Amendment 0002 - SCU Operators Manual.pdf

US ARMY JOINT

MUNITIONS COMMAND

AMMUNITION PECULIAR EQUIPMENT

OPERATIONAL MANUAL AND PARTS LIST FOR

APE 1408 SAFETY CERTIFICATION SYSTEM

FOR SMALL ARMS BRASS

JANUARY 2007

NOTICE

THIS SYSTEM IS A PIECE OF APPROVED AMMUNITION PECULIAR

EQUIPMENT (APE).

IT HAS BEEN THROUGH A THOROUGH RESEARCH, DEVELOPMENT, TESTING,

DOCUMENTATION AND APPROVAL PROCESS.

MODIFICATION OR IMPROPER USE IS UNAUTHORIZED AS PER AR 700-20

AND COULD RESULT IN DAMAGE TO THE SYSTEM AND/OR DEATH OR

INJURY TO PERSONNEL IN AND AROUND THE SYSTEM’S VICINITY.

REQUIREMENTS FOR MODIFICATION MUST BE APPROVED THROUGH

PROPER COMMAND CHANNELS PRIOR TO ANY ALTERATION IN THE

MACHINE OR ITS INTENDED USE.

OPERATIONAL MANUAL AND PARTS LIST FOR

APE 1408 SAFETY CERTIFICATION SYSTEM

FOR SMALL ARMS BRASS

PREPARED BY

AMMUNITION EQUIPMENT DIVISION

DIRECTORATE OF AMMUNITION, LOGISTICS AND ENGINEERING

TOOELE ARMY DEPOT

TOOELE, UTAH 84074

JANUARY 2007

THIS PAGE INTENTIONALLY LEFT BLANK

TABLE OF CONTENTS

PARA PAGE

Section I – INTRODUCTION

Purpose and Scope .........................................................................................1-1 1.1 Application........................................................................................................1-2 1.1 Reporting of Deficiencies..................................................................................1-3 1.2

Section II - DESCRIPTION AND DATA Description .......................................................................................................2-1 2.1 Tabulated Data.................................................................................................2-2 2.2

Section III - INSTALLATION AND OPERATION Receipt .............................................................................................................3-1 3.1 Installation ...................................................................................................... 3-2 3.1 Grounding.........................................................................................................3-3 3.1 Controls ............................................................................................................3-4 3.2 Pre-operating Procedures ................................................................................3-5 3.2 Operating Instructions .....................................................................................3-6 3.3 Operational Sequence......................................................................................3-7 3.4 Disassembly Operation ....................................................................................3-8 3.4

Section IV – MAINTENANCE Responsibilities and Intervals ...........................................................................4-1 4.1 Lubrication Locations........................................................................................4-2 4.4 Maintenance Records.......................................................................................4-3 4.4 Cleaning ...........................................................................................................4-4 4.4 Rust Removal ...................................................................................................4-5 4.4 Troubleshooting................................................................................................4-6 4.4

Section V - INSPECTION, STORAGE AND SHIPMENT Inspection .........................................................................................................5-1 5.1 Storage and Shipment......................................................................................5-2 5.1 i

TABLE OF CONTENTS (cont.)

PAGE

APPENDIX A –PARTS LIST............................................................................................................. A.1 APPENDIX B –ASSEMBLY DRAWINGS ......................................................................................... B.1 APPENDIX C - MANUFACTURER”S INSTRUCTIONS....................................................................C.1

LIST OF TABLES

Table 4-1 Preventive Maintenance Checks and Services ................................................................ 4.2 Table 4-2 Recommended Lubricants ............................................................................................... 4.4 Table 4-3 Troubleshooting................................................................................................................ 4.5

LIST OF ILLUSTRATIONS

Figure 1-1 – APE 1408 Overall Picture (Curbside Front) ................................................................. 1.1 Figure 2-1 – APE 1408 Safety Certification System Curbside View ................................................. 2.1 Figure 2-2 – APE 1408 Control Panel............................................................................................... 2.2 Figure 3-1 – Power Transfer Switch Box ......................................................................................... 3.1 Figure 3-2 – APE 1408 Control Area ............................................................................................... 3.3 Figure 3-3 - Rotation Sensor Location .............................................................................................. 3.3 ii

SAFETY SUMMARY SHEET

APE 1408 SAFETY CERTIFICATION SYSTEM FOR SMALL ARMS BRASS

1 General Safety Instructions.

This manual describes physical and chemical processes which may cause injury or death to personnel, or damage to equipment if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personal safety and protection of equipment. Prior to performing any task, the WARNINGs, CAUTIONs, and NOTEs included in that task shall be reviewed and understood.

2 Warnings, Cautions, and Notes WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance procedures, practices, conditions or statements which are considered essential to protection of personnel (WARNING) or equipment (CAUTION). WARNINGs and CAUTIONs immediately precede the step or procedure to which they apply. WARNINGs and CAUTIONs consist of four parts: heading (WARNING, CAUTION, or Icon for HAZARDOUS MATERIALs WARNINGS), a statement of the hazard, minimum precautions, and possible result if disregarded. NOTEs are used in this manual to highlight operating or maintenance procedures, practices, conditions or statements which are not essential to protection of personnel or equipment. NOTEs may precede or follow the step or procedure depending upon the information to be highlighted. The headings used and their definitions are as follows:

WARNING

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in injury to, or death of, personnel or long term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in damage to, or destruction of, equipment, or loss of mission effectiveness.

CAUTION

NOTE

Highlights an essential operating or maintenance procedure, practice, condition, or statement.

3. Machine Specific Safety Warnings

• Never operate this unit without first connecting it to an earth ground.

• The brass coming out of the out feed conveyor is extremely “HOT” handling of this brass is not recommended until it has completely cooled down.

• Prior to any servicing or troubleshooting adequate time should be allowed to let the unit cool down to prevent any burns to the operators or maintenance personnel.

• Do not operate the APE 1408 in an enclosed structure. Proper ventilation is required.

iii iv

Section I -INTRODUCTION

Figure 1-1 - APE 1408 Overall Picture (Curbside Front)

1-1 Purpose and Scope

This manual is intended for use by individuals assigned the responsibility for the installation, operation, and maintenance of the APE 1408 Safety Certification System for Small Arms Brass. It provides technical information for receipt, inspection, installation, operation, troubleshooting, shipping and limited storage.

1-2 Application

a. The provisions of this manual will be regarded as specific requirements, but will not be so construed as to prevent responsible individuals from prescribing additional or more detailed requirements as may be necessary to meet specific local problems or conditions.

b. Personnel assigned the responsibility for this equipment should have a basic knowledge of AMC-R 385-100 and/or AR 385-64. Information contained In this manual does not supersede any requirements of these publications.

c. Refer to the operation and maintenance procedures in this manual for precautions to be taken during operation of this equipment.

d. No attempt shall be made to operate and/or repair this equipment until the person performing the task becomes familiar with all publications pertaining to the equipment. This operational manual must be made available to the personnel responsible for operation and maintenance of the equipment.

1.1

1-3 Reporting of Deficiencies

a. Quality deficiency reports will be submitted as directed in AR 700-20. Comments on any deficiencies in equipment covered herein, and errors or omissions in this manual will be forwarded to:

Commander US Army Joint Munitions Command

ATTN: AMSJM-SND

Rock Island, IL 61299-6000

b. Comments regarding changes and/or corrections to this manual should be submitted on DA Form 2028 (Recommended Changes to Publications and Blank Forms) to the above address.

c. When safety is involved, one copy will be furnished to:

Commander US Army Joint Munitions Command

ATTN: AMSJM-SF

Rock Island, IL 61299-6000

1.2

Section II –DESCRIPTION AND DATA

Figure 2-1 - APE 1408 Safety Certification System Curbside View

2-1 Description

a. The APE 1408 Safety Certification System for Small Arms Brass (SCS) is designed to thermally certify that pre-inspected 5.56 mm through .50 caliber range residue brass is inert and/or free of energetics and certifiable for turning over to a DRMO or a qualified recycler.

b. After the range brass is inspected in accordance with the provisions outlined in DoD 4160.21-M, Section 4B3., the operator loads the range brass in the infeed conveyor hopper. The hopper meters the brass onto the infeed conveyor that deposits the brass through a feed chute into the rotating heating chamber agitator. The brass is heated by a propane burner as it feeds through the heating chamber agitator, reaching a temperature where any energetics that are not detected at the inspection process will activate. The heated brass falls onto the outfeed conveyor into residue yard container.

c. The SCS is made up of the following items (see Figure 2-1). The names are accompanied by a brief description of their function:

(1.) The Heating Chamber Agitator heats the brass, agitates the brass load and transfers the brass from the propane burner end to the outfeed end. It rotates at a constant feed and is heated at a constant rate.

(2.) The Infeed Conveyor has a hopper that meters the brass onto the conveyor into the Heating Chamber Agitator. The conveyor will run only after an initial Heating Chamber Agitator warm-up time and will continue to run if the heating chamber temperature is above a pre-determined temperature detected by a thermocouple in the discharge area.

(3.) The Outfeed Conveyor transfers the heated brass from the Heating Chamber Agitator into a residue yard provided receptacle.

(4.) The Trailer provides a transportation, leveling and stabilizing platform for the APE 1408 Safety Certification System.

2.1

(5.) The Burner Compartment houses the propane burner, regulators and valves. The burner system complies with the requirements of NFPA 86 “Standards for Ovens and Furnaces”.

(6.) The Control Panel has switches that control main power, agitator rotation, infeed and outfeed conveyor power, burner blower power and emergency stop. It contains a meter indicating the heating chamber temperature. A red light indicator shows if the timer has timed out without the heating chamber reaching prescribed temperature. The hour meter shows the total accumulated run time of the APE 1408.

(7.) The transfer switch allows the operator to determine if the unit will be operated using site supplied power or generator supplied power. The hour meter on the transfer switch shows the total generator run time and should be used for generator maintenance.

2-2 Tabulated Data Figure 2-2 APE 1408 Control Panel

a. Shipping weight: 7,500 pounds, approximately

b. Overall dimensions (Installed):

(1) Length 29’4” (8.9 meters)

(2) Width 8’3” (2514 mm)

(3) Height 8’4” (2540 mm)

c. Overall cube: 2016 cu. ft. (57.1 cu meter)

d. Occupied floor space: 242 square feet. (22.5 sq. meter)

e. Utility requirements:

Electrical -220 Volts AC single phase, four conductor wire rated at 30 amps minimum (optional).

Propane - 11 inches Water Column pressure (100-500 gallon tank) (380 – 1890 liters)

f. Production capacity: approx. 1000 pounds per hour, depending on size of round.

2.2

Section III –INSTALLATION AND OPERATION

3-1 Receipt

a. The machine will be shipped to the using installation as an open item. Upon receipt of the unit, it is the responsibility of the individual in charge to insure that the machine has been properly prepared to perform its intended function. For this purpose, the APE1408 should be inspected to insure that it is properly assembled, adjusted, lubricated and complete.

b. Visually inspect for any obvious signs of physical damage. Inspection should include but not be limited to:

(1.) External controls and plumbing for physical damage.

(2.) Serviceability and adjustment of all internal drive chains and belts.

(3.) The trailer should be inspected for any damage to the frame AND all equipment attached to it.

3-2 Installation

a. Locate unit where you plan to operate. The location should be as level as possible and located away from flammable materials. If required, explosive siting of the APE1408 should be performed by local Quality Assurance Specialist Ammo Surveillance (QASAS) personnel.

b. Chock trailer wheels to prevent movement.

c. Stabilize and level trailer with stabilizing jacks on the corners of the trailer.

d. If local line power is to be used, feed line power (220 VAC, 1 phase) into the transfer switch box (figure 3-1). Connect the line neutral to the third pole (N3). Connect L1 to N1 in the switch box, and L2 to N2. Connect ground wire to ground bus (see Figure 3-1). Make sure handle is in the “UP” position. Close and secure transfer switch cover.

GROUND BUS

e. Inspect for proper fluid levels in infeed and outfeed conveyor gear boxes and generator.

3-3 Grounding

Grounding of this machine is required and shall be done in accordance with AMC-R 385-100, chapter 7. A grounding point for the trailer is located at the front near the tongue.

3.1

3-4 Controls

a. A Propane on/off valve controls the flow of propane to the engine and burner for operation.

b. Additional controls for the APE 1408 consist of the following switches which are located on the control panel:

(1.) The Generator on/off key switch which is used for starting and stopping the engine.

(2.) The Power on/off key switch which acts as a power distribution system to the APE 1408’s subsystems. This switch should be in the OFF position during startup and shutdown of the generator.

(3.) The Outfeed conveyor on/off switch which controls movement of the outfeed conveyor.

(4.) The Agitator on/off switch which controls the retort (heating chamber rotation).

(5.) The Blower on/off switch which controls the ignition sequence for the burner.

(6.) The Infeed on/off switch which controls the infeed conveyor.

c. Two Emergency stop buttons are located on the certification unit:

(1.) The button located on the control panel is used for an immediate stopping of the entire unit.

(2.) The button located on the outfeed conveyor (curb side) is used for stopping the outfeed conveyor in case of jamming.

d. A power transfer switch is used to select electric power source with choices being the self-contained generator or commercial site-provided power.

3-5 Pre-operating Procedures

a. Check the oil level of the engine on the generator. Adjust as necessary.

b. Visually inspect ground wire to make certain that it is securely connected at the trailer and earth ground connections.

c. Place appropriately sized container under outfeed conveyor.

d. Open the power transfer switch box and select the appropriate power source. If operating on commercial line power, lever will be switched “UP”. If operating on the generator, lever will be switched

“DOWN”.

e. Turn propane on at tank connection. Turn gas valve on APE 1408 to the “ON” position.

3.2

3-6 Operating Instructions

a. Starting of the APE 1408 is as follows: (see Figure 3-2) (1.) If operating the APE 1408 with the generator, start the generator with the key switch labeled GENERATOR. Turn the switch to engage the starter. Once the generator has started, release the key switch.

(2.) Turn power key switch to the “ON” position. Temperature indicator will turn on and indicate temperature. If temperature indicator does not turn on, check electrical connections and emergency stops.

(3.) Turn outfeed conveyor switch to the “ON” position. Check to make sure outfeed conveyor is moving by checking shaft rotation on the outfeed conveyor take-up bearing. If shaft is not rotating, stop operations and tighten take-up on the outfeed conveyor.

Figure 3-2 APE 1408 Control Area

(4.) Turn agitator switch to the “ON” position. Check that heating chamber is rotating and that rotation sensor lever is tripping the flag (see Figure 3-3). If rotation sensor lever does not trip, adjust lever so that flag is tripped.

ROTATION

SENSOR

LEVER

HEATING

CHAMBER

FEED END

VIEW

FLAG

ROTATION

(5.) Turn blower switch to the “ON” position and wait approximately 45 seconds for burner purging and ignition.

(a.) If the burner ignites, proceed to step 3-6.a.(6.)

(b.) If the burner fails to ignite, check the lights on the

Honeywell controller located to the left of the control panel. If the red light labeled ALARM is on, RESET the Honeywell Controller.

Open the ACCESS DOOR FOR BURNER RESET. If the light on the pressure switch is on, follow these steps:

(1.) Turn all switches except the GENERATOR keyswitch to the “OFF” position.

(2.) Press RESET button on the Honeywell Controller. Figure 3-3 Rotation Sensor Location

(3.) Open ACCESS DOOR FOR BURNER

RESET.

(4.) Locate the pressure switch. If there is a red light on the pressure switch, reset the pressure switch by placing your fingers on the clear plastic lens and your thumb on the back of the switch.

Squeeze switch together. This should clear the indicator light.

3.3

(5.) Repeat startup sequence procedure beginning with step 3-6.a.(5.). You may have to repeat this procedure several times to clear all of the air out from the line.

NOTE

There is a delay built into the infeed conveyor. The infeed conveyor will not start until the operating temperature is reached. Once the operating temperature is achieved start to feed small arms brass into infeed hopper.

(6.) Turn infeed conveyor switch to the “ON” position. The infeed conveyor will automatically start after heating chamber reaches proper feeding temperature.

b. Place brass in the infeed conveyor hopper. Operating temperature of the heating chamber will determine final feed rate of the brass. Conveyor speeds and burner temperature are preset and require no adjustment.

Hot surfaces are located at the outfeed end. Brass discharged from the outfeed conveyor is very hot! Proper personal protective equipment shall be worn.

WARNING

c. To stop the APE 1408, perform the following steps:

(1.) Turn infeed conveyor switch to “OFF” position.

(2.) Turn blower switch to the “OFF” position.

(3.) Wait for 30min to allow unit to cool down.

(4.) After 30min turn agitator switch to the “OFF” position.

(5.) Turn outfeed switch to the “OFF” position.

(6.) Turn main power switch and generator (if used) to the “OFF” position.

(7.) Turn propane valve to the “OFF” position.

d. Emergency shutdown of the unit at any time can be accomplished by pressing the EMERGENCY SHUTDOWN button on the control panel or at the outfeed side of the trailer.

3-7 Operational Sequence

a. The APE 1408 is located at desired location, leveled for operation, and connected to a fuel source and an earth ground.

b. After a controlled startup and warm-up, inspected brass is fed through the APE 1408 for thermal destruction of any energetic residue.

c. Brass which has been processed through the certification unit is collected, cooled, and sent to a disposal location.

3-8 Disassembly Operation Disassembly of the APE 1408 is not required.

3.4

Section IV –MAINTENANCE AND TROUBLESHOOTING

4-1 Responsibilities and Intervals

Longevity of equipment and effectiveness of its use depends in large on the maintenance which is performed on the unit. Refer to Table 4-1 for the required maintenance and lubrication schedule. Refer to Table 4-2 for the required lubricant.

Prior to any servicing, the item being serviced will be locked out / tagged out to prevent injury to personnel or equipment during the servicing process. If servicing an electrically driven device, the motor starter for that item must be locked in the OFF position prior to performing required service.

WARNING

At lubrication points where grease is applied using a grease gun, the following procedure will be followed except where noted:

1 Wipe off the grease fitting and item being lubricated to remove any old grease and dirt.

2 Connect grease gun to grease fitting.

3 Apply grease until new grease can be seen exiting the item.

4 Remove grease gun from grease fitting.

5 Wipe off the grease fitting and item being lubricated to remove any excess grease.

Do not over-apply any lubricant as it can allow additional dirt and dust to accumulate and add to the wear on an item. Make certain that the correct lubricant is used. Use of lower grades of lubricants can result in premature equipment failure.

NOTE

Heating chamber shaft bearings do not require grease. Shaft will rotate in the non-rotating graphite bearing. As the APE 1408 runs, a gap will appear between shaft and bearing. When the gap exceeds 1/8 of an inch, loosen pipe plug on bearing and rotate bearing 180 degrees. Use until gap exceeds 1/4 of an inch.

4.1

TABLE 4-1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES

INTERVAL B- BEFORE OPERATION A- AFTER OPERATION M- MONTHLY

OPERATOR ORG D- DURING OPERATION W- WEEKLY Q- QUARTERLY

DAILY ITEM

NO. B D A W M Q

ITEM TO BE INSPECTED

OR SERVICED PROCEDURE REFERENCE

1. X Infeed conveyor Grease pulley bearings TABLE 4-2, ITEM 1.

2a. X Inspect belt plates for loose nuts, bent plates;

replace as needed

2b. X

Infeed conveyor drive belt

Remove lower cover.

Lubricate pintle chains and sprockets

TABLE 4-2, ITEM

3.

3. X Infeed conveyor worm gear speed reducer

Inspect reducer for appropriate fluid level;

adjust as necessary

TABLE 4-2, ITEM

2.

4. X Outfeed conveyor Grease pulley bearings TABLE 4-2, ITEM 1.

5a. X Inspect belt for cracks extending into cord;

replace as needed

5b. X

Outfeed conveyor drive belt

Remove lower cover.

Adjust conveyor belt tracking

6. X Outfeed conveyor worm gear speed reducer

Inspect reducer for appropriate fluid level;

replace as necessary

TABLE 4-2, ITEM 2

7. Trailer wheels (annually)

Repack wheel bearings TABLE 4-2, ITEM 1

8. X Leveling jacks Lubricate at grease bearings

TABLE 4-2, ITEM 1

4.2

TABLE 4-1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (cont.)

INTERVAL B- BEFORE OPERATION A- AFTER OPERATION M- MONTHLY

OPERATOR ORG D- DURING OPERATION W- WEEKLY Q- QUARTERLY

DAILY ITEM

NO. B D A W M Q

ITEM TO BE INSPECTED

OR SERVICED PROCEDURE REFERENCE

9a. X Check oil level 9b. Change oil in generator

(every 50 hours or every season)

9c. Service air cleaner pre-cleaner (every 25 hours or every season, more if operated in dirty environment)

9d. Service air cleaner cartridge (every 100 hours or every season, more if operated in dirty environment)

9e. Clean/replace spark plugs (yearly)

9f.

Propane generator (Service if used)

Check valve clearance (every 100 hours)

GREEN MANUAL-

BRIGGS AND

STRATTON

OPERATING AND

MAINTENANCE

INSTRUCTIONS

4.3

TABLE 4-2. RECOMMENDED LUBRICANTS

ITEM DESCRIPTION SPECIFICATION RECOMMENDED (or equivalent)

1. Grease, general purpose MIL-G-10924

2. Gear lubricant Chevron, Non Leaded Gear Compound # 150

3. Lubricating oil, general purpose

MIL-PRF-32033 9150-00-231-6689

4-2 Lubrication Locations

Any piece of equipment depends on a maintenance schedule to assure longevity of its use. That schedule includes identifying the places which require lubrication and application of the appropriate type, grade and quantity of the prescribed lubrication.

4-3 Maintenance Records

Records of repairs and maintenance, other than standard daily maintenance, become a valuable tool in equipment redesign and upgrade. In order to support this need, a record of these types of repairs and maintenance should be kept for this equipment and be made available at such time as an overhaul becomes warranted.

4-4 Cleaning

Cleaning of this equipment shall be performed in accordance with TM 43-0001-47, Appendix C. If outside the U.S. military, refer to local guidance for cleaning instructions.

4-5 Rust Removal

Rust removal on this machine shall be performed in accordance with TM 43-0001-47, Appendix C. If outside the U.S. military, refer to local guidance for rust removal instructions.

4-6 Troubleshooting

Troubleshooting is a systematic approach to the elimination of possible factors for a piece of equipment not to function. Table 4-3 has been written for general problems only. For more specific problems with a piece of equipment in the system, you are referred to the manufacturer’s manual. While efforts have been made to anticipate problems which you may encounter, it is realized that others may exist. If you should encounter such a problem, it is requested that a description of the problem together with solutions you may have found be forwarded to Commander, Tooele Army Depot, ATTN: SJMTE-ALE-AE Tooele, UT 84074-5000. Such information exchange will allow for equipment improvement and documentation updating.

4.4

TABLE 4-3 TROUBLESHOOTING

MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION

1. Battery not connected. 1a. Connect battery. Generator won’t crank.

2. Battery has lost it’s charge. 2a. Check battery for correct water level. Connect battery charger and charge battery.

1. Propane tank low or empty. 1a. Have tank filled. Generator won’t start

2. Propane valve not turned on. 2a. Turn valve on.

1. Contactor has tripped. 1a. Open control panel and reset contactor.

2. Belt is out of adjustment. 2a. Adjust tension on belt.

Outfeed conveyor won’t operate or stops operating.

3. Foreign object jammed in belt. 3a. Turn off conveyor. Remove object. Restart conveyor.

1. Air in propane line. 1a. Refer to para. 3-6.a.(5.).

2. Propane tank low or empty. 2a. Have tank filled.

3. Propane valve not turned on. 3a. Turn valve on

Burner won’t light.

4. Check spark plug to see if spark is present during firing. If not replace spark plug.

4a. Replace spark plug.

Infeed conveyor not operating. 1. Unit not up to feeding temperature.

1a. Wait until operating temperature has been obtained

1. Feeding temperature dropped below set-point.

1a. Wait for heating chamber to heat up to proper temperature.

2. Burner not operating 2a. Reset Honeywell Controller

Infeed conveyor stops

3. Infeed conveyor jammed. 3a. Remove jammed brass or other jam.

1. Propane tank low or empty ? 1a. Have tank filled.

2. Rotation counter lever either missing tripping flag or dragging on heating chamber

2a. Readjust counter lever to properly count heating chamber rotation.

Flame goes out during operation.

3. Brass is jamming rotation of heating chamber.

3a. Clear jammed brass. If problem occurs frequently, shaft pillow blocks will need to be adjusted/shimmed.

4.5

4.6

Section V –INSPECTION, STORAGE AND SHIPMENT

5-1 Inspection Items a. through c. are for storage inspection. Items a. through e. are for receipt and issue inspection.

Inspection reports shall be forwarded in accordance with AR 700-20.

a. Check the APE Identification tag for proper identification and correct serial number.

b. Check the machine to assure that all parts are present and assembled properly as instructed in this manual.

c. Check the machine to assure it is properly painted and preserved.

d. Connect machine to propane or electrical source. Apply electrical power and start conveyor motors and agitator motor and check for smooth operation. During operation of the machine, check to see that it meets all safety regulations.

e. Inspect accessories and critical parts, if applicable. Assemble each accessory to machine in accordance with instructions in this manual. Using inert items of ammunition, check for proper operations of machine with accessories attached.

5-2 Storage and Shipment

a. Storage and shipment of APE shall meet the requirements of Appendix C of TM 43-0001-47, Army Equipment Data Sheets Ammunition Peculiar Equipment.

b. Do not ship APE 1408 on its leveling jacks because damage to machine could occur.

c. Required support equipment: Propane tank (user furnished) approximately 300 gallon is recommended.

5.1

5.2

APPENDIX A

Parts List

A.1

A.2

A.3

GENERAL ASSEMBLY

1408A000PL

DRAWING

OR

DOCU.NO.

NOMENCLATURE QTY UNIT PART OR

IDENT. NO.

CAGE

NO. PART

REPL

1408A001 HEATING CHAMBER 1 EA 27507 1BNF0 C,M

1408A002 TRAILER 1 EA 27506 1BNF0 C,M

1408A003 INFEED CONVEYOR 1 EA 27504 1BNF0 C,M

1408A004 OUTFEED CONVEYOR 1 EA 27505 1BNF0 C,M

1408A005 BURNER COMPARTMENT 1 EA 27508 1BNF0 C,M

1408A006 INFEED CONVEYOR BELT 1 EA 1408A006 21624 M

1408A007 ELECTRICAL 1 EA 1408A007 21624 M

14080001

GENERATOR SET, PROPANE, 9.5 KVA AT 60

HZ, 115/230V

REF: PRAMAC INDUSTRIES, PRAMAC LIFTER

SM 9500

COMPRISING OF:

NSM GENERATOR P/N: MS 100 LL BRIGGS &

STRATTON PROPANE ENGINE MODEL:

354447 TYPE: 0044-E1 1 EA

SM 9500 1ZKG1 C

14080002 BATTERY, 12-VOLT, BCI GROUP SIZE U1, 350

CCA 1 EA UIP-7 72222 C

http://DOCU.NO

A.4

HEATING CHAMBER

1408A001PL

DRAWING

OR

DOCU.NO

NOMENCLATURE QTY UNIT PART OR

IDENT. NO.

CAGE

NO.

PART

REPL

14080003 EXHAUST/EXIT CHUTE ASSEMBLY 1 AY 23638 1BNF0 C, M

14080004 HOOD/COVER ASSEMBLY 1 AY 23639 1BNF0 C, M

14080005 MANIFOLD ASSEMBLY FOR BURNER 1 AY 23643 1BNF0 C, M

14080006 INFEED EN/CHUTE ASSEMBLY 1 AY 23640 1BNF0 C, M

14080007

FRAME ASSEMBLY/HEATING

CHAMBER 1 AY 23641 1BNF0 C, M

14080008 DRUM ASSEMBLY 1 AY 23642 1BNF0 C, M

14080009 ROLLER CHAIN, #50 RIV 120 IN 76474 C

14080010 LINK, HALF, #50 1 EA 76474 C

14080011 LINK, MASTER, #50 1 EA 76474 C

14080012

SPROCKET, 50B40, 1-1/2 BORE, 3/8 IN. KEYWAY,

2 EA. 3/8” SETSCREWS 2 EA 50B40 76474 C

14080013

SPROCKET, 50B 12, 1” BORE, 1/4 IN.

KEYWAY, 2 EA. 5/16” SETSCREWS 2 EA 50B12 76474 C

14080014 SPROCKET, IDLER, 50B12 W/BUSHING 2 EA 50B12 76474 C

14080015 GEARBOX, 57.5 TO 1 RATIO 1 EA 4Z614 5A581 C

14080016

BEARING, HIGH TEMPERATURE, 1-1/2

INCH ID 8 EA

P2BLT10-

UPC:

782475 C

14080017 PIPE, WRAP, HIGH TEMPERATURE 83” X 51-1/2” 1 EA 72456 1BNF0 C, M

14080018

PIPE, WRAP, HIGH TEMPERATURE 7-1/2” X

21-1/4” 1 EA 72455 1BNF0 C, M

14080019

MOTOR, 1/4 HP, 1725 RPM, 208-230 VAC, 1

PH, 1.15 SERVICE FACTOR, TEFC, CFACE

MOUNT 1 EA 102866.00 56065 C

14080020 DRIVE WHEEL 4 EA 23644 1BNF0 C, M

14080021 SPACER 2 EA 48814 1BNF0 C, M

14080022 SPACER 2 EA 48815 1BNF0 C, M

14080023 SPACER 2 EA 48816 1BNF0 C, M

14080024 SHAFT 2 EA 48817 1BNF0 C, M

14080025 KEYSTOCK, 3/8” X 4-3/8” 2 EA C

14080026 KEYSTOCK, 3/8” X 2” 2 EA C

14080027 KEYSTOCK, 1/4” X 1-1/4” 2 EA C

14080028 MANIFOLD, CONNECTOR 1 EA 23645 1BNF0 C, M

14081005 WELDMENT, FLAME DEFLECTOR 1 EA 14081005 21624 M

14080030

THERMOWELL, THREADED FOR 1/4” OD ELEMENT,

1/2” NPT, 316 SST, FOR 15” THERMOCOUPLE 1 EA

1/2”B260 U131/2316 88234 C

A.5

HEATING CHAMBER

1408A001PL

(cont.)

DRAWING

OR

DOCU.NO

NOMENCLATURE QTY UNIT PART OR

IDENT. NO.

CAGE

NO.

PART

REPL

14080031 FLAG 1 EA 48952 1BNF0 C, M

14080032 LIMIT SWITCH BRACKET ASSEMBLY 1 AY 23665 1BNF0 C, M

14080033 LIMIT SWITCH, COMPRISED OF: BODY,

HEAD 1 AY 3SE03-SA

3SE0E-DR1 0ACF4 C

14080034

COUPLING, LOW PRESSURE, 304SST,

1/2” NPT 1 EA 4335T62 39428 C

A.6

TRAILER

1408A002PL

DRAWING

OR

DOCU.NO

NOMENCLATURE QTY UNIT PART OR

IDENT. NO.

CAGE

NO.

PART

REPL

14080035 TANDEM II KIT, No AXLE #27-108 1 EA 72191 1BNF0 C, M

14080036 COUPLER, MARVEL, A-FRAME 2” 1 EA 18-250 4LH25 C

14080037 JACK, TOP WIND, 2000# 1 EA 18-260 4LH25 C

14080038

WHEEL, GRY655, 15 X 6, 17-118-22,

#27-008 4 EA 72194 1BNF0 C, M

14080039 LUG NUT, 6-80-5, 8 LUG HUB, #27-008 24 EA 72195 1BNF0 C, M

14080040 FENDERS, FOR TANDEM AXLES 4 EA 72196 1BNF0 C, M

14080041

SAFETY CABLE, 3/8” DIA, W/ HOOKS,

#13-310 1 EA 72314 1BNF0 C, M

14080042 AXLE, W/ ELECTRIC BRAKE (26-503) 2 EA 72444 1BNF0 C, M

14080043 FENDER BACKS (03-045) 2 EA 72446 1BNF0 C, M

14080044

RUBBER GROMMETS FOR CLEARANCE

LIGHTS 5 EA 72447 1BNF0 C, M

14080045 CLEARANCE LIGHTS, RED 3 EA 72448 1BNF0 C, M

14080046 CLEARANCE LIGHTS, AMBER 2 EA 72449 1BNF0 C, M

14080047

BREAKAWAY SYSTEM, W/ CHARGER

(20-236-2) 1 EA 72445

14080048 TAILLIGHTS 50532-5/50542-5 2 EA 96781 1BNF0 C, M

14080049 CONNECTOR, 6-POLE TRAILER LIGHT 1 EA 96782 1BNF0 C, M

14080050 HRF, 1/4 X 6 X 8 (A17) 1 EA 48144 1BNF0 C, M

14080051 TIRE, RADIAL, 6 PLY, 235/15 4 EA C

14080052 WELDMENT, TRAILER FRAME 1 EA 27506 1BNF0 C, M

14080053

JACK, INDUSTRIAL, SWING AWAY,

PIVOT, CRANK TYPE, 2000 LBS CAP., 10”

MAX LIFT 4 EA 210TS11A 08LX6 C

14080054 LEVEL, BULLSEYE, 1-7/16” DIA 4 EA 2308A9 39428 C

14081003 WELDMENT, ELECTRICAL BRACKET 1 EA 14081003 21624 M

A.7

INFEED CONVEYOR

1408A003PL

DRAWING

OR

DOCU.NO

NOMENCLATURE QTY UNIT PART OR

IDENT. NO.

CAGE

NO.

PART

REPL

14080055 CONVEYOR FRAME ASSEMBLY 1 AY 23619 1BNF0 C, M

14080056 GUARD/ CHAIN ASSEMBLY 1 AY 23621 1BNF0 C, M

14080057 CHUTE ASSEMBLY 1 AY 23622 1BNF0 C, M

14080058 HOPPER ASSEMBLY 1 AY 23623 1BNF0 C, M

14080059 GUARD/ TAKE UP ASSEMBLY 1 AY 23624 1BNF0 C, M

14080060 FRONT LEG ASSEMBLY 1 AY 23625 1BNF0 C, M

14080061 REAR LEG ASSEMBLY 1 AY 23626 1BNF0 C, M

14080062

SPROCKET, 40B38, 1” BORE, 1/4”

KEYWAY, 2 EA. 5/16” SETSCREWS 1 EA 50B38 76474 C

14080063

SPROCKET, 40B18, 1-1/8” BORE, 1/4”

KEYWAY, 2 EA. 5/16” SETSCREWS 1 EA 40B18 76474 C

14080064

BEARING, 1” INNER DIA., 2 BOLT,

PILLOW BLOCK 4 EA

P2B-DL-

UPC:

782475 C

14080065 CHAIN, #40 RIV 43 IN 76474 C

14080066 LINK, MASTER, #40 1 EA 76474 C

14080067 LINK, HALF, #40 1 EA 76474 C

14080068 SHAFT, DRIVE 1 EA 48725 1BNF0 C, M

14080069

ALL-THREAD ROD, 5/8-16UNC X 4 LG,

W/NUT AND LOCKWASHER 1 EA

C

14080070

GEARBOX, 60:1 RATIO, DOUBLE SOLID

SHAFT EXTENSION, MOTORIZED QUILL

INPUT, 2.62 IN. CENTER DISTANCE, 56C

INPUT FLANGE 1 EA

BM1-826-

60-D-56 56065 C

14080071

MOTOR, 3/4 HP, SINGLE PHASE, 1725

RPM, TEFC, 56C FACE 1 EA 110057 56065 C

14080072 SPROCKET, PINTLE 1 EA 50367 1BNF0 C, M

14080073

TELESCOPER TAKE-UP, REF: BRYANT

PRODUCTS, IXONIA, WI 53036 1 EA

100-6-MS-

BP

14080074 SHAFT, TAKE-UP 1 EA 30493 1BNF0 C, M

14080075 WEAR STRIP 2 EA 48724 1BNF0 C, M

14080076 BELTING, RUBBER 4 EA 70536 1BNF0 C, M

1408A006 INFEED BELT ASSEMBLY 1 AY 1408A006 21624 M

14081004 GUARD, CONVEYOR 4 EA 14081004 21624 M

A.8

OUTFEED CONVEYOR

1408A004PL

DRAWING

OR

DOCU.NO.

NOMENCLATURE QTY UNIT PART OR

IDENT. NO.

CAGE

NO.

PART

REPL

14080080 GUARD/ CHAIN ASSEMBLY 1 AY 23620 1BNF0 C, M

14080081

SPROCKET, 40B15, 1” BORE, 1/4”

KEYWAY, 2 EA. 5/16” SETSCREWS 1 EA 40B15 76474 C

14080082

SPROCKET, 40B18, 1-1/8” BORE, 1/4”

KEYWAY, 2 EA. 5/16” SETSCREWS 1 EA 40B18 76474 C

14080083

BEARING, 1” ID, 2 BOLT, PILLOW

BLOCK 1 EA

P2B-DL-

UPC:

782475 C

14080084 CHAIN, #40 RIV 44 IN 76474 C

14080085 LINK, MASTER, #40 1 EA 76474 C

14080086 LINK, HALF, #40 1 EA 76474 C

14080087 ROLLER, DRIVE 1 EA 21742 1BNF0 C, M

14080088

ALL-THREAD ROD, 5/8-1 1UNC X 4 LG

WITH NUT AND LOCKWASHER 1 EA

14080089

GEARBOX, 60:1 RATIO, DOUBLE SOLID

SHAFT EXTENSION, MOTORIZED QUILL

INPUT, 2.62 INCH CENTER DISTANCE,

56C INPUT FLANGE 1 EA

BMQ-826-

60-D-56

56065 C

14080090

MOTOR, 3/4 HP, SINGLE PHASE, 1725

RPM, TEFC, 56C FACE 1 EA 110057 56065 C

14080091 HRF, 1/2” X 2” X 96-1/2” 2 EA 48739 1BNF0 C, M

14080092

TELESCOPER TAKE-UP, REF: BRYANT

PRODUCTS, IXONIA, WI 53036 1 EA

100-6-MS-

BP

14080093 ROLLER, IDLER 1 EA 21743 1BNF0 C, M

14080094

BELT/KEVLAR ASSEMBLY, 5/16 X 14” X

17’-9”, CLEATED 1 AY 72440 1BNF0 C, M

14080095 GUARD, TAKE-UP 1 EA 20224 1BNF0 C, M

14080096 CONVEYOR FRAME ASSEMBLY 1 AY 23629 1BNF0 C, M

14080097 CHUTE ASSEMBLY 1 AY 23631 1BNF0 C, M

14080098 LEG/ FRONT ASSEMBLY 1 AY 23632 1BNF0 C, M

14080099 LEG/ REAR ASSEMBLY 1 AY 23635 1BNF0 C, M

14081006 CHUTE GUARD 1 EA 14081006 21624 M

A.9

BURNER COMPARTMENT

1408A005PL

DRAWING

OR

DOCU.NO

NOMENCLATURE QTY UNIT PART OR

IDENT. NO

CAGE

NO.

PART

REPL

14080100 SIDE/ ACCESS DOOR ASSEMBLY 1 AY 23628 1BNF0 C, M

14080101 GUARD/ BURNER COMPARTMENT LH 1 AY 23635 1BNF0 C, M

14080102 GUARD/ BURNER COMPARTMENT RH 1 AY 23636 1BNF0 C, M

14080103 SHEET, HRFS 29.85” X 2.5” X 14 GA 1 EA 48771 1BNF0 C, M

14080104 SHEET, HRFS 29.85” X 2.5” X 14 GA 1 EA 48772 1BNF0 C, M

14080105 SHEET, HRFS 22” X 49.29” X 14 GA 1 EA 48779 1BNF0 C, M

14080106 HOSE, FOR LP GAS, 3/4” X 28” LONG 1 EA 72451 1BNF0 C, M

BURNER, PROPANE, RATED 1,080,000

BTU/HR @ 0% EXCESS AIR, 180 SCFM AIR,

8.0” WC MIN GAS RESSURE 120/1/60 4.5

AMPS ELECTRICAL

1 EA J121A-3 92995 C 14080107

W/ SPARE PARTS:

BLOWER SWITCH 1 EA 8425-19

ELECTRODE 1 EA 6418-00

SWITCH, THERMAL 1 EA 8425-18

BURNER CONTROL 1 EA 7800 SERIES

CONSISTING OF:

RELAY MODULE, INTERRUPTED

PILOT, 120VAC 1 EA RM7895C

SUBBASE, PANEL MOUNT 1 EA Q7800 A1062

AMPLIFIER, 0.8 SEC W/ FLAME ROD 1 EA R7847 A1025

14080108

1 EA S7800 A1001 DISPLAY MODULE

27320 C

INFEED CONVEYOR BELT

1408A006PL

DRAWING

OR

DOCU.NO.

NOMENCLATURE QTY UNIT PART OR

IDENT. NO.

CA

GE

NO.

PART

REPL

14080109

CHAIN, PINTLE, CHAIN NO. D662 W/

ATTACHMENT STYLE “AS” 100 FT

AL AL0662

AS ATT 40195 C

14080110

LINK, CONNECTING, CHAIN NO. D662, W/

ATTACHMENT STYLE “AS” 2 EA

AL AL662

AS C/L-

ATT LINK 40195 C

14080111

CAPSCREW, HEX-HD, 1/4-20UNC X 3/4

LG, CARBON STEEL 240 EA 92965A540 39428 C

14080112 NUT, HEX HD, FLANGED, STEEL 240 EA 9483 1A029 39428 C

14081001 INFEED CONVEYOR BELT SEGMENT 120 EA 14081001 21624 M

14081002 INFEED CONVEYOR BELT ARRESTOR AR EA 14081002 21624 M

A.10

INFEED CONVEYOR BELT

1408A006PL

DRAWING

OR

DOCU.NO.

NOMENCLATURE QTY UNIT PART OR

IDENT. NO.

CAGE

NO.

PART

REPL

14080113

RELAY, LOGO 230R

REF: www.siemens.com/logo 1 EA

6ED1052-

A00-0BA0

14080114

SWITCH, PROXIMITY, COMET 9-IN

PERFECT LR AC/DC 1 EA 13103 6513 UPC:

782113 C

14080115 STARTER, MANUAL, 4 - 6 AMP 2 EA

1 VU1 3001

MK00 0ACF4 C

14080116 STARTER, MANUAL, 2.4 – 4 AMP 1 EA

3VU1 3001

MJ00 0ACF4 C

14080117 CONTACT, 9 AMP, 120V 3 EA 0ACF4 C

14080118 SWITCH, ESTOP, 3SB02513 W/35X9901 1 EA 96163 1BNF0 C, M

14080119 SWITCH, PUSH BUTTON, PUSH-

PULL/TWIST RED3SN02-K4R 1 EA 96139 1BNF0 C, M

14080120 CONTACT BLOCK, 1NC, 3SB1400-0C 2 EA 96137 1BNF0 C, M

14080121 BREAKER, SINGLE POLE, 6 AMP

5SX2106-7 1 EA 96857 1BNF0 C, M

14080122 CONTACT BLOCK, 1NO, 3SB1400-0B 5 EA 96141 1BNF0 C, M

14080123 SWITCH, 2 POSITION, MAINT BLK.,

3SB02-2MKB 4 EA 96138 1BNF0 C, M

14080124 PINSOCKET, #8, PF083A 2 EA 96146 1BNF0 C, M

14080125 RELAY, BEA122 2 EA 96142 1BNF0 C, M

14080126 TEMPERATURE CONTROLLER 1 EA CN13233 29907 C

14080127 TRANSFER SWITCH, 30 AMP

1 EA

MTHXFDB

30030

ERU16B 81118 C

14080128 PILOT LIGHT

REF: O-Z/GEDNEY 1 EA PL1 12 RED C

14080129 HOUR METER, 230VAC

REF: O-Z/GEDNEY 1 EA 1672T22 39428 C

14080130 3 AMP FUSE, TIME-DELAY 1 EA KLDR 3 75915 C

14080131 1/10 AMP FUSE, TIME-DELAY 1 EA KLDR 1/10 75915 C

A.11 http://www.siemens.com/logo

A.12

B.1

APPENDIX B

Assembly Drawings

B.2

Figure B-1. APE 1408 General Assembly B.3

B.4

Figure B-2. APE 1408 Heating Chamber Assy.

B.5 Figure B-3. APE 1408 Heating Chamber Sensors

Figure B-4. APE 1408 Trailer Details

B.6

Figure B-5. APE 1408 Infeed Conveyor Assembly

B.7

Figure B-6. APE 1408 Outfeed Conveyor Assembly

B.8

Figure B-7. APE 1408 Burner Compartment

B.9

Figure B-8. APE 1408 Infeed Conveyor Belt

B.10

Figure B-9. APE Electrical Schematic

B.11

B.12

APPENDIX C

Manufacturer’s Instructions

C.1

C.2

GENERAL SAFETY INFORMATION

GENERAL OPERATING INSTRUCTIONS

GENERATOR INFORMATION

WARNING: LUBRICATING OIL

CONFORMING TO THE ENGINE

MANUFACTURER’S SPECIFICATION

MUST BE ADDED TO THE PROPER

LEVEL BEFORE OPERATION.

FAILURE TO FILL THE CRANKCASE

WITH LUBRICATING OIL WILL VOID

ALL ENGINE WARRANTIES.

WARNING!!

THIS GENERATOR IS EQUIPPED WITH AN

ELECTRIC STARTING SYSTEM. THE BATTERY

CABLES ARE CONNECTED TO THE ENGINE, BUT

ARE NOT CONNECTED TO THE BATTERY.

DO NOT OPERATE THIS GENERATOR UNTIL THE

BATTERY HAS BEEN INSTALLED AND THE

BATTERY CABLES ARE PROPERLY CONNECTED

TO THE BATTERY.

IF OPERATION OF THE GENERATOR IS DESIRED

IN HAND/ RECOIL START MODE ONLY, THE

BATTERY CABLES MUST BE REMOVED

COMPLETELY FROM THE ENGINE.

FAILURE TO FOLLOW THE ABOVE GUIDELINES

COULD RESULT IN SPARKING FROM THE

BATTERY CABLES WITH POTENTIAL DAMAGE TO

THE CHARGING SYSTEM AND A POSSIBLE FIRE

HAZARD.

AC GENERATORS

ALTERNATORI SERIE

ALTERNATORS TYPE

ALTERNATEURSSERIE

MS 100

ISTRUZIONI D`USO

Lo scopo delle presenti istruzioni é indicare agli utilizzatori le corrette condizioni d`impiego degli alternatori NSM.

ATTENZIONE!

Le istruzioni fornite riportano informazioni atte ad essere utilizzate da personale tecnico qualificato;

esse devono essere integrate dalle leggi ed dalle norme vigenti.

Le macchine elettriche rotanti presentano parti pe-ricolose in quanto poste sotto tensione ed in rota-zione. Pertanto un uso improprio, la carenza di manutenzione e lo scollegamento dei dispositivi di protezione possono essere causa di gravi danni a persone o cose.

VERIFICHE PRELIMINARI

Al momento della ricezione si raccomanda di esaminare l`alternatore per controllare che non abbia subito danni durante il trasporto.

IMMAGAZZINAGGIO

Se l`alternatore non viene posto immediatamente in servizio dovrà essere immagazzinato in luogo coperto, pulito, e privo d`umidità.

Prima della messa in servizio dopo lunghi periodi di inattività é consigliabile verificare la resistenza di isolamento di tutti gli avvolgimenti. Con mac-china a temperatura ambiente si devono misurare valori maggiori di 2 MΩ. In caso contrario bisogna procedere all`essicazione in forno (a circa 60º-80º C).

ACCOPPIAMENTO MECCANICO

Si vedano le istruzioni per il montaggio a pag.4.

COLLEGAMENTO ELETTRICO

Verificare che i dati di targa siano conformi alle ca-ratteristiche dell`impianto a cui l`alternatore é col-legato. Eseguire i collegamento di pag.2. Provve-dere anche al collegamento a terra dell`alternatore utilizzando i morsetti predisposti.

Prima della messa in funzione é necessario verifi-care la bontà di tutti i collegamenti e l`assenza di impedimenti alla rotazione del rotore.

INSTALLAZIONE

Installare il gruppo in un locale ben ventilato. Fare attenzione che le aperture di aspirazione ed espulsione dell`aria di raffreddamento siano libere.

E' importante evitare che l`alternatore aspiri l`aria calda espulsa dall`alternatore stesso e/o dal moto-re primo nonchè i gas di scarico del motore.

MANUTENZIONE

L`alternatore e gli eventuali accessori devono es-sere sempre tenuti puliti.

Verificare periodicamente che il gruppo funzioni senza vibrazioni o rumori anomali e che il circuito di ventilazione non sia ostruito.

INSTRUCTIONS

Object of these instructions is to give the user cor-rect operating-conditions about NSM alternators.

ATTENTION!

The operating instructions include only the direc-tions to be followed by the qualified personnel;

they must be supplemented by the relevant legal provisions and standards.

Electric rotating machines have dangerous parts:

they have live and rotating components. There-fore: improper use inadequate inspection and maintenance and the removal of protective covers and the disconnection of protection devices can cause severe personal injury or property damage.

PRELIMINARY CHECKS

On receipt it is recommended to inspect the alter-nator to find out whether it has got damages dur-ing transportation.

STORAGE

If the alternator is not installed immediately, it should be kept indoor, in a clean and dry place.

Before starting up the alternator after long periods of inactivity or storage, the insulation resistance winding is to be measured.

That should be higher than 2 MΩ at room tem-perature. If this value cannot be obtained it is nec-essary to reset the insulation drying the winding (using an oven at 60º-80º C).

MECHANICAL COUPLING

See assembling instructions at pag.4

ELECTRIC CONNECTION

As to the electric connection, the security ruling standard are to be complied with. Check that data on the plate are according to the circuit features, to which the alternator is to be connected.

Connections to be made are in pag.2. Earthing the alternator using the suitable terminals.

Before starting up it is advisable to check the quality of all connections and there is not obstacle to the rotation of the rotor.

INSTALLATION

Set up the unit in a well-cooled place.

Make sure that cooling air intake and discharge openings are free and unblocked.

It is important the alternator doesn’t such the warm air coming from the outlet of the alternator itself or/and from the prime mover and motors gas.

MAINTENANCE

The alternator as well as the possible accessories should always be kept clean.

It is recommended to periodically check whether the set operates without anomalous vibrations or noises, and the ventilation circuit is not obstructed.

MODE D`EMPLOI

L`objet des ces instructions est d`indiquer aux uti-lisateurs les correctes conditions d`emploi concer-nant NSM alternateurs.

ATTENTION!

Les instructions fournies contiennent des informa-tions destinèes au personnel qualifiè; elles doivent etre completèes par le dispositions de loi ou par les Normes techniques en viguer.

Les machines electriques rotatives sont des ma-chines prèsentant des parties dangereuses car elles sont sous tension ou en mouvement. Par consèquent: une utilisation anormale, la non in-spection et le dèbranchement des disposititifs de protection peuvent entrainer de graves dommages pour les personnes ou les choses.

VERIFICATION PRELIMINAIRES

Aprés la réception on récommande d`examiner le alternateur afin de vérifier qu`il n`a pas été en-dommagé pendant le transport.

STOCKAGE

Au cas où l`alternateur ne doit pas être mis en service immédiatament, il faut le stocker dans un endroit couvert, propre et sec. Aprés de longues périodes d`inactivité ou de stockage, on conseille de measurer la résistance d`isolation de enroule-ment qui devra être au dessue de 2 MΩ .

Si l`on ne peut pas obtenir cette valeur il est né-cessaire de remettre l`isolation en état, en séchant l`enroulement (utilisant un four a 60º-80º C).

ACCOUPLEMENT MECANIQUE

Voyez l`operation de montage à la pag.4.

CONNEXION ELECTRIQUE

En ce qui concerne la connexion électrique, il vaut bien respecter les dispositions de sécurité en vi-gueúr, et s`assurer que les données nominales soient en conformité aux circuit auquel l`alternateur doit être connecté. Effectué le con-nexions de la fig.4 à la pag.2 et la mise á la terre de l`alternateur. Avant la mise en service il est né-cessaire de contrôler le qualité des connexions et qu`il n`existe aucun empechement a la rotation du rotor.

INSTALLATION

Le groupe doit être installé dans un endroit bien ventilé. S`assurer que les ouvertures de ventilation ne sont pas obstruées. Éviter l`aspiration de l`air chaude émise par l`alternateur lui-meme ou par le moteur principal et du gaz d`èchappement du moteur.

ENTRETIEN

L`alternateur et les éventuels accessoires doivent être toujourus propres. Vérifier périodiquement que le groupe fonctionne sans vibrations ou bruits anomaux, et que le circuit de ventilation ne soit pas obstruée.

STATORE AUS. CARICA BATT. ROTORE STATORE AUS. CARICA BATT. ROTORE

STATOR AUX. BATT. CHARG. ROTOR STATOR AUX. BATT. CHARG. ROTOR

Kva ESTATOR HILFSW. CHARGE BATT. Kva ESTATOR HILFSW. CHARGE BATT.

BATT.LADER BATT.LADER

Ω Ω Ω Ω 230V 240V Ω Ω Ω Ω 230V 240V

MS100 SD 3,0 0,99 7,01 0,16 3,24 13 14 4,0 0,60 3,95 0,13 3,24 18 20

MS100 SE 4,0 0,69 4,80 0,14 3,86 18 20 5,0 0,43 2,40 0,11 3,86 30 35

MS100 SF 5,0 0,43 3,12 0,11 4,33 30 35 6,0 0,31 1,98 0,09 4,33 30 35

MS100 LG 6,0 0,32 2,40 0,11 4,86 35 40 7,2 0,21 1,49 0,09 4,86 45 50

MS100 LH 7,0 0,23 1,80 0,10 5,64 40 45 8,5 0,16 1,07 0,08 5,64 45 50

MS100 LL 8,0 0,20 1,46 0,10 6,33 45 50 9,5 0,14 0,93 0,07 6,33 50 55

KONDENSATOR

µF (*) µF (*)

TIPO

TYPE

CONDENS.

CAPACITORS

KONDENSATOR

50Hz - 3000rpm - 115/230V (120/240V) 60Hz - 3600rpm - 115/230V (120/240V)

CONDENS.

CAPACITORS

Schema di collegamento - Wiring diagram - Schema des connexions Anschlubschema - Esquema de conexiones

Resistenze avvolgimenti (20°C) e condensatori - Winding resistance (20°C) and capacitors - Resistances des bobinage (20°C) et condensateurs - Wicklungswiderstande (20°C) und Kondens. -

Resistencias de los bobinados (20°C) e cond.

MAX CORRENTE PER UNA PRESA

MAX CURRENT FROM ONE SOCKET

MAX COURANT POUR UNE PRISE

MAXIMALSTROM FUR EINEN STECKER

MAX CORRIENTE PARA UNA TOMA

: 16A

OPTIONAL

QUADRO ELETTRICO

ELECTRIC PANEL

TABLEAU ÉLECTRIQUE

KLINKENFELD

CUADRO ELECTRICO

OPTIONAL:

OPTIONAL:

(*):Valori indicativi: possono essere modificati in sede di collaudo. Indicative values: they can be changed during the test.

Valeurs indicatives: ils peuvent changer dans les essais. Ungefahre Angaben: Konnen bei der Abnahme abgeandert werden.

Valores indicativos: pueden ser modificados en el control final.

brent.hunt1 Highlight brent.hunt1 Highlight brent.hunt1 Highlight

Tensione corretta a vuoto, troppo bassa a carico.

Surriscaldamento della macchina

Tensione instabile

Macchina rumorosa a)Diodi rotanti difettosi: sostituirli b)Possibile sovraccarico: controllare la corrente di carico c)Il motore rallenta: contattare il costruttore del motore;

possibile scelta errata del motore a)Aperture di ventilazione parzialmente ostruite: smon-tare e pulire la cuffia di aspirazione e le cuffie di espulsione aria b)Possibile sovraccarico: controllare la corrente di carico a)Contatti incerti: controllare le connessioni b)Irregolaritá di rotazione: verificare l'uniformitá di ro-tazione (contattare il costruttore del motore).

a)Cuscinetti avariati: sostituirli b)Accoppiamento difettoso: verificare e riparare

Manca tensione in uscita a vuoto alla partenza

Tensione in uscita a vuoto minore dell' 80% del valore nominale

Tensione in uscita a vuoto troppo alta a)Macchina smagnetizzata: a macchima avviata appli-care ai morsetti d'uscita per un secondo una tensione continua compresa tra i 4.5 e 12V b)Condensatore difettoso: sostituirlo c)Diodi rotanti difettosi: sostituirli d)Avvolgimento in cto o difetto di isolamento o connes-sioni difettose.