Operating Instructions Trough Screw Convey-

or

AHAS - 200
- 250
- 315
- 400

AHAS-67003-1-en-1208
Original Operating instructions

Copyright by BCHA
 Table of contents

1 Important information............................................................................................. 6
1.1 Scope of validity .........................................................................................................6
1.2 Supporting documents ...............................................................................................6
1.3 Contact.......................................................................................................................6
1.4 Personnel qualification...............................................................................................6
1.4.1 Mechanics ....................................................................................................6
1.4.2 Electricians ...................................................................................................7
1.4.3 Welders ........................................................................................................7
1.5 Typographical conventions ........................................................................................7
1.5.1 Explanation of the warning instructions ........................................................7

2 Safety ................................................................................................................... 8
2.1 Designated use ..........................................................................................................8
2.2 Technical condition ....................................................................................................8
2.3 ATEX ID .....................................................................................................................8
2.4 Personnel qualification...............................................................................................8
2.5 Protection against unexpected start-up .....................................................................9
2.6 Protective devices ......................................................................................................9
2.7 Safety signs ...............................................................................................................9
2.8 Safe work environment ..............................................................................................9
2.8.1 Slipping and stumbling hazard .....................................................................9
2.9 Residual risk ............................................................................................................10
2.9.1 Safety concept for the control units ............................................................10
2.9.2 Safety of persons .......................................................................................10

3 Technical data ..................................................................................................... 11

3.1 Ambient conditions ..................................................................................................11
3.2 Capacity data ...........................................................................................................11
3.3 Airborne sound emission .........................................................................................11
3.3.1 Measured data ...........................................................................................11
3.4 Weights ....................................................................................................................11
3.4.1 AHAS-200...................................................................................................11
3.4.2 AHAS-250...................................................................................................11
3.4.3 AHAS-315...................................................................................................11
3.4.4 AHAS-400...................................................................................................12
3.5 Dimensions ..............................................................................................................12

4 Description .......................................................................................................... 13
4.1 Identification .............................................................................................................13
4.1.1 Specification key ........................................................................................13
4.1.2 ATEX ID for use in Ex zone 22...................................................................13
4.1.3 ATEX ID without approval for potentially explosive zone...........................13
4.2 Overview ..................................................................................................................14
4.3 Function ...................................................................................................................15

BCHA
AHAS-67003-1-en1208
Table of contents 3
 4.3.1 Drive unit ....................................................................................................15
4.3.2 End and intermediate trough ......................................................................16
4.3.3 Intermediate bearing ..................................................................................17
4.3.4 Intermediate bearing one-sided .................................................................18
4.3.5 Inlet trough..................................................................................................18
4.3.6 Shaft speed monitor ...................................................................................19
4.3.7 Screw outlet core slide MUFA ....................................................................20
4.4 Planning notes .........................................................................................................20
4.4.1 General notes .............................................................................................20
4.4.2 Space requirement in case of parallel arrangement of the trough screw
conveyor .....................................................................................................20
4.4.3 Fastening the trough screw conveyor ........................................................21
4.4.4 Trough screw conveyor with divided screw shaft .......................................22

5 Transport ............................................................................................................ 23
5.1 Packaging symbols ..................................................................................................23
5.2 Checking the delivery ..............................................................................................23
5.3 Intermediate storage ................................................................................................23
5.4 Transportation specifications ...................................................................................23
5.5 Lifting instructions ....................................................................................................24

6 Installation ........................................................................................................... 25
6.1 Overview of installation sequence ...........................................................................25
6.2 General ....................................................................................................................25
6.3 Set-up ......................................................................................................................25
6.4 Installation sequence ...............................................................................................25
6.5 Chain transmission ..................................................................................................27
6.6 Geared motor directly coupled ................................................................................28
6.7 Flender and SEW spur geared motors ....................................................................28
6.7.1 Spur gear train and geared motors ............................................................28
6.8 Disassembly ............................................................................................................28
6.9 Electrical components..............................................................................................28
6.9.1 Position switch of the trough cover with choke release .............................28
6.9.2 Proximity switch inductive to the shaft speed monitor ...............................29
6.10 Pneumatic components ...........................................................................................30
6.10.1 Screw outlet core slide MUFA ....................................................................30

7 Commissioning.................................................................................................... 31
7.1 Initial start-up ...........................................................................................................31
7.2 Inspection prior to commissioning ...........................................................................31
7.3 Setting the switching distance of the sensors .........................................................32
7.4 Checklist for checking EC conformity ......................................................................32

8 Operation ............................................................................................................ 33
8.1 Operating the conveyor ...........................................................................................33
8.2 Conveyance characteristics .....................................................................................33

9 Troubleshooting .................................................................................................. 34
9.1.1 Troubleshooting in the gear train ...............................................................35

10 Maintenance ....................................................................................................... 37
10.1 Maintenance schedule .............................................................................................37
10.2 Lubrication schedule ................................................................................................38

BCHA
AHAS-67003-1-en-1208
4 Table of contents
10.3 Lubrication ...............................................................................................................38
10.3.1 Spur gear train and geared motors ............................................................38
10.4 Lubricant tables .......................................................................................................39
10.4.1 Spur gear train ............................................................................................39
10.4.2 Rolling bearings for the geared motor ........................................................39
10.4.3 End bearings ..............................................................................................39
10.4.4 Chain transmission .....................................................................................39
10.5 Cleaning schedule ...................................................................................................40

11 Decommissioning ................................................................................................ 41
11.1 Disposal ...................................................................................................................41

12 Spare parts ......................................................................................................... 42

12.1 Inventory of spare parts ...........................................................................................42
12.2 Spare parts identification .........................................................................................42
12.3 Order instructions ....................................................................................................42

BCHA
AHAS-67003-1-en-1208
Table of contents 5
 1 Important information

1.1 Scope of validity

Type Outside diameter of the ribbon flight [mm]
AHAS-200 200
AHAS-250 250
AHAS-315 315
AHAS-400 400

The Trough screw conveyor AHAS is designed for transporting floury, fine-grained
and coarse-grained bulk material. It can be used as screw conveyor, mixing screw
or collecting conveyor, with several inlet and outlet ports, for horizontal and inclined
conveying.

1.2 Supporting documents

The following documents are part of these Operating instructions:

Designation Identification number

Spare part list AHAS - 8126
AHAS – 8127
AHAS – 8128
AHAS – 8129

1.3 Contact
 In case of inquiries, please contact the after-sales service department of manu-
facturer.
 Have the Operation Manual at hand.

Address
Buhler (Changzhou) Machinery Co., Ltd.
Address: Tianmu Lake Industrial Park, Liyang City, Jiangsu Province, China
Tel: +86-519-87966666
Fax: +86-519-87966000

1.4 Personnel qualification

1.4.1 Mechanics

Personnel that work on mechanical devices must be technically trained or have

completed training provided by the manufacturer.

BCHA
AHAS-67003-1-en-1208
6 Chapter 1 Important information
1.4.2 Electricians

Personnel that work on electrical devices must be technically trained or have com-
pleted training provided by the manufacturer.

1.4.3 Welders

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

1.5 Typographical conventions

1.5.1 Explanation of the warning instructions

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

WARNING

Type and source of danger

Danger can result in death or serious injury.
 Actions for protecting against danger.

CAUTION

Type and source of danger

Danger can result in injury.
 Actions for protecting against danger.

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

BCHA
AHAS-67003-1-en-1208
Chapter 1 Important information 7
 2 Safety

2.1 Designated use

 Always use the machine in compliance with its intended use.
 The Trough screw conveyor AHAS is designed only to process the products
within the contractually defined field of application. Any use beyond that is con-
sidered contrary to its designated use.
 Always operate the machine in accordance with these Operating instructions.

2.2 Technical condition

If the machine is operated in defective condition, the safety, function and availabil-
ity are impaired.
 Never operate the machine unless it is in proper technical condition.
 Always comply with the maintenance plan.
 Always use the original spare parts as listed in the Spare parts catalog.
 If the operating behaviour of the machine changes, check the machine for
faults.
 Remedy all faults immediately.
 Never carry out unauthorised conversions or modifications to the machine.

2.3 ATEX ID
The ATEX ID indicates the conditions required for integrating the machine into an
Ex zone or connecting the machine to an Ex zone.
DANGER
Explosion hazard!
 If the machine is permitted to operate in potentially explosive zones in ac-
cordance with the nameplate, it is absolutely imperative that the hazard in-
structions marked with the EX symbol are adhered to in order to maintain
ignition protection.
 Observe the identification plate.

2.4 Personnel qualification

Unqualified personnel cannot identify risks and thus are subject to greater dangers.
 Always assign the activities listed in these Operating instructions to technically
qualified personnel.
 The owner/operator must ensure that the personnel comply with the locally val-
id regulations and laws pertaining to safety and safety-conscious work.

BCHA
AHAS-67003-1-en-1208
8 Chapter 2 Safety
  The owner/operator must assign responsibilities and tasks and inform person-
nel of these assignments. Give keys and passwords to authorised personnel
only.

2.5 Protection against unexpected start-up

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

2.6 Protective devices

If protective devices are ineffective, this poses a danger to people.
 Before operating the machine, always verify that all protective devices are ef-
fective.
 The Trough screw conveyor AHAS is normally part of an installation and there-
fore integrated into the safety concept of the installation.
 If the Trough screw conveyor AHAS is not used within this safety concept, the
user has to redefine the risk estimation of the dangers involved and has to take
suitable measures.
 The design and construction of the machine comply with EC regulations and
USA-FDA regulations with respect to safety and hygiene.
 The CE mark can be attached and the EC declaration of conformity issued af-
ter commissioning and safety inspection.

2.7 Safety signs

If safety signs are not visible or legible, this poses a danger to people.
 Replace safety signs that are not visible or legible.
 Do not remove or cover up safety signs.

2.8 Safe work environment

2.8.1 Slipping and stumbling hazard

Slippery surfaces and stumbling hazards can result in serious accidents.

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

BCHA
AHAS-67003-1-en-1208
Chapter 2 Safety 9
 2.9 Residual risk

2.9.1 Safety concept for the control units

► The machine and installation control system supplied by Buhler is an integrat-

ed part of the safety concept for the prevention of accidents. Prior to commis-
sioning the machine, the installation control system must be checked by a
Buhler specialist.
► If an installation control system for Buhler machines is supplied by third parties,
it must be built according to Buhler specifications. Prior to commissioning it
must be checked thoroughly by trained specialists according to the instruc-
tions in the documentation provided and released with a signature.
Connecting to the electrical mains

► Observe the regulations of the local safety authorities.

► The power supply has to be fuse-protected according to the local regulations.
► Check whether the operating voltage and frequency correspond to the specifi-
cations given on the identification plate and in the control cabinet.
► All electrical connections to the control systems must be made according to
the wiring diagram to ensure that the phase conductors are really switched in
the case of single-phase power supplies.

2.9.2 Safety of persons

► Guards must always remain mounted and closed. Open or dismounted guards
represent danger areas where there is risk of injury through crushing or cutting.
► Safety devices must always be maintained in good functioning order. Safety
devices may not be bypassed or rendered functionless.
► Maintenance work on the trough screw conveyor AHAS may be carried out
only when the system is shut down. It is absolutely necessary to switch off the
system and secure the switch with a lock against activation!

BCHA
AHAS-67003-1-en-1208
10 Chapter 2 Safety
3 Technical data

3.1 Ambient conditions

Designation Value Unit
Temperature range -20 — +80 ℃

3.2 Capacity data

Connected wattage ： The machines have a customer-specific country-specific
connected wattage.

3.3 Airborne sound emission

3.3.1 Measured data

Designation Value Unit

Equivalent noise level in the vicinity of the machine Leq ≤70 dB (A)

► The noise levels listed are the values which were determined for an existing
system.
► Measurement method / measured values： Measurement point 1 m away
from the biggest source of noise, under the worst conditions (empty conveyor).

3.4 Weights

3.4.1 AHAS-200

Designation Value Unit

Empty weight 50 kg per running metre
Operating weight 60 kg per running metre
Drive with geared motor 110 kg per piece.

3.4.2 AHAS-250

Designation Value Unit

Empty weight 70 kg per running metre
Operating weight 90 kg per running metre
Drive with geared motor 120 kg per piece.

3.4.3 AHAS-315

Designation Value Unit

Empty weight 120 kg per running metre
Operating weight 150 kg per running metre

BCHA
AHAS-67003-1-en-1208
Chapter 3 Technical data 11
 Designation Value Unit
Drive with geared motor 160 kg per piece.

3.4.4 AHAS-400

Designation Value Unit

Empty weight 150 kg per running metre
Operating weight 200 kg per running metre
Drive with geared motor 260 kg per piece.

► Empty weight: Trough, screw shaft with full thread 1.0 x D, trough cover, base,
bearing, however without core-slide.
► Operating weight: Empty weight, bulk material with 750 kg/m3, fill factor ap-
prox. 45%.
► Drive with geared motor: Motor mounting plate with coupling cover, largest
possible geared motor.

3.5 Dimensions

Type A B C D E Lmax F G Le
AHAS-200 200 220 186 306 340 21m 200 220 21m
AHAS-250 250 270 214 356 390 21m 250 270 21m
AHAS-315 315 335 237 425 480 21m 315 335 21m
AHAS-400 400 420 287 530 590 21m 400 420 21m
Fig. 3.1

BCHA
AHAS-67003-1-en-1208
12 Chapter 3 Technical data
4 Description

4.1 Identification

4.1.1 Specification key

AHAS – 250 – Ex
AHAS Machine Code
250 Outside diameter of the ribbon flight，Unit：mm
Ex Approval for an area where there is risk of explosion

4.1.2 ATEX ID for use in Ex zone 22

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

II */3D T=125 °C

Explanation of symbols:
— ATEX symbol

II — Device group
*/ — Internal category: No inherent internal source of ignition
/3 — External category 3
D — Dust atmosphere
T — Maximum expected surface temperature in °C in normal operation at
full load with an ambient temperature of 40 °C.

4.1.3 ATEX ID without approval for potentially explosive zone

II */-D

Explanation of symbols:
— ATEX symbol

II — Device group
*/ — Internal category: No inherent internal source of ignition
/- — No approval for use within an Ex zone
D — Dust atmosphere

BCHA
AHAS-67003-1-en-1208
Chapter 4 Description 13
 4.2 Overview
► Complex arrangements can also be made with the flexible mechanical con-
veying element by combining various components.
► It is available in lengths of 0.9 m to 21 m with a gradation of 100 mm in normal
steel and in a corrosion-resistant design. As it is equipped with discharge
gates, it meets particularly high hygiene requirements. The high trough shape
allows the assembly of an aspiration. All construction materials and lubricants
which have been used are food-compatible.
DANGER
Explosion hazard!
 In potentially explosive zones the machine must only be operated with the
corresponding authorization.

► The trough screw conveyor AHAS mainly consists of:

Fig. 4.1
(1) Drive unit (5) End trough
(2) Intermediate trough (6) Trough cover
(3) Intermediate bearing (7) End plate for drive unit (1)
(4) Screw shaft
Components
► Components made of food-compatible construction materials
► Trough sheets 2 mm (type 200 and 250)
► Trough sheets 3 mm (type 315 and 400)
► Completely closed and sealed
► All movable parts are fully enclosed.

BCHA
AHAS-67003-1-en-1208
14 Chapter 4 Description
4.3 Function

4.3.1 Drive unit

The trough screw conveyor AHAS can be driven both from the inlet as well as the
outlet side.
Direct drive:

The screw shaft is driven via the drive bolt (1). It is connected to the power output
shaft of the geared motor (7) through a flexible coupling (6). The screw shaft is put
together with and screwed to the drive bolt and end bolt (4).

Fig. 4.2 Drive unit 《direct drive》

(1) Drive bolt (5) End bearing
(2) Drive bearing (6) Flexible coupling
(3) End plate (7) Geared motor
(4) End bolt
Chain transmission:

The screw shaft is driven via the drive bolt (1). The drive bolt is connected to the
power input shaft of the geared motor (9) via a chain drive (6, 7, 8). The screw
shaft is put together with and joined to the drive bolt and end bolt with screws. The
drive unit can be mounted in the four positions (A, B, C, D).

Fig. 4.3 Drive unit 《chain transmission》

(1) Drive bolt (6) Chain wheel
(2) Drive bearing (7) Driving chain

BCHA
AHAS-67003-1-en-1208
Chapter 4 Description 15
 (3) End bolt (8) Drive chain wheel
(4) End bearing (9) Geared motor
(5) End plate

4.3.2 End and intermediate trough

► The troughs are absolutely closed and guarantee a dust-free operation. In or-
der to convey, the screw shaft (7, 15) is used with right-hand thread and an
inclination which is specified depending on the helical diameter (I = 0.3 / 0.5 /
0.7 / 1.0 x D). The paddle shaft (8, 16) is used to mix the product at the same
time. Troughs with discharge gates (20) are used to meet higher hygienic re-
quirements. The trough cover (1) on the end trough is available in a simple
design or with choke release (2). If there is product back-up, actuate the posi-
tion switch (3) by lifting the choke release which causes an immediate stand-
still of the trough screw conveyor and the elements prior to it.
► It is possible to mount one or more intermediate outlet ports (11). Each trough
has a maximum length of 3 m. The intermediate bearing (14), which connects
two screw shafts and arranges their bearings at the same time, is located be-
tween two troughs.

Fig. 4.4 End trough

(1)Trough cover of the end trough (7)Screw shaft of the end trough
(2)Choke release (8)Paddle shaft of the end trough
(3)Position switch (9) Return paddle
(4) End trough (10) Discharge gate
(5)End outlet (11) Intermediate outlet port
(6)Trough base

BCHA
AHAS-67003-1-en-1208
16 Chapter 4 Description
 Fig. 4.5 Intermediate trough
(6) Trough base (13) Intermediate trough
(10) Discharge gate (14) Intermediate bearing
(11) Intermediate outlet port (15)Screw shaft of the end trough
(12) Trough cover (16)Paddle shaft of the end trough

4.3.3 Intermediate bearing

The intermediate bearing with coupling bolt (5), which connects two screw shafts
and arranges their bearings at the same time, is on the trough joint between two
troughs. The bearing bush (3), which consists of two parts, enables a simple instal-
lation and a quick replacement of the sliding bearing.

Fig. 4.6
(1) Supporting bracket (4) Sealing
(2) Bearing bracket (5) Coupling bolt
(3) Bearing bush

BCHA
AHAS-67003-1-en-1208
Chapter 4 Description 17
 4.3.4 Intermediate bearing one-sided

The screw shaft is divided into two pieces if the trough screw conveyors are very
long. They are driven separately. One-sided intermediate bearings with end bolt
are used as bearing for the screw shafts at the separation point.

Fig. 4.7
(6) End bolt

4.3.5 Inlet trough

► The inlet trough (1) is used, mostly under a bin, when the product feed rate is
not controlled. Depending on the requirements of the customer, inlet lengths
of 600 mm to 2100 mm with a gradation of 300 m.
► The stream of material is controlled according to the inlet trough (1) with the
inlet seat (2). The progressive screw shaft (3) ensures an optimum product
discharge.

Fig. 4.8
(1) Inlet trough
(2) Inlet seat
(3) Progressive screw shaft
(4) Intermediate bearing

BCHA
AHAS-67003-1-en-1208
18 Chapter 4 Description
4.3.6 Shaft speed monitor

The shaft speed monitor which is fastened to the base plate (3) on the front end
plate is used optionally. The bracket (1) is screwed to the end bolt and turns with
the screw shaft. The movement of the bracket is recorded by the inductive proximi-
ty switch (2). A missing signal breaks the electric circuit of the geared motor and
results in an immediate standstill of the trough screw conveyor and the elements
prior to it.

Fig. 4.9
(1) Bracket (4) Cover
(2) Inductive proximity switch (5) Front end plate
(3) Base plate (6) Flanged bearing

BCHA
AHAS-67003-1-en-1208
Chapter 4 Description 19
 4.3.7 Screw outlet core slide MUFA

(Refer to the operating instructions MUFA)

Fig. 4.10

4.4 Planning notes

4.4.1 General notes

► The maximum permissible speeds depend on the construction size and the
product.
► In order to treat the bulk material with care and prevent a dust explosion, the
trough screw conveyor AHAS may be designed only by the Buhler engineer-
ing team.
► Maximum angle in case of inclined transportation: 12°
▷ In case of dampening screws or distribution screws after dampening: ≤
6°.
▷ A reduction in the conveying capacity must be anticipated.
► Maximum recommended conveying distance with continuous screw shaft and
a motor: 21 m
► Maximum possible conveying distance: 42 m
► The use of the inlet trough with progressive screw shaft and inlet seat is rec-
ommended when the product feed rate is not controlled.
► Troughs with discharge gates are used to meet higher hygienic requirements.
► A minimum space requirement of 500 mm must be taken into account for op-
erating the discharge gate.

4.4.2 Space requirement in case of parallel arrangement of the trough screw conveyor

The trough base is available in various heights so that trough screw conveyors
which have different sizes can reach the same level if they are arranged parallel to
each other.

BCHA
AHAS-67003-1-en-1208
20 Chapter 4 Description
 Fig. 4.11 Trough base level AHAS-400

4.4.3 Fastening the trough screw conveyor

1. The trough screw conveyor AHAS is suspended / supported with angularly ad-
justable fastening elements (1). They can be fastened to the trough at an in-
terval of 500 mm.
2. R 1Y2" pipes (wall thickness 3.25 mm) are used as suspension or supporting
elements for the types AHAS-200, AHAS-250 and R 1Y2" pipes (wall thick-
ness 3.25 mm) for the types AHAS-315, AHAS-400 (2). The ends of the pipes
are closed with plastic plugs (3).
3. The recommended design of the suspension / support elements with rein-
forcement sheets (4) ensures the necessary stability and, under normal tem-
perature conditions, flexibility of the trough in the conveying direction.
4. An additional support for the drive is recommended.

Fig.4.12
5. The fastening device can also be mounted on the trough flange (5) for trough
screw conveyor sizes AHAS-315 and AHAS-400.

BCHA
AHAS-67003-1-en-1208
Chapter 4 Description 21
 Fig. 4.13

4.4.4 Trough screw conveyor with divided screw shaft

If the trough screw conveyors are longer than 21 m, the screw shaft is divided into
two pieces which are driven separately. One-sided intermediate bearings (1) are
used as bearing for the screw shafts at the separation point.

Fig. 4.14
(1) Intermediate bearing

BCHA
AHAS-67003-1-en-1208
22 Chapter 4 Description
5 Transport

5.1 Packaging symbols

1 This side up 2 Protect from moisture 3 Centre of gravity

4 Fragile 5 Attach here
► Observe the packaging symbols.
► For transportation by lorry or train, the trough screw conveyor AHAS is packed
and shipped in strong wooden crates, and for transportation by ship, it is
packed in closed crates in a seaworthy manner.

5.2 Checking the delivery

► Check the delivery for completeness according to the delivery note.
► Report any missing parts or transport damage. See Chapter "1.3 Contact".

5.3 Intermediate storage

► Observe the packaging symbols.
► Leave the machine and machine parts in the original packaging until begin-
ning the installation.
► Do not store the machine outdoors.
► Protect the machine from the effects of weather.
► Avoid temperature fluctuations.

→ Temperature fluctuations cause corrosion from condensation.

5.4 Transportation specifications

NOTICE
 Transportation should only be carried out by personnel familiar with this
task and trained for this purpose.

► The trough screw conveyor AHAS is pre-assembled in lengths of maximum

6 m.
► Observe the specified transportation position of the components. It is forbid-
den to transport them in any other position.
► Use appropriate transportation locking devices depending on the type and du-
ration of transportation. If the conveyors have been disassembled into several

BCHA
AHAS-67003-1-en-1208
Chapter 5 Transport 23
 parts, the locking transportation device specified by UNT-16130 should be
used for fixing the screw shaft where the intermediate bearing is missing.

Fig. 5.1

5.5 Lifting instructions

► A crane can be used for unloading and transportation.
NOTICE
 Check the permissible load-bearing capacity of the crane and whether the
crane is appropriate for unloading and transportation.

► Components should be protected from the effects of extreme temperature

fluctuation during transportation, as condensation can otherwise form under
the packing material. Avoid jolting the components.
► Freezing can result in bursting of motors, gear trains, pressure lines and fit-
tings.
► A crane can be used for unloading and transportation. In order to safely lift the
components with a crane, use cables whose lengths are suitable for lifting the
load.
► Select cable lengths which allow components to be suspended from the crane
in a horizontal position.
DANGER
 Never stand underneath suspended loads.

BCHA
AHAS-67003-1-en-1208
24 Chapter 5 Transport
6 Installation

6.1 Overview of installation sequence

Note the space requirement, floor openings, contact surfaces and floor loading
specified in the separate planning documents.

6.2 General
Check whether the .elements are deformed before beginning with the installation. It
is particularly important to check whether the trough flange is at right angles to the
axis and the screw shaft is straight. Possibly required alignment work must be car-
ried out before the installation.
NOTICE
 The installation manager is responsible for training his personnel and en-
suring their safety. All persons who work with the machine must have ac-
cess to the operating instructions.

6.3 Set-up
Before beginning with the installation, the individual elements must be identified
according to the disposition drawing and placed accordingly.

6.4 Installation sequence

The trough screw conveyor AHAS is pre-assembled by the manufacturer in lengths
of maximum 6 m. The following sequence must be observed for a complete instal-
lation at the location:
1. Pre-assemble the screw shafts (1), the intermediate bearings (2), the drive
bolts (3) and the end bolts (4). In case there is a progressive screw shaft (5),
make sure that it has the correct assembly position. Use suitable lubricants to
prevent frictional corrosion of the connections.

BCHA
AHAS-67003-1-en-1208
Chapter 6 Installation 25
 Fig. 6.1
2. Pre-assemble the drive unit (6) and the troughs (7). Do not mount the end
plate (CR foam tape Vitoflex NF 150, self-adhesive, UNR-53745-003).

Fig. 6.2
3. Now the pre-assembled screw shafts and the intermediate bearings can be
inserted into the troughs. Do not push them right up to the front end plate (9).
Fasten the supporting bracket (10) of the intermediate bearings to the holes
on the trough which have been provided for this purpose. Make sure that the
intermediate bearings do not get damaged due to sagging of the screw shafts.
Mount the end plate unit (11). Align the intermediate bearings and the flanged
bearings in such a manner that they are precisely aligned with the axis.
4. You should be able to turn the screw shaft slightly. The sliding bearings may
not squeak or become hot during continuous operation. If they squeak, align
the intermediate bearings more precisely with the axis and check the straight-
ness of the screw shafts and the troughs. If the troughs are not straight, they
can be slightly lifted with a pad.
5. The flanged bearing (12) functions as the fixed bearing. This is done by re-
moving the play at the outer ring of the rolling bearing with the fixed ring (13).
The flanged bearing (14) of the end plate unit does not require any fixed ring
as a floating bearing.

BCHA
AHAS-67003-1-en-1208
26 Chapter 6 Installation
 Fig. 6.3
6. Mount the trough cover (use CR foam tape Vitoflex NF 150, self-adhesive,
UNR- 53745-003). The inlet collars (15) can be attached at any point of the
trough screw conveyor depending on the local conditions. For this, suitable
holes which have the diameter of the gravity spout must be cut in the trough
cover.

Fig.6.4

6.5 Chain transmission

1. Fix the chain wheels, which should be precisely above each other, on the cor-
responding shafts with the clamping bushes (1).
2. The chain can be tensioned by shifting the geared motor (2).
3. Slightly open the fastening screws (3) on the geared motor.
4. Push the geared motor (4) slightly with the help of the straining screw (4) at
the back of the mounting plate (5).
5. Tension the chain only so much that it can be moved by hand by approx. 10
mm.

Fig. 6.5

BCHA
AHAS-67003-1-en-1208
Chapter 6 Installation 27
 6.6 Geared motor directly coupled
If the machine has a direct drive, make sure that the gear power output shaft and
the screw shaft are perfectly aligned. If required, align the gear train with the help
of pads. Observe the notes of the coupling supplier while mounting the coupling.

6.7 Flender and SEW spur geared motors

If the drives are delivered in a dismantled state, then they must be installed accord-
ing to the specifications of the manufacturer.

6.7.1 Spur gear train and geared motors

Preparation

► The specifications on the identification plate of the drive must correspond to

the voltage supply.
► The anti-corrosive agents must be removed totally from the power output
shafts and the flange surfaces (use usual commercial solvent). Do not allow
the solvent to enter the sealing lips of the rotary shaft seals (material damage).
► Prior to commissioning the machine, the screw plug must be replaced with the
delivered vent screw or ventilating valve. The screw plug is marked with a
plastic plug and may be over painted.
► Use only the prescribed material for the installation.

6.8 Disassembly
► After completing the work with the trough screw conveyor (extensive overhaul,
decomposition or scrapping), carry out its disassembly in the sequence of
steps opposite to that of installation.
► We recommend requesting a Buhler specialist to carry out the disassembly.
► Before beginning with the disassembly work, the responsible person must ask
the manufacturer for his instructions to ensure a safe disassembly.
► The trough screw conveyor may be disassembled only under observance of
all accident prevention measures and exclusively by personnel who have
been instructed to do so. This personnel must be familiarized with the safety
precautions.

6.9 Electrical components

Electrical connections must be made according to the supplied electrical wiring di-
agram.

6.9.1 Position switch of the trough cover with choke release

The function of the position switch on the choke release is to provide safety of per-
sons. When the choke release is lifted, the control circuit to the motor contactor is
switched off immediately.

BCHA
AHAS-67003-1-en-1208
28 Chapter 6 Installation
 Fig. 6.6
(1) Switch point for return (5) Switch condition
(2) Forced opening (5a) open
(3) Switch point acc. to EN 50041 (5b) closed
(4) Switch path in lift. direct

6.9.2 Proximity switch inductive to the shaft speed monitor

► The distance between the vane (2) at the shaft end and the proximity switch
(1) must be set during installation and must be 5 ... 8 mm.
► The proximity switch may not touch the vane (2).
► While setting the shaft speed monitor, make sure that in case of shaft break-
age, the motor is switched off via the control within 2 seconds.
A = External start monitoring B = Proximity switch

Fig. 6.7

BCHA
AHAS-67003-1-en-1208
Chapter 6 Installation 29
 6.10 Pneumatic components

6.10.1 Screw outlet core slide MUFA

(Refer to the operating instructions MUFA)

Fig. 6.8

BCHA
AHAS-67003-1-en-1208
30 Chapter 6 Installation
7 Commissioning

7.1 Initial start-up

DANGER
 Carry out all inspection work only when the machine is shut down (all ma-
chine movements have come to a standstill).
 The all-pole disconnecting safety switch must be at 《0》 and closed.
 It is forbidden to remove safety devices or to render them functionless for
the purpose of continuing to use the machine in spite of malfunctioning.

7.2 Inspection prior to commissioning

The inspection prior to commissioning must be carried out by specialised person-
nel.
1. Check the alignment of the troughs and the screw shaft.
2. There should be no foreign bodies inside the troughs.
3. Check the oil level in the gear train.
4. Check the lubrication of the flanged bearings.
5. Check whether the chain transmission has the required chain tension and cor-
rect it if necessary.
6. Check whether all sensors and switches are functioning properly.
7. The screw shaft must turn in the conveying direction in the counter-clockwise
direction.
8. The ribbon flight may not graze against the trough.
9. If the progressive screw shaft exists:
It should be mounted in such a manner that the inclination increases in the
conveying direction.
10. Are the coupling or chain cover and the trough cover attached to the conveyor
with screws?. Are the discharge gates (if present) closed?
Possible malfunctions must be remedied immediately.

NOTICE
 The conveyor should be run empty (no-load operation) for approximately
one to two hours before conveying material with it for the first time. During
the empty run, check whether, in particular, the bearings, the gear train and
the motor are heated and all trough connections as well as the suspension /
support become loose.

BCHA
AHAS-67003-1-en-1208
Chapter 7 Commissioning 31
 7.3 Setting the switching distance of the sensors
If sensors such as:
► capacitive sensors in the subsequent gravity spouting
► choke release with position switch
► shaft speed monitor
are present, they must be set in such a manner that a product back-up or the
standstill of the screw shaft can be detected immediately.

7.4 Checklist for checking EC conformity

The following points must be checked prior to/during commissioning of the ma-
chine：
1. The user is informed that the personnel must always have access to the oper-
ating instructions and that he is responsible for instructing the personnel.
2. Mounting and installation have been implemented in accordance with the op-
erating instructions,
3. The safety switch is wired correctly and its proper functioning has been tested.
4. The position switch on the choke release (if included in the planning) is
properly connected and its proper functioning has been tested.
5. The shaft speed monitor and the capacitive sensor (if included in the planning)
are properly connected and their proper functioning has been tested.
6. The electrical lines on and to the trough screw conveyor are properly connect-
ed according to the system diagram (check the correct position of the phases)
and secured against electric shocks and short circuit according to the local
safety regulations.
Warning signs have been attached to the following machine parts:
▷ Discharge gates
▷ Coupling / chain cover
▷ Choke release

BCHA
AHAS-67003-1-en-1208
32 Chapter 7 Commissioning
8 Operation

8.1 Operating the conveyor

► The AHAS is operated in series with other conveyors. The control is carried
out centrally. No control elements are attached to the AHAS.
► The user's part in the operation is limited to checking whether the operation is
being executed properly and monitoring the feeding and delivery of the mate-
rial which is to be conveyed. There should be no back-up as it could impair the
error-free functioning of the AHAS.
► If you notice a back-up of the conveyed material at the outlet, relevant
measures must be taken immediately to avoid machine damage.

8.2 Conveyance characteristics

► Almost all materials change their conveyance characteristics with humidity
(moisture content of the material to be conveyed as well as air humidity), tem-
perature, granulation etc.
► Changes in these characteristics influence the conveying capacity.
► Therefore, take appropriate measures to ensure that these changes are not
too extreme when the materials are being conveyed.
► Whenever possible, the AHAS should be run empty before shutting it down.

BCHA
AHAS-67003-1-en-1208
Chapter 8 Operation 33
 9 Troubleshooting

Fault Cause Remedy

High dust for- The trough cover, the choke ► Close the opening.
mation in the release or a discharge gate
vicinity of the is not properly closed.
trough
screw conveyor A product or aspiration line ► Check all lines and, if
is not properly connected. necessary, connect them
properly or replace them if
they are damaged

The motor is The screw is clogged ► Remove the back-up in

switched on but the subsequent element.
the trough Remedy the malfunction.
screw conveyor
► Move the product that has
is not conveying
got stuck by switching on
and off the motor several
times.
► If necessary, switch off
the motor and lock the
safety switch. Dismantle
the connecting sleeve or
the trough cover at the
outlet and clean the screw
The trough screw conveyor ► Check the conveyance
is empty element (or the machine)
on the inlet side
Screw shaft or drive bolt is ► Repair the damage
broken ► Contact the customer
service at Buhler AG
The capacitive sensor in the ► Remedy the malfunction
subsequent gravity spouting ► If required, correct the
or the position switch on the setting of the sensor
choke release respond

Error in the shaft speed ► Check the connection and

monitor the setting of the shaft
speed monitor

Failure in the geared motor ► Refer to the documents of

the manufacturer

BCHA
AHAS-67003-1-en-1208
34 Chapter 9 Troubleshooting
 Fault Cause Remedy

Trough screw Screw helix is grazing ► Check the flanged bear-

conveyor is against the trough ings and reset them if
making unusual necessary
noises The intermediate bearings ► Check whether the inter-
are 《squeaking》 mediate bearings have
worn out and replace the
bearing bushes if neces-
sary
► Align the flanged bearings
and the intermediate
bearings
The screw is clogged ► Remove the back-up in
the subsequent element.
Remedy the malfunction
► Move the product that has
got stuck by switching on
and off the motor several
times
► If necessary, switch off
the motor and lock the
safety switch. Dismantle
the connecting sleeve or
the trough cover at the
outlet and clean the screw
Foreign body in the trough ► Switch off the motor, lock
screw conveyor the safety switch and re-
move the foreign body

9.1.1 Troubleshooting in the gear train

Fault Cause Remedy

Unusual, regu- Rolling / grinding noise: De- ► Check the oil level
lar running fective bearings ► Contact the customer ser-
noises vice
Knocking noise: Irregularity
in the toothed wheel work

Unusual, irregu- Foreign body in oil ► Check the oil level

lar running noi- ► Shut down the drive,
ses. ► Contact the customer ser-
vice
Oil leakage at a) Seal is defective ► In case of a), contact the
the motor flange customer Service
b) Gear train has not been
in the motor ► In case of b), deaerate the
deaerated
shaft seal gear train
in the gear train
flange
in the rotary
shaft seal on
the drive side
Oil is leaking Too much oil ► Correct the oil quantity

BCHA
AHAS-67003-1-en-1208
Chapter 9 Troubleshooting 35
 Fault Cause Remedy

out of the vent The vent screw has been ► Mount the vent screw cor-
screw mounted incorrectly rectly

Frequent cold start (oil ► Replace the vent screw

foams) and/ or high oil level with a valve

Rise in temper- The oil level in the gear trai- ► Check the oil level at room
ature at housing is too low temperature, if necessary
the bearing refill oil
points The oil is too old ► Check when the oil was
changed the last time.if
necessary, change the oil
(refer to the maintenance
schedule)
Defective bearings ► Replace the defective
bearings
Rise in opera- The oil level in the gear train ► Check the oil level at room
ting tempera- housing is too high temperature, if necessary
ture correct the oil level

The oil is too old ► Check when the oil was

changed the last time. if
necessary, change the oil
(refer to the maintenance
schedule)
The oil is extremely soiled ► Change the oil

The ventilator cowl of the ► Clean the ventilator cowl

motor and/or the drive is very and the drive surface
dirty
Gear train nois- The toothed wheel work is ► Consult the customer ser-
es have damaged vice team; check the
changed toothed components, if
necessary replace the
damaged components
Bearing clearance has be- ► Set the bearing clearance
come larger

Defective bearings ► Replace the defective

bearings
Too high external load on the ► Reduce the load to the
power input or output nominal value

BCHA
AHAS-67003-1-en-1208
36 Chapter 9 Troubleshooting
10 Maintenance

DANGER
 Carry out all maintenance, cleaning and overhaul work only when the ma-
chine is shut down (all machine movements have come to a standstill).
 Set the service or local switch to《0》 and secure it with a lock against
activation.

10.1 Maintenance schedule

After carrying out maintenance work, always make sure that there are no foreign
bodies on the inner side of the trough screw conveyor.
Machine part Action Interval

Troughs and Check whether they have worn Every 3 months

screw out. Minimal wear and tear is per-
shafts missible. The operation should be
carried out until the next overhaul
Gear motor Check the oil temperature Daily
Check whether the gear train
noises have changed
Check the oil level Once a month
Check whether the gear train is
sealed properly
Check whether the fastening At least once a year
screws have a tight fit
Carry out a complete check-up of
the drive
Intermediate / Acoustic check to determine unu- Daily
end bearings sual noises
Intermediate If there is a wear and tear of 3 mm No maintenance work
bearings replace the sliding bearings. The required under normal
operation should be carried out operating conditions.
until the next overhaul. The sliding Recommendation: Ap-
bearings may not become over- prox.
heated every 10000 hours; at
the latest 2 years after
the last over-haul
Electrical con- Operational check of the electrical
trol system control system including emer-
gency stop and inspection of the Once a year
acknowledgement in the control (unless stipulated oth-
system. Inspection of the setting erwise by law)
of the motor safety device
General inspection of the whole
electrical
equipment and threaded joints as
well as insulation

BCHA
AHAS-67003-1-en-1208
Chapter 10 Maintenance 37
 Machine part Action Interval

Coupling Check whether the gear rim has No maintenance work

worn out required under normal
operating conditions.
Inspection during gen-
eral over haul of the
conveyor
Chain trans- Check chain tension according to Every 3 months
mission 《Chain transmission》

10.2 Lubrication schedule

Machine part Action Interval
Geared motor Relubricate the rolling Every 4000 hours; at the latest
bearings 1 year after the last lubrication

First and all subse- Approx. every 10000 hours; at

quent oil changes the latest 3 years after the last
oil change
Chain transmission Lubricate the chain Every 6 months

10.3 Lubrication

NOTICE
 We recommend observing the special maintenance instructions of the con-
cerned manufacturer in any.

10.3.1 Spur gear train and geared motors

► If the gear train is making noises, it is necessary to repair or replace it.

► Change the oil only when the gear train has achieved the operating tempera-
ture as the lack of flowability due to too cold oil can make it difficult to dis-
charge correctly.
DANGER
 The surface of the gear train may only be warm to the touch.
 There is danger of combustion if the oil is too hot.

1. Put the container under the oil drain plug.

2. Remove the oil level screw, vent screw/valve and the oil drain plug.
3. Drain the oil completely.
4. Screw in the oil drain plug.
5. Fill in fresh oil through the vent bore hole. Check the oil quantity with the oil
level screw.
6. Screw in the oil level screw.
7. Screw in the vent screw/valve.
The rolling bearings have been filled with grease by the manufacturer.

BCHA
AHAS-67003-1-en-1208
38 Chapter 10 Maintenance
 NOTICE
 It is recommended that bearings with lubricating nipples be lubricated at
weekly or monthly intervals (depending on the daily running time). Motors
with fittings for subsequent lubrication generally have a plate affixed with
details of lubricating intervals and quantities.

10.4 Lubricant tables

10.4.1 Spur gear train

The oil viscosity (ISO VG class) specified on the performance plate of the gear
train is decisive for the selection of oil. The specified viscosity class applies to the
contractually agreed operating instructions.
NOTICE
 For further instructions, refer to the operating instructions of the manufac-
turer.

10.4.2 Rolling bearings for the geared motor

10.4.3 End bearings

End bearings: KIübersinth UH1 14-31

(Rolling and sliding bearing grease for low temperatures and high speeds)

10.4.4 Chain transmission

Use viscous oil with adherence additives or usual commercial chain grease as lub-
ricant. It is important that the lubricant penetrates right up to the joint surfaces.

BCHA
AHAS-67003-1-en-1208
Chapter 10 Maintenance 39
 10.5 Cleaning schedule
The trough screw conveyor must be cleaned when the whole system is cleaned.
System part Measure Cleaning interval

Geared mo- Clean the vent screw Every 3 months

tor Clean the drive Depending on how dirty it
is
End bearings Dismount the rolling bearings, No maintenance work re-
clean with petroleum ether (do quired under normal oper-
not use petroleum) and fill ap- ating conditions
proximately 50% of the available Recommendation: Approx.
room in the bearings with new every 10000 hours; at the
food-compatible rolling bearing latest 2 years after the last
grease over-haul
Chain Wash the chain thoroughly with Once a year
transmission petroleum ether (do not use pet-
rol or diesel) and keep it in a
solvent for chains for half an hour

BCHA
AHAS-67003-1-en-1208
40 Chapter 10 Maintenance
11 Decommissioning

11.1 Disposal
► The trough screw conveyor and its components must be disposed of accord-
ing to the applicable local laws.
► If the machine is put out of operation for environmental protection and recy-
cling, observe the following:
▷ Drain the liquids (gear train oil) in special containers and deposit them
with treatment factories.
▷ Dispose of special waste (e.g. batteries) in accordance with relevant reg-
ulations.
▷ Separate plastic parts and give away for recycling.
▷ Separate metallic parts according to the type of metal for shredding or
scrapping.

BCHA
AHAS-67003-1-en-1208
Chapter 11 Decommissioning 41
 12 Spare parts

12.1 Inventory of spare parts

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

12.2 Spare parts identification

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

12.3 Order instructions

Incomplete information in spare parts orders can result in incorrect deliveries.
An order for spare parts must include the following information:

 Machine No.
 Subassembly number or part No.
 Designation
 Quantity
 Motors: Manufacturer and motor number
 Gears: Manufacturer and gear number

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

BCHA
AHAS-67003-1-en-1208
42 Chapter 12 Spare parts