Operating Instructions

Two component proportioning valve

ZKW

Colortronic GmbH

ZKW
Colortronic GmbH
Otto-Hahn-Strae 10-14
D-61381 Friedrichsdorf

USA
Colortronic, Inc.
VPR Commerc Center, Suite 406/407
1001 Lower Landing Road
Blackwood, NJ 08012

Telephone (0 61 75) 7 92-0

Telefax (0 61 75) 7 92-1 79

Telephone (609) 374-9200

Telefax (609) 374-9311
Email cltronic@aol.com

Technical service:
Telephone
Service department: (0 61 75) 7 92-1 54
Spare parts department: (0 61 75) 7 92-1 85
Telefax
Service department: (0 61 75) 7 92-1 19
Spare parts department: (0 61 75) 7 92-1 08

Edition: 04/97
Order number: 64 10 0014 GB 02

These operating instructions are for:*

Serial number:
Built in:
Date of delivery:
Number of delivery:
Date of commissioning:
Location:
Group of machines:

ZKW

Colortronic GmbH retains all rights to change the information in these operating
instructions at any time without notice.
We assume no liability for any errors or direct or indirect damage resulting in
context with these operating instructions.
Copying, translation or publication in any form except for personal use of
purchaser requires approval from Colortronic GmbH.
All rights reserved.

ZKW

Table of contents
1. Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.
1.2.
1.3.
1.4.

Warnings and symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Explanations and information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
For the operating safety of the equipment . . . . . . . . . . . . . . . . . . 13

2. Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2. Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.1. Connection to a single conveyor unit
F 40/CKF 40-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2.2. Connection to a single conveyor unit
CSK2-V/CEF 50/CEF 65 . . . . . . . . . . . . . . . . . . . . . . . .
2.2.3. Connection to a conveyance control system . . . . . . . .
2.3. Compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17
18
18
19
19
20

3. Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2. Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1. ZKW Version 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1.1. Conveying ratio . . . . . . . . . . . . . . . . . . . . . . .
3.2.1.2. Switching cycles . . . . . . . . . . . . . . . . . . . . . . .
3.2.2. ZKW Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22
23
23
24
25
26

4. Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1. Adjusting the conveying ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2. Determining the switching cycle duration . . . . . . . . . . . . . . . . . . . 29
4.3. Setting the switching cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Table of contents 4

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5. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.1. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.2. Checking for smooth operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6. Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.1. Dimension sheet ZKW 40/50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2. Dimension sheet ZKW 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.1. Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Table of contents 5

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1. Safety instructions
These safety instructions apply to all persons within the
range of action of the equipment.
Please inform all persons within the range of action of the
equipment of the direct and indirect hazards connected
with the equipment.
These operating instructions are to be used by all persons
assigned activities connected with the equipment.
Knowledge of the English language is prerequisite.
Ensure in each case that the operating personnel are
familiar with the operating instructions and the function of
the equipment.

Safety instructions 6

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1.1. Warnings and symbols
The following warnings and symbols are used in these operating instructions:
This symbol indicates danger to life! Fatal or serious injury
is possible if the corresponding instructions, regulations or
warnings are not observed.

This symbol indicates that serious injury is possible if the

corresponding instructions, regulations or warnings are
not observed.

This symbol indicates that extensive damage to equipment

is possible if the corresponding instructions, regulations or
warnings are not observed.

&

This symbol indicates information important for becoming

familiar with the equipment, i.e. technical correlations.

This symbol indicates that a technical term is explained at

this point.

Safety instructions 7

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1.2. Explanations and information
Various terms and designations are used frequently in these operating
instructions to ensure clarity. Therefore please note that the terms used in the
text stand for the corresponding explanations listed below.

Equipment
Equipment can mean an individual unit, a machine or an installation.
personnel
Operating
The operating personnel are persons operating the equipment on their own
responsibility or according to instructions (minimum age: 16).

Operator
The operator of the equipment (production manager, foreman, etc.) is the
person responsible for all production sequences. The operator instructs the
operating personnel of what is to be done.
instructions
Operating
The plant operating instructions describe the interaction of the equipment,
production sequences or methods. The plant operating instructions must be
compiled by the operator of the equipment.
foreman
Equipment
When several operating personnel work on one machine, the equipment
foreman coordinates the sequences. The equipment foreman must be appointed
by the operator.
personnel
Trained
Trained personnel are persons who, due to their training, are authorized to carry
out the required work in good practice.

Safety instructions 8

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1.3. For your safety

The operating personnel of this equipment must be at least 16 years old.

read these operating instructions carefully before taking into operation for
Please
the first time. All points are to be observed. Contact us should questions arise.
This avoids injury and damage to equipment!
operating instructions must be kept available at all times at the place of
These
operation of the equipment.
Improper operation results in danger of accidents!
note that, for reasons of clarity, not all conceivable cases regarding
Please
operation or maintenance of the equipment can be covered in these operating
instructions.
observe all safety instructions and warnings on the equipment.
Please
This avoids injury and damage to equipment!
work on the equipment is to be carried out by persons whose qualifications
All
are specified in the pertaining chapters of the operating instructions.
Improper operation results in danger of accidents!
proper working clothes are to be worn during any work on the equipment.
The
This avoids injury!
the connected loads with those of the mains supply.
Compare
Danger of injury through electrical shock!
using lifting gear, please observe the pertaining regulations.
When
Caution: Danger of accidents!
note that all installation, start-up and maintenance procedures are to be
Please
carried out by qualified, trained personnel only.
Improper operation results in danger of accidents!

Safety instructions 9

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local regulations and requirements pertaining to the equipment must be
The
observed.
5 safety rules as provided in DIN VDE 0105, Section 1, must be observed
The
for all work carried out on the equipment.
electrical components from the mains supply before work is carried
Disconnect
out on these components.
Caution: Danger to life through electrical shock!
not modify, add other equipment or change the design of the equipment
Do
without the approval of the manufacturer.
Caution: Danger of accidents!
detailed plant operating instructions based on the supplied operating
Compile
instructions for the sequence of procedures to be carried out on this equipment.
Improper operation results in danger of accidents!

Appoint an equipment foreman to be responsible for the equipment.

that the operating personnel are thorough training in the operation of the
Ensure
equipment.
Improper operation results in danger of accidents!
the main switch is switched off for reasons pertaining to safety, it must be
When
secured against unauthorized activation.
Caution: Danger of accidents!

Before starting maintenance work, appoint a supervisor.

the responsible personnel before maintenance work on the system is
Inform
started.
Caution: Danger of accidents!

Safety instructions 10

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the equipment from mains supply before starting maintenance
Disconnect
procedures to ensure that it cannot be switched on unintentionally.
Caution: Danger of accidents!
work may be carried out by trained personnel only.
Repair
Caution: Danger of accidents!
operate the equipment when partially dismantled.
Never
Caution! Limbs may be caught in machinery; danger of electrical shock!
case of malfunction, shut down the equipment immediately. Have malfunctions
Incorrected
immediately.
Caution: Danger of accidents!
equipment is intended only for conveying granulated plastics and regrinds.
The
Other use of the equipment is contrary to its specifications.

This equipment is not suitable for food processing.

observe that sound levels exceeding 85 dB(A) may lead to health
Please
problems after prolonged exposure. Use suitable ear protection.
This prevents ear damage!
not supplied by Colortronic must be manufactured in accordance
Attachments
with safety instruction EN 294.
Caution: Danger of accidents!
all pipes, hoses and screwed connections for leaks and damage on a
Check
regular basis. Correct such damages immediately.
Caution: Danger of accidents!
all compressed air piping before maintenance work.
Depressurize
Danger! Limbs may be caught in machinery!
operate the equipment without elbows.
Never
Danger! Limbs may be caught in machinery!

Safety instructions 11

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equipment may only be operated when all appertaining components are
The
connected properly and comply with applicable regulations.

The equipment may only be operated in conjunction with a conveyor unit.

Observe the safety instructions for connected equipment.

Safety instructions 12

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1.4. For the operating safety of the equipment

Never change settings if the consequences are not precisely known.

Use only original Colortronic spare parts.
Observe the maintenance instructions.
Keep record of all maintenance and repair procedures.
Please note that electronic components may be damaged by static discharge.
all electrical connections for secure fit before the equipment is taken into
Check
operation and at regular intervals.

Never adjust sensors without exact knowledge of their function.

Please note that the maximum ambient temperature must not exceed 45 C.
Align the suction tubes of the individual components equally.
Please note that the set conveying ratio determines the conveying time.
Please note that compressed air supply is required for the operation of the ZKW.
set a higher operating pressure than 6 bar for the ZKW (system
Never
overpressure).
whether the regrind is connected to the left-hand intake port (1) of the
Check
ZKW.
VA-steel pipe bends when conveying abrasive material (ZKW 40,
Install
ZKW 50).

Safety instructions 13

ZKW

Please note that ZKW 65 may not be used for conveying abrasive materials.
Please note that the ZKW can only be used in conjunction with a conveyor unit.
observe the operating instructions of the connected conveyance control
Please
system.

Safety instructions 14

ZKW

2. Installation instructions
These installation instructions are intended for persons
with skills in electrical and mechanical areas due to their
training, experience and received instructions.
Personnel using these installation instructions must be
instructed in the regulations for the prevention of
accidents, the operating conditions and safety regulations
and their implementation.
Ensure in each case that the personnel are informed.
The installation instructions provided in the corresponding
operating instructions apply for all connected equipment.
Observe safety regulations with regard to lifting gear
handling
All installation work must be carried out with the
equipment disconnected from electrical power and
compressed air supply.

For installation work taking place at heights of over

approx. 6 feet, use only ladders or similar equipment and
working platforms intended for this purpose. At greater
heights, the proper equipment for protection against falling
must be worn.
Use only suitable lifting gear which is in proper working
order and load suspension devices with sufficient carrying
capacity. Do not stand or work under suspended loads!
Use suitable workshop equipment.

Installation instructions 15

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Install the equipment such that all parts are easily

accessible; this facilitates maintenance and repair work.

Installation instructions 16

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2.1. Installation
Installation is possible in any position. A mounting bracket is already attached.
The control unit must be accessible at any time
Install VA-steel pipe bends (ZKW 40, ZKW 50) when
conveying abrasive materials.
ZKW 65 may not be used for conveying abrasive materials.

Install the ZKW in such manner that differences in conveying distances for the
two components are avoided.
Please note that the maximum ambient temperature near the ZKW must not
exceed 45 C.
Remove the plugs from the
pipe bends.
Outlet to hopper loader

Install the regrind line at intake

port 1 of the ZKW.
Install the virgin material line
at intake port 1 of the ZKW.
Install the feed line to the
hopper loader at the outlet port
of the ZKW.
Align both suction pipes
equally in order to avoid
inaccurate
percentage
preselection results.

Inlet for
regrind

Inlet for
virgin

Assembly ZKW

Installation instructions 17

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2.2. Electrical connection
2.2.1. Connection to a single conveyor unit F 40/CKF 40-2
Electrical connections are to be made by trained
personnel only.
Observe the regulations of your local Electricity Board.
All work is to be carried out with the equipment
disconnected from electric power and compressed air
supply.

The power consumption value of the ZKW is approx. 15 Watts.

The operating voltage of the ZKW is 230 V/50 Hz.
Special voltage on request.
Lay a cable (min. 3 x 1 mm2) from the single conveyor unit to the ZKW.
Install the supplied plugs.
Install the plug of the ZKW at the plug connector of the single conveyor control
unit.
Observe the operating instructions of the single conveyor unit.

Installation instructions 18

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2.2.2. Connection to a single conveyor unit CSK2-V/CEF 50/CEF 65
Electrical connections are to be made by trained
personnel only.
Observe the regulations of your local Electricity Board.
All work is to be carried out with the equipment
disconnected from electric power and compressed air
supply.

The power consumption value of the ZKW is approx. 15 Watts.

The operating voltage of the ZKW is 24 V.
Lay a cable (min. 3 x 1 mm2) from the single conveyor unit to the ZKW.
Install the supplied plugs.
Install the plug of the ZKW at the plug connector of the single conveyor control
unit.
Observe the operating instructions of the single conveyor unit.
2.2.3. Connection to a conveyance control system
The electrical connection to a conveyance control system
(SG, CS-VF, CS-PF or SPS) may only be made by skilled
personnel authorized by Colortronic.
Other persons are not permitted to install electrical
connections.

Installation instructions 19

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2.3. Compressed air supply
For actuating the piston in the ZKW
a
compressed
air
supply
connection (1/4 inch) is required.
Check compressed air piping for
correct installation and assembly.
Check fittings, length and quality of
the
hose
connections
for
agreement with requirements.
The operating pressure of the ZKW
is 5-6 bar (system overpressure).
Check the compressed air supplied
by the plants supply network.
Maintenance unit

Adjust compressed air pressure to

5-6 bar (system overpressure).
Compressed air must be dewatered and oiled.

Install a maintenance unit (pressure reducer with water separator and oiler) if
required.
Connect the ZKW to the plants supply network by means of a hose.

Depressurize compressed air supply lines which must be

opened.

Compressed air must be dewatered and oiled.

Adjust pressure to a max. value of 6 bar (system
overpressure).

Installation instructions 20

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3. Functional description
This functional description is intended for the operating
personnel of the equipment.
Prerequisite for this functional description is general
knowledge of conveyor systems operation.
Ensure in each case that the operating personnel are
sufficiently informed.

The ZKW can only be operated in conjunction with a

conveyor unit.

Functional description 21

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3.1. General information
The ZKW has 2 elbows (virgin material intake port, regrind intake port) and an
outlet pipe socket leading to the conveyor unit.
With the ZKW it is possible to convey two components to a hopper loader.
The ZKW works in dependence on the conveying cycles of the conveyor unit. It
is only in operation when material is conveyed.
The ZKW is available in 2 versions:
1
Version
Operation on ZKW
ZKW for connection to a single conveyor unit F 40/CKF 40-2/CSK 2-V/CEF 50
or CEF 65 or to a conveying control SG5/SG10/CS-PF/CS-VF or SPS (PLC).
2
Version
Operation on the conveying control
ZKW for connection to a conveying control CS-VF or SPS (PLC).

Functional description 22

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3.2. Control
3.2.1. ZKW Version 1
The control unit is installed at the housing of the ZKW.
The conveying ratio as well as the switching cycles are set by means of the keys
on the front side of the control system.

Percentage key

Arrow key

Display

ZKW control system

Functional description 23

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3.2.1.1. Conveying ratio
The conveying ratio between component 1 (= regrind) and component 2 (= virgin
material) can be freely selected.
The control setting refers to the conveying time of component 1 (= regrind).
The conveying time of component 1 can be set from 0 to 99 % of total conveying
time.
Example
Proportioning valve setting: 22 %
Conveying ratio: 22 % component 1 and 78 % component 2

&

Conveying ratio relates to conveying time, not to the

amount of material conveyed.

Functional description 24

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3.2.1.2. Switching cycles
During each switching cycle, the ZKW switches back and forth one time. The
pre-set conveying ratio is not affected by this. In order to prevent strong formation
of layers in the conveyed material, the number of switching cycles per conveying
procedure can be freely selected. Setting takes place by entry of one cycle
period. The cycle period can be set between 5 and 50 seconds. The setting is
carried out in five seconds.

The cycle period may not be longer than the conveying

time.

&

The shorter the cycle period, the higher the number of

switching cycles.
The higher the number of switching cycles, the less
significant is the zoning effect in the hopper loader.

Example
Conveying time: 90 seconds, cycle period = 15 seconds
Calculation of switching cycles:
conveying time
= switching cycles
cycle period

90 s
= 6 switching cycles
15 s

Cycle period must always be high enough that both virgin

material and regrind are conveyed properly.

Functional description 25

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3.2.2. ZKW Version 2
On the ZKW housing, a terminal box is installed (optional: terminal box with 3
light-emitting diodes = LEDs for limit position monitoring).

&

The two green LEDs indicate the limit positions of the

rotary piston. The red LED goes on in case of a
disturbance.

The conveying ratio and the switching cycles are entered into the control system
of the conveying control.
Observe the operating manual of the conveying control.

Functional description 26

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4. Start-up
This chapter is intended for operating personnel.
Prerequisite for this chapter is general knowledge of the
operation of conveying units.
Also prerequisite for this chapter is that the functional
description has been read and understood.
Ensure in each case that the operating personnel are
sufficiently informed.

Check the compressed air supply (max. 6 bar system

overpressure).
Check the connections of the conveying lines.
Check the suction pipe adjustment.

&

The ZKW can only be operated in conjunction with a

conveying system.

Start-up 27

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4.1. Adjusting the conveying ratio
Adjust the conveying ratio according to your specific requirements.
ZKW Version 1
By means of the arrow key, set the percentage of
component 1 (= regrind).
Example
Desired conveying ratio: 40 % regrind and 60 % raw material.
Press the arrow key until 40" appears on the display.

When conveying poorly flowing components, set higher

values.

ZKW Version 2
Set the percentage of component 1 (= regrind) by means of the control system
of the conveying control.
Observe the operating manual of the conveying control.

Start-up 28

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4.2. Determining the switching cycle duration
Measure the conveying time of the respective hopper.
Take out the table.
Look for the value in the column conveying time.
Select a number of switching cycles.
Press the percentage key.
By means of the arrow key, select the desired switching cycle.
Carry through one conveying procedure.
If you are not satisfied with the result, check the setting and correct, if necessary.

No thick layers may form in the hopper loader.

Example
Conveying time: 50 s
Conveying ratio: 40 % regrind, 60 % virgin material
Setting options for a conveying time of 50 s:

Conveying
time

Number of switching cycles at cycle period (seconds)

(seconds)

50

45

40

35

30

25

20

15

10

50

1,1

1,3

1,4

1,7

2,5

3,3

10

Start-up 29

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a.) Setting 50 seconds = 1 switching cycle per conveying procedure

The ZKW switches twice; it conveys

regrind for 20 seconds and virgin
material for 30 seconds.
Significant zoning.
Virgin

Regrind

b.) Setting 10 = 5 switching cycles per conveying procedure

The ZKW switches ten times; it

conveys regrind for 4 seconds and
virgin material for 6 seconds.
Insignificant zoning.
Virgin

Regrind

Start-up 30

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c.) Setting 5 = 10 switching cycles per conveying cycle

The ZKW switches 20 times; it

conveys regrind for 2 seconds and
virgin material for 3 seconds. This
process is repeated 10 times.
No correct conveyance possible.
With a conveying time of 2 to 3
seconds the material cannot be
conveyed properly.

Start-up 31

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4.3. Setting the switching cycles
ZKW Version 1
Press the percentage key.
By means of the arrow key, set the determined switching cycle.
Check the result.
If the result is not satisfactory, correct the setting.

&

If there are too many switching cycles, proper conveying is

not possible.

ZKW Version 2
Set the determined value by means of the control system of the conveying
control.
Observe the operating manual of the conveying control.
Check the result.
If the result is not satisfactory, correct the setting.

&

The conveying control CS-VF checks and corrects the

setting independently if the result is not satisfactory.

Start-up 32

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5. Maintenance
This chapter is intended for persons with skills in electrical
and mechanical areas due to their training, experience
and received instructions.
Personnel using the instructions in this chapter must be
instructed of the regulations for the prevention of
accidents, the operating conditions and safety regulations
and their implementation.
Ensure in each case that the personnel are informed
accordingly.
For maintenance work taking place at heights of over
approx. 6 feet, use only ladders or similar equipment and
working platforms intended for this purpose. At greater
heights, the proper equipment for protection against falling
must be worn.
Use only suitable lifting gear which is in proper working
order and load suspension devices with sufficient carrying
capacity. Do not stand or work under suspended loads!
Ensure that the electric motors/switch cabinets are
sufficiently protected against moisture.
Use only suitable workshop equipment.
Before starting maintenance work, appoint a supervisor.
Inform the responsible personnel before maintenance
work on the system is started.
Never operate the equipment when partially dismantled.
All maintenance and repair work not described in this
chapter may only be carried out by Colortronic service
personnel or authorized personnel (appointed by
Colortronic).

Maintenance 33

ZKW

Disconnect the equipment from mains supply before

starting maintenance procedures to ensure that it cannot
be switched on unintentionally.
Depressurize all compressed air piping of the equipment
before starting maintenance work.

Please observe the maintenance intervals.

Before starting maintenance work, clean the equipment of
oil, fuel or lubricants.
Ensure that materials and incidentals required for
operation as well as spare parts are disposed of properly
and in an environmentally sound manner.
Use only original Colortronic spare parts.
Keep record of all maintenance and repair procedures.

Maintenance 34

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5.1. Maintenance intervals
Daily:

Check warning signs on equipment for good

legibility and completeness.
Check the oil level in the oiler.
Empty the water separator.
Check operating pressure of the plants supply
network (5-6 bar system overpressure).

Every three months:

Check the ZKW for smooth operation.

Every six months:

Check all electrical and mechanical connections

for secure fit.

In case of soiled material and material with a high dust

content equipment should be checked monthly for smooth
operation.

Maintenance 35

ZKW
5.2. Checking for smooth operation
Disconnect the equipment from mains power supply to
ensure that it cannot be switched on unintentionally.
In order to check for smooth operation compressed air
supply to the ZKW must be maintained.
Danger! Limbs may be caught in machinery!

Unscrew the plug at the solenoid

valve.
Remove the hose from the hopper
loader outlet port.

Manual actuator

Move the manual actuator of the

solenoid valve from position B to
position A and back
Observe the piston through the pipe
socket at the hopper loader outlet
port.

The piston must move back and forth

quickly.
Put the hose at the hopper loader
outlet port back in place.
Screw the plug to the solenoid valve.

Solenoid valve with manual actuator

Maintenance 36

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6. Technical data
Versions:

ZKW 40
ZKW 50
ZKW 65

ZKW 40
Height:

305 mm

Width:

246 mm

Depth:

235 mm

Weight:

7.5 kg

Compressed air supply:

4-6 bar system overpressure

Piping system:

40 mm

ZKW 50
Height:

305 mm

Width:

256 mm

Depth:

235 mm

Weight:

7.5 kg

Compressed air supply:

4-6 bar system overpressure

Piping system:

50 mm

ZKW 65
Height:

340 mm

Width:

290 mm

Depth:

245 mm

Weight:

12.5 kg

Compressed air supply:

4-6 bar system overpressure

Piping system:

65 mm

Technical data 37

ZKW
6.1. Dimension sheet ZKW 40/50

All dimensions in mm. Specifications may be subject to alteration.

Technical data 38

ZKW
6.2. Dimension sheet ZKW 65

All dimensions in mm. Specifications may be subject to alteration.

Technical data 39

ZKW

7. Appendix
This chapter is intended to be used only by Colortronic
service personnel and trained personnel authorized by
Colortronic.
Other persons are not permitted to modify or repair the
equipment.

Appendix 40

ZKW
7.1. Spare parts list
This spare parts list is intended to be used only by
Colortronic service personnel and trained personnel
authorized by Colortronic.
Other persons are not permitted to modify or repair the
equipment.

Appendix 41

18,31,32

64 10 0014 GB 02 04/97

25

12

24

23

16

20
15

28

26

6 bar

27

5 -

22

21

19

17

13

14

33

10
11

ZKW

ZKW 40 (03596)

Appendix 42

ZKW

64 10 0014 GB 02 04/97

03596
Pos.

Orderno.

Designation

0001

03546

Housing

0002

03576

Piston

0003

96366

Deep groove ball bearing

0004

03575

Bearing lid

0005

95944

Spring lock washer

0006

95842

Screw

0007

96043

Screw

0008

95840

Threaded pin

0009

97706

Pipe socket

0010

96384

Sealingring

0011

95839

Threaded pin

0012

98167

Hose nozzle

0014

03573

Bend

0015

27603

Support

0016

95841

Screw

0018

96045

Screw

0019

96373

Rotary drive

0020

98753

Coupling piece

0021

96372

Solenoid valve

0022

95985

Screw

0023

98752

Coupling piece

0024

98742

Silencer

0025

03604

Bow

0026

95844

Screw

0027

95956

Disc

0028

98750

Hose

0029

95556

Screw

0031

95948

Disc

0032

93882

Nut

0033

15475

Sealing

Appendix 43

18,31,32

64 10 0014 GB 02 04/97

15

16

20

14

50

11

10

19

13

5 -

6 bar

28

27

26

25

12

24

23

22

21

17

ZKW

ZKW 50 (03597)

Appendix 44

ZKW

64 10 0014 GB 02 04/97

03597
Pos.

Orderno.

Designation

0001

03547

Housing

0002

03576

Piston

0003

96366

Deep groove ball bearing

0004

03575

Bearing lid

0005

95842

Screw

0007

96043

Screw

0008

95840

Threaded pin

0009

97704

Pipe socket

0010

96383

Sealingring

0011

95839

Threaded pin

0012

98167

Hose nozzle

0013

95955

Disc

0014

03574

Bend

0015

27603

Support

0016

95841

Screw

0018

96045

Screw

0019

96373

Rotary drive

0020

98753

Coupling piece

0021

96372

Solenoid valve

0022

95985

Screw

0023

98752

Coupling piece

0024

98742

Silencer

0025

03604

Bow

0026

95844

Screw

0027

95956

Disc

0028

98750

Hose

0031

95948

Disc

0032

93882

Nut

0033

15476

Sealing

Appendix 45

50
2

51

64 10 0014 GB 02 04/97

14

20

19

18,31,32

17

28

27

26

25

12

24

23

22

16
5 - 6 bar

21

15

6
13

ZKW

ZKW 65 (12446)

Appendix 46

ZKW

64 10 0014 GB 02 04/97

12446
Pos.

Orderno.

Designation

0001

12416

Housing

0002

12418

Piston

0003

92226

Deep groove ball bearing

0004

12417

Bearing lid

0005

95944

Spring lock washer

0006

95842

Screw

0007

96043

Screw

0008

95840

Threaded pin

0009

17208

Pipe socket

0012

98167

Hose nozzle

0013

95955

Disc

0014

12414

Bend

0015

27603

Support

0016

95841

Screw

0017

99931

Cable

0018

96045

Screw

0019

96373

Rotary drive

0020

98753

Coupling piece

0021

96372

Solenoid valve

0022

95985

Screw

0023

98752

Coupling piece

0024

98742

Silencer

0025

03604

Bow

0026

95844

Screw

0027

95956

Disc

0028

98750

Hose

0031

95948

Disc

0032

93882

Nut

0050

15477

Sealing

0051

88141

Sealing

Appendix 47

36

29

38,40

37
2

64 10 0014 GB 02 04/97

39

33

50
14

10
11

20

19

35

41

42

13

5 - 6 bar

34

28

27

26

12

24

23

22

21

17

ZKW

CLV 40 (10102)

Appendix 48

ZKW

64 10 0014 GB 02 04/97

10102
Pos.

Orderno.

Designation

0001

03546

Housing

0002

09518

Piston with final switch position check

0003

96366

Deep groove ball bearing

0004

09519

Bearing lid with final switch position check

0005

95944

Spring lock washer

0006

95842

Screw

0007

96043

Screw

0008

95840

Threaded pin

0009

97706

Pipe socket

0010

96384

Sealingring

0011

95839

Threaded pin

0012

98167

Hose nozzle

0013

95957

Disc

0014

03573

Bend

0017

99931

Cable

0019

96373

Rotary drive

0020

98753

Coupling piece

0021

96372

Solenoid valve

0022

95985

Screw

0023

98752

Coupling piece

0024

98742

Silencer

0026

95844

Screw

0027

95956

Disc

0028

98750

Hose

0029

96038

Screw

0033

97763

Conical caps

0034

92477

3-wire -initiator with LED

0035

88071

Screw

0036

11503

Nozzle

0037

93228

Sieve

Appendix 49

ZKW
11122

Housing

0039

99944

Coupling piece

0040

92470

ZKW-MLV control card

0041

98609

Coupling piece

0042

93075

Welsh plug

0050

15475

Sealing

0051

85982

Distance bolt

0052

95946

Spring lock washer

0053

95970

Nut

64 10 0014 GB 02 04/97

0038

Appendix 50

ZKW
Connection diagram

HAN6

STAKAP 3

0V
2

0V

SPS
3
3
SV

1
24V

64 10 0014 GB 02 04/97

24V

ZKW

Abscheider
Hopper Loader
Sparateur
Appendix 51

Conveying
time

Number of switching cycles at cycle period (seconds)

(seconds)

50

45

40

35

30

25

20

15

10

10

15

1,5

20

1,3

25

1,3

1,7

2,5

30

1,2

1,5

35

1,2

1,4

1,8

2,3

3,5

40

1,1

1,3

1,6

2,7

45

1,1

1,3

1,5

1,8

2,3

4,5

50

1,1

1,3

1,4

1,7

2,5

3,3

10

55

1,1

1,2

1,4

1,6

1,8

2,2

2,8

3,7

5,5

11

60

1,2

1,3

1,5

1,7

2,4

12

65

1,3

1,4

1,6

1,9

2,2

2,6

3,3

4,3

6,5

13

70

1,4

1,5

1,8

2,3

2,8

3,5

4,7

14

75

1,5

1,7

1,9

2,1

2,5

3,8

7,5

15

80

1,6

1,8

2,3

2,7

3,2

5,3

16

85

1,7

1,9

2,1

2,4

2,8

3,4

4,3

5,7

8,5

17

90

1,8

2,3

2,6

3,6

4,5

18

95

1,9

2,1

2,4

2,7

3,2

3,8

4,8

6,3

9,5

19

100

2,2

2,5

2,9

3,3

6,7

10

20

105

2,1

2,3

2,6

3,5

4,2

5,3

10,5

21

110

2,2

2,4

2,8

3,1

3,7

4,4

5,5

7,3

11

22

115

2,3

2,6

2,9

3,3

3,8

4,6

5,8

7,7

11,5

23

120

2,4

2,7

3,4

4,8

12

24

* = Setting not permitted