct grade of oil.
Before filling ensure that the top of the reservoir is clean and free from dust or any other product
that may contaminate the hydraulic oil.

After the first 100 hours running change oil. Repeat this afterwards every 2.500 hours running.

Recommended Oil: SHELL TELLUS OIL 37 Capacity: 11 litres

2. Airlock Gearbox

Airlock gearbox is filled to the correct level and with the correct grade of oil.

Oil level plug is situated on the side of the gearbox, approx mid-way up.

After the first 500 hours running (i.e. approx after the first 3 months) change oil in the geared
electric motor driving the rotary valve.

Repeat this afterwards every 10,000 hours running or at least every 2 years.

Recommended Oil: SHELL OMALA OIL 150 or an accepted equivalent.

3. Every 200 hours running (i.e. every month) clean thoroughly all rotation and hinging surfaces,
then grease or oil them.

Grease every 500 hours the bearing units with three shots from a grease gun.

Recommended Oil: SHELL ALVANIA (LF) GREASE R3 or equivalent.

}
PCF COOLER PAGE 22
OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

START-UP CHECKS

Before start up check the following points:-

a. Hydraulic power pack reservoir is filled to the correct level and with the correct grade of oil.
(see page 21)
b. Airlock gearbox is filled to the correct level and with the correct grade of oil and that the filler
breather has been fitted. (Page 21)
c. All safety systems are working correctly.
d. Top bunker has been checked for any tramp material and any found removed.
e. All flange connections have been completed.
f. Motors rotate in the correct direction as signified by the arrow on them.
g. Airlock is operating.
h. Cooling air fan is running.
i. Correct stroke has been selected for the product being cooled.
j. All fixings are tight.
k. Operatives have read and understood this manual.
l. Check for free movement of the reciprocating table by moving it by hand.

Once the above checks have been completed the Counterflow Cooler may be started without
product. Temperature of both motors should be checked as should that of the hydraulic cylinder,
power pack and hydraulic pipework.

Temperatures should not exceed 40 degrees Celcius.

Check for free movement of the reciprocating table, there should be very little rise in hydraulic
pressure.

Run the Counterflow Cooler for some 2 - 4 hours without product to ensure all components have
settled. Stop the Counterflow Cooler and check oil levels, temperatures and fixings for tightness.

The product spreader can be adjusted from outside of the top bunker. To adjust proceed as follows,
but note that two people working together will shorten the setting time.

Through the door in the front panel, the distribution of product entering the Counterflow Cooler
may be observed. From the outside of the Counterflow Cooler the product spreader rod can be seen
passing through a small boss.

On the outside of the boss is a locking screw which needs to be loosened. Once loosened the
product spreader can be moved. Move the adjustment rod until an even distribution of product is
obtained and then tighten the fixing screw and locknut.

}
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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

MAINTENANCE (CONDITIONED)

The Counterflow Cooler contains very few moving parts and therefore requires little maintenance.
However, attention to the following areas will assist in obtaining trouble free operation.

Airlock

This unit is of simple construction and consists of a vaned rotor, supported between two flanged
bearing units, fitted in a housing. The housing is flanged to fit the cooler and accept the spouting
from the machine producing the product to be cooled.

Airlock gearbox

The gearbox fitted to the Airlock is a SEW shaft mounted gearbox type FA40 DT80 K4 - 0.55 KW
at 24rpm. It is supplied pre-filled with the correct grade and quantity of lubricant.
(see Lubrication page 22-01-a)

CHECK OIL LEVEL PRIOR TO STARTING:

To ensure adequate cooling, deposits of dust, dirt and other contaminants must be removed at
frequent intervals. Particular attention should be given to the drive motor, ensuring that all deposits
are removed from between the cooling fins and at the motor fan grid.

Airlock Rotor Bearings

Bearings fitted are two off flanged bearing units, ref RHP-SF30. They should be greased every 500
hours of operation. (See lubrication page 22-01-a)

Reciprocating Table Hydraulics

The hydraulic power pack requires little maintenance other than regularly checking the oil level and
changing at periodic intervals. (See lubrication page 22-01-a).

To ensure adequate cooling, deposits of dust, dirt and other contaminants must be removed at
frequent intervals from both the powerpack and cylinder. Particular attention should be given to the
drive motor, ensuring that all deposits are removed from between the cooling fins and at the motor
fan grid.

}
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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

Level Probes and Reciprocating Table Position Sensors

These items require no running maintenance other than periodically cleaning the sensing faces of
dust, dirt or other contaminants.

Roto-Bin-Dicators should have periodically, dust, dirt or other contaminant removed from the
rotating shaft particularly where it emerges from the protective tube.

Reciprocating Table

Maintenance of this unit is confined to checking the condition of the rollers. They are grease filled
for life and therefore, require no further lubrication.

General

After the first 100 hours of operation all fixings should be checked for tightness and tightened as
required. Thereafter, they should be checked after every 10,000 hours of operation.

TROUBLE SHOOTING

TROUBLE SHOOTING:

Before commencing any trouble shooting read the safety instructions given
in this manual.

1. COUNTERFLOW COOLER WILL NOT START:

- Safety interlocks not made or malfunction

- Wiring faulty
- Blown fuses
- No power

2. PELLETS TOO WARM AT DISCHARGE:

- Air system malfunction

- Product bed depth too low
- Residence time too short

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PCF COUNTERFLOW COOLER – SINGLE DECK

3. PELLETS TOO COOL AT DISCHARGE:

- Air system malfunction

- Product bed depth too high
- Residence time too long

4. PELLETS NOT DISCHARGING CORRECTLY:

- Reciprocating table sensor position incorrect

- Reciprocating table sensor malfunction

5. RECIPROCATING TABLE NOT MOVING:

- Position sensor malfunction

- Power pack oil level low
- Power pack valve solenoid malfunction
- Reciprocating table jammed
- Electrical control system malfunction

TWO FINAL OBSERVATIONS

Whenever you perform any work on the cooler (e.g. cleaning, lubrication,
dismantling, re-assembly, etc) always switch off all drive motors.

Use only genuine AFB replacement parts. Failure to do so will invalidate

the warranty and could result in irreparable damage to your machine.
Similar looking parts from other sources may not be to the correct
specification.

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PCF COUNTERFLOW COOLER – SINGLE DECK

MOVABLE ROTATING SENSORS

As previously noted ,the product bed depth is controlled by a working level probe may be either a
capacitance probe or rotating level sensor. These rotating level sensors will be mounted on the top
panel of the cooler. For improvement, The two sensors now are mounted on two adjustable
panels . This makes the sensor more easy to be adjusted. Each panel is tightened on the side wall
of the cooler by four knobs. When loosing four knobs, the panel can be moved up and down to the
desire position and then tighten the knobs . Each adjustable panel (together with the rotating
sensor)can be moved in range of 350mm.

Now for the standard cooler we fitted with Rotary Paddle Level Switch RT20C-400
made by
Shanghai Zero Automatic Control Equipment Co. Ltd. See attached documentation
for more detail of the sensor.

Note: If the customer need other company products, Please contact our marketing
people .

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PCF COUNTERFLOW COOLER – SINGLE DECK

FIRE DAMPER AND THERMOSTAT (OPTION)

The coolers are fitted with fire damper and thermostat in the air outlet .See attached
picture, The air vale’s handle is connected with a cylinder mounted below the outlet
flange. When in operating status , the cylinder piston rod stroke=0 and the air vale will be
full open. In case of overheating or get fire , The thermostat mounted on the top of the
outlet will detect the higher temperature and trigger following action:
1. Generate alarm.
2. Stop the exhaust fan.
3. The cylinder piston rod will stick out and the air valve will be closed.
This will stop the supply of fresh oxygen and the fire will stop.

See attached documentation of valve: MFH-5-1/8-B

Solenoid: MSFG-230--50/60-OD
Cylinder: DNC-32-150-PPA
Limit Switch : XCKM115

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

ROTARY DISTRIBUTOR（ OPTION）

Rotary distributor is mounted on the bunker , Its function is to spread the pellets equably
and makes all pellets stay at as same level as possible in the bunker. Optimizes cooling
effect .

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OPERATING INSTRUCTIONS AND SERVICE MANUAL

PCF COUNTERFLOW COOLER – SINGLE DECK

How to mount the rotary distributor

There are holes and screws on both left sidewall and right sidewall, following step as:
1,Put the beam into the bunker and bolted ( not tight for all bolts)
2,Mount two top rotary plate on the beam.
3,Mount the drive motor bracket and then put on the coupling and the motor.(tighten
allbolts)
4, Put on the cover plate to cover the coupling.

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PCF COUNTERFLOW COOLER – SINGLE DECK

No motor end on left sidewall:

Motor end on right sidewall:

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

Adjusting the rotary distributor

Adjust the top rotary plates guidance angle and the gap between the two plates according
to different size pellet.

No good result:

Good result:

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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

LEVEL RAKE（ OPTION）

Level Rake is also a optional device mounted on the bunker , It has similar function as
the Rotary Distributor to make all pellets stay at as same level as possible in the bunker.
Optimizes cooling effect .

LUBRICATION
D - After the first 500 hours running ( i.e. after the first 3 months, approximately ),
change oil in the geared electric motor driving the rotary valve. Repeat this
afterwards every 10.000 hours running, or at least every 2 year.
Quantity for geared electric motor: Type RX57 dt 80, model M1: 0,6litre.
Recommended oil: MINERAL OIL: ( Shell Omala 220 )
( or an accepted equivalent)
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OPERATING INSTRUCTIONS AND SERVICE MANUAL
PCF COUNTERFLOW COOLER – SINGLE DECK

How to mount the Level Rake

It is the similar way as the Rotary Distributor to mount the Lever Rake.