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User’s Manual for
Installation, maintenance
and working
Edition 01/2003 Version 03.01
Chapter 1: Introduction
1 INTRODUCTION.....................................................................................................................4
1.1 HOW TO USE THE USER’S MANUAL..............................................................................41.2 Manual users......................................................................................................................41.3 General information.......................................................................................................5
1.3.1 Supplier data..................................................................................................................51.3.2 Machine data..................................................................................................................51.3.3 Machine Technical service.............................................................................................5
1.4 Safety warning....................................................................................................................61.5 Guarantee...........................................................................................................................61.6 General delivery requirements...........................................................................................61.7 Personnel professional qualification...................................................................................71.8 Assistance request.............................................................................................................7
2 Preliminary machine description......................................................................8
2.1 Introduction.........................................................................................................................82.2 Supplied Components........................................................................................................82.3 Attachment (Optional).........................................................................................................82.4 Technical data....................................................................................................................92.5 Standard usage................................................................................................................102.6 Non-standard usage.........................................................................................................102.7 Worker intervention..........................................................................................................102.8 Risks.................................................................................................................................10
3 TRANSPORT - MOVING....................................................................................11
3.1 Storage.............................................................................................................................113.1.1 General recommendation.............................................................................................11
3.2 Machine lifting...................................................................................................................113.2.1 Weights.........................................................................................................................11
3.3 Moving packed devices....................................................................................................113.4 Storage.............................................................................................................................11
4 INSTALLATION...............................................................................................12
4.1 Introduction.......................................................................................................................124.2 Required space for usage and maintenance....................................................................12It is recommended to use the machine inside an enclosed space in order to perform both control and maintenance easier...............................................................................................................124.3 Placing..............................................................................................................................12
5 Machine Usage..............................................................................................15
5.1 General prescriptions.......................................................................................................155.2 Test...................................................................................................................................155.3 Warnings..........................................................................................................................155.4 Process description..........................................................................................................155.5 Setting for work.................................................................................................................165.6 Noise emission.................................................................................................................175.7 Cleaning...........................................................................................................................17
5.7.1 Warnings......................................................................................................................175.7.2 Cleaning operation.......................................................................................................17
5.8 Maintenance and repair....................................................................................................176 DEMOLITION..................................................................................................18
7 WORKING IN SAFETY......................................................................................19
7.1 General usage safety prescriptions..................................................................................197.2 Safety prescriptions for service engineer.........................................................................19
8 ENCLOSURES.................................................................................................20
8.1 Maintenance - repair........................................................................................................20
Chapter 1: Introduction
8.2 Main failure summary.......................................................................................................218.3 Spare parts summary.......................................................................................................228.4 Schema quadro elettrico..................................................................................................238.5 Certificato di collaudo.......................................................................................................248.6 Dichiarazione CE di conformità........................................................................................25
Chapter 1: Introduction
1 INTRODUCTION
1.1 HOW TO USE THE USER’S MANUAL
According to Direttiva macchine (98/37/CE) the User’s manual is considered an integral part of machine supplying The contents of present manual can be modified without notice and are not binding for "ECOMAC S.r.l."All documents provide with the machine (including present User’s manual), are "ECOMAC S.r.l." property which reserves all rights.This User’s manual can not be reproduced or photocopied, even partly (as well as its attachments), without "ECOMAC S.r.l.", authorization"ECOMAC S.r.l" is not responsible for damages caused by both an incorrect machine use, and an improper machine maintenance or cleaning.
It is strictly recommended to read this manual before to use the machine.
Customer is responsible of his improper actions which compromise the correct machine working, and he is obliged to observe all safety recommendations described in the present manual The manual has to be used in such way to avoid content damage. It is strictly forbidden to remove, or rewrite part of the manual. Furthermore the manual has to be kept dry, protected from heat source. Finally it should be always available for consultations.
1.2 Manual usersThe manual has to be read by:
all' Amministratore dell' azienda
al Responsabile del Servizio di prevenzione e protezione (RSPP)
al Capo Tecnico o Capo Reparto
Installation personnel
Running personnel
Maintenance personnel
Chapter 1: Introduction
1.3 General information
1.3.1 Supplier data
Headquarter : ECOMAC S.R.L.Via Galileo Ferraris, 1284018 Scafati (SA)Phone: 081 850 22 16Fax 081 856 75 63 e-mail : [email protected] : www.ecomacsrl.com
1.3.2 Machine data
Type
Identification number :
Installed Power:
Construction year:
In case of spare part request, both type and identification number indicate on rating plate (shown below) have to be provided
Rating plate always has to be kept clean and readable
1.3.3 Machine Technical service"ECOMAC S.r.l." is not responsible for improper machine working, if all recommendations present in this manual are nor properly respected
Chapter 1: Introduction
1.4 Safety warningOperations described in the present user’s manual concerning machine life cycle have been carefully analyzed by Ecomac S.r.l.
Warning !
"Ecomac S.r.l." refuses all responsibility concerning both injuries and damages caused by non-observance of prescribed recommendation
Workers have to be informed about dangers connected with machine working
1.5 GuaranteeA one-year guarantee starting since sending date is included. The guarantee does not include defects caused by non-observance of prescribed recommendation as well as those due to deterioration of components subjected to periodic replacement;Faulty components and equipments if provided by guarantee conditions, will be delivered free of charge as soon as possible.Guarantee conditions do not include disassembly and assembly of component or device to be substituted as well as every further expense due to faulty component.
1.6 General delivery requirementsOn receipt of the machine, remove the package and check:
The integrity of supplied devices
The correspondence between supplied devices technical features and those required in the supplying specification (see delivery note)
If damages are discovered, please inform immediately and in detail the carrier and "Ecomac S.r.l." for information. Supplying includes
User’s Manual
Test certificate.
CE Compliance declaration
Chapter 1: Introduction
1.7 Personnel professional qualification
Device maintenance, installation and working have to be carried out by highly qualified staff as well as electric connection.
1.8 Assistance requestService is provided by:
ECOMAC S.R.L.Via Galileo Ferraris, 1284018 Scafati (SA)Phone. 081 850 2216 Fax 081 856 7563 E-mail : [email protected] site : www.ecomacsrl.com
Chapter 5 Usage
2 Preliminary machine description
2.1 IntroductionPolyelectrolyte preparation section performs automatic making of polymer solutions used as agglomerative for suspended particles contained in waste water coming from treatment plant; in fact these solutions are used for waste water treatment both in primary clari-flocculation phase and in sludge dehydration final phase. Powder amount, measured by a cochlea provided with a converter, drops into a polizene tank (characterized by a high molecular density and low humidity adsorbing capacity) where using pressurized water, a suitable dilution is performed. Obtained solution drops into below tank, which is the primary dispersion section. Subsequently the solution flows into secondary section, and finally into tertiary section used for storage.Solution is continuously stirred by low speed agitators, placed along sections, the system is provided with a control panel, which allows automatic system working. In fact control panel allows:
automatic starting and stopping for both powder dosage system and water inlet (by level probes);
Safety shutdown; Minimum solution level control; Minimum water pressure alarm; Starting and control of other devices.
2.2 Supplied Components Tank obtained with folded INOX AISI 304 sheets, comparted in different sections, and
equipped with supporting system; Tank covering made of INOX AISI 304; Dilution tank made of plastics; Powder batching system made of INOX AISI 304, provided with 10% to 100% regulation
system; N° 2 stirrers (186 - 140 rpm) provided with INOX AISI 304 shaft and screw; Pipeline for water inlet, equipped with filtering system, pressure reducing valve, flow meter,
pressure switch, gauge, electric valve and regulation valve.
2.3 Attachment (Optional)
Discharge manifold Anti-condensate system; Powder level control system Third stirrer Metering pump prearrangement (max two) Metering pump remote control Fourth section equipped with pump Electronic control system
Chapter 5 Usage
2.4 Technical data
Type A[mm]
B[mm]
C[mm]
Volume[l]
Hoppercapacity[kg]
Flow rate[l/h]
Empty weight[kg]
Electric power[kW]
STPL 10 1600 1700 1300 1200 50 1000 420 1.28
STPL 12 1500 1700 1300 1350 50 1200 450 1.28
STPL 15 2000 1700 1300 1800 50 1500 480 1.28
STPL 20 2500 1700 1300 2250 50 2000 530 1.28
STPL 25 3000 1700 1300 2700 50 2500 560 1.28
STPL 30 3000 1700 1500 3430 75 3000 620 1.68
STPL 40 3000 2400 1500 4680 100 4000 680 1.68
STPL 50 3500 2400 1500 5460 100 5000 720 1.68
STPL 60 4000 2400 1500 6460 100 6000 750 1.68
STPL 12 - 60
STPL 10
Chapter 5 Usage
2.5 Standard usage
Automatic preparation of polymeric solutions used for agglomeration of suspended matter present in water coming from waste water treatment plant
2.6 Non-standard usage The machine has to be used by highly qualified staff which have read user’s manual
Warning !"Ecomac S.r.l." refuses all responsibility concerning both injuries and damages caused by non-observance of prescribed recommendation Workers have to be informed about dangers connected with machine working
2.7 Worker interventionThe machine works automatically, worker will perform periodic controls as prescribed in user’s manual.
2.8 RisksDuring machine working safety distance has to be respected Accidents can be caused from non-observance of safety recommendation
Chapter 5 Usage
3 TRANSPORT - MOVING
3.1 Storage
3.1.1 General recommendation
During machine moving, safety distance has to be respected Move the machine very slowly and carefully using a forklift truck/crane, verifying their
suitability for considered weight
Warning !The machine barycentre is not coincident with geometric centre
3.2 Machine liftingFor machine lifting it is strictly recommended to use two cables or straps placed on the machine extremities.Both lifting device (forklift truck/crane) and the cables have to be suitable for machine weight
Warning !
Moving and transport of machine even if it is still packed have to be performed by highly qualified staff.
Moreover considering machine overall dimensions it is strictly recommended that the lift truck operator receives necessary instructions from assistants
3.2.1 WeightsSee technical attachments
3.3 Moving packed devicesUse suitable lifting device.
3.4 StorageThe machine also if packed, has to be stored in a covered, clean and dry place, protected from dust and atmospheric agents.
Chapter 5 Usage
4 INSTALLATION
4.1 IntroductionDuring installation precautionary measures have to be taken in order to avoid incorrect assembling.Installation, assembling and maintenance have to be performed by highly qualified staff which have read user’s manual.
4.2 Required space for usage and maintenance
It is recommended to use the machine inside an enclosed space in order to perform both control and maintenance easier.
4.3 PlacingThe machine has to be placed on a clean basement; For machine usage only required electric and hydraulic connections are required
Hydraulic connection
Ingresso acqua
DataType ……………
Chapter 5 Usage
Water system pressure Bar min. 2 – max. 4Water system flow rate Mc/h >50% Machine flow rate
Machine is provide with a pipeline equipped with:
Water inlet filter Pressure reducing valve Flow rate control valve Pressure switch Solenoid valve Flow meter Dissolver
Chapter 5 Usage
Electric connections
Data
TYPE ……………INPUT VOLTAGE V 400PHASE NUMBER - 3FREQUENCY Hz 50ELECTRIC POWER kW See technical table
Electric machine components are already cabled on board, so the operator must just connect the machine to the electric panel (see attached electric scheme)
Warning !Check motor direction of rotation and if it is different from the one indicates, exchange the phases. Provide an emergency stop button near the machine
Chapter 5 Usage
5 Machine Usage
5.1 General prescriptionsAll operations necessary for machine working have to be performed by highly qualified staff.Before using the machine, it is strictly recommended to check it in order to verify absence of damages occurred during transport and installation. More over make sure that request input voltage is properly provided to the machine
5.2 TestBefore sending the machine has been subjected tests. Inspection report is an attachment of present user’s manual (see paragraph 8.4)
5.3 Warnings
Check the machine has been properly fastened Comply with ht information content in the user’s manual
5.4 Process descriptionPowder amount, measured by a cochlea (3) provided with a converter, drops into a polizene tank (5) (characterized by a high molecular density and low humidity adsorbing capacity) where using pressurized water, a suitable dilution is performed.Obtained solution drops into below tank, which is the primary dispersion section. Subsequently the solution flows into secondary section, and finally into tertiary section used for storage.Solution is continuously stirred by low speed agitators (6) (7), placed along sections, the system is provided with a control panel, which allows automatic system working.
Chapter 5 Usage
5.5 Setting for work
Warning !Check motor direction of rotation and if it is different from the one indicates, exchange the phases.
Preliminary operations:
1. Check both hydraulic and electric connections2. Close bottom valve3. Check powder level in the charging hopper4. Check water pressure and if necessary tune up it using the pressure reducing valve5. Set all device in automatic mode working6. Push start cycle button7. Control dilution water flow rate according with hourly machine flow rate (see page 8)8. Control powder dosage (using provide inverter) taking into account powder characteristics
and required concentration.
Ingresso acqua
Warning
Powder dosage control has to be performed only when the motor is running
Chapter 5 Usage
5.6 Noise emissionMachine noise level is less than allowable limits.
5.7 Cleaning
5.7.1 WarningsDuring cleaning is necessary:
Switch off input voltage and disconnect hydraulic input from the machine
Make sure that security lock is on (on electric panel)
Worker has to wear suitable protection devices
5.7.2 Cleaning operationUse water to clean mechanical components.
5.8 Maintenance and repair
SEE ATTACHMENTS FOR MAIN MAINTENANCE OPERATIONS
SEE ATTACHMENTS FOR MAIN FAILURE LIST
SEE ATTACHMENTS FOR SPARES
Cap 6: Demolition
6 DEMOLITION
WARNINGMachine deactivation and demolition have to be performed by highly qualified staff
In order to allow raw materials reuse, it is necessary to separate:
Package
Metallic parts
Synthetic parts
Exhausted lubricating oil
Electric motor
Attention!It is compulsory to comply with regulations in force concerning production, collection and disposal of waste (V. D.Lgs n. 22/97). Exhausted lubricating oil must be disposed through Consorzio Nazionale Obbligatorio. Package must be disposed in according with TIT. II del Decreto Legislativo 22/97.
If the customer requires a service intervention for machine demolition or repair, he takes all risks concerning both demolition operations and waste disposal. Similarly he assumes all responsibility if provides by himself for machine demolition
Attention!Ecomac S.r.l. refuses all responsibilities for damages or injuries caused by an unsuitable reuse of machine single parts.
WarningsIn case of demolition, both rating plate and all machine documents must be destroyed
Cap 7: Further information
7 WORKING IN SAFETY
7.1 General usage safety prescriptions - It is absolutely forbidden to wear:
Rings, watch, jewels, dangling clothing (like tie), torn dress, scarves, unbuttoned jacket, blouse with open zip.
- Otherwise it is strictly recommended to wear anti-industrial injury clothing like: helmet, anti-sliding shoes, anti-noise device, safety glasses, gloves ect.
- Consult employer for more information about safety prescription and anti-industrial injury devices.
- Do not start machine in failure conditions - Before starting, make sure that no risk condition is present- Inform immediately a person in charge of maintenance when irregular working is occurred- Make sure of safety devices integrity and efficiency
7.2 Safety prescriptions for service engineer - Keep clean and dry the zone where maintenance operations are performed, eliminate
immediately spots of oil- Every maintenance operations must be performed after the machine has been switched off
and disconnected from current - Every maintenance operations must be performed exclusively by authorized personnel - Every maintenance operations must be previously authorized- Observe recommended prescriptions concerning maintenance operations- Do not insert fingers, limbs and other body parts inside cutting openings- Do not use pressurized air for cleaning, and if it is absolutely necessary, use anti-injury
glasses, and keep the pressure below 2 bar- Do not use free flame during maintenance operations- Do not lubricate the machine when working- If an accident due to electrocution occurs:
o disconnect the machine from current,o remove injured worker from conductor being him usually unconsciouso if electric disconnection is not possible aid injured using insulators like wood, PVC,
leather or fabrico call immediately medical staff and hospitalize the injured
Cap 8: Attachments
8 ENCLOSURES
8.1 Maintenance - repair
Main maintenance intervention:
Check periodically machine level noise
Clean periodically level probe
Clean periodically powder dosage cochlea and connected pipeline
Check periodically efficiency of components related to water dilution line
Clean powder dilution system
Clean periodically the flow meter
Clean filter at water dilution inlet section
Above operations must be carried out after disconnection of machine from hydraulic and electric input
Cap 8: Attachments
8.2 Main failure summary
Problem Probably reason Action
1 Starting failure:
1.1 insufficient pressure system 1.1 Try to restore correct pressure
1.2 non-adjusted pressure switch
1.2 Call Ecomac s.r.l. service
1.3 dirty probes level 1.3 Try to clean the probes
2Excessive motors
vibration
2.1 incorrect motor direction of rotation
2.1 Try to restore correct direction
2.2 Too dense solution 2.2 Try to reduce density
2.3 Nuts and bolts loosed 2.3 Try to tighten
3 Too dense solution3.1 Excessive powder dosage 3.1 Reduce the powder dosage
3.2 Insufficient water dilution flow rate
3.2 Increase water dilution flow rate
4 Too diluted solution
4.1 Insufficient powder dosage 4.1 Increase powder dosage
4.2 Excessive water dilution flow rate 4.2 Reduce water dilution flow rate
4.3 Dosage cochlea clogged 4.3 Clean the cochlea
4.4 Powder charging hopper empty 4.4 Fill the hopper
5 Lumpy solution
5.1 Excessive powder dosage 5.1 Reduce the powder dosage
5.2 low quality powder 5.2 Change product
5.3 Low operation pressure 5.3 Try to restore correct pressure
Cap 8: Attachments
8.3 Spare parts summary
Component CODE
Water inlet filter FTD…
pressure reducing valve RIDP...
regulation valve VRBG…
Pressure switch RPT…
electric valve EV…
Flow meter FL…
Dilution system GDAP…
Powder dosage system ( motor – inverter – reduction gear) GCDP…
Powder dosage motor MDP…
Powder dosage inverter VDP…
Powder dosage reduction gear RDP…
Electric stirrer in first dilution tank std ELG1
Electric stirrer in second dilution tank std ELG2
Electric stirrer in third dilution tank (optional) std ELG3
Electric stirrer’s motors MEAG…
Electric stirrer reduction gear in first dilution tank RE1V…
Electric stirrer reduction gear in second and third dilution tanks RE2-3V…
Bottom discharge valves VSF…
Powder dosage cochlea CDP…
Powder feeding line std CAP…
Heated powder feeding line std (optional) CAPR…
Powder charging hopper TCP…
ICD ICD…
Shaker VBR
Cap 8: Attachments
8.4 Schema quadro elettrico
Cap 8: Attachments
8.5 Certificato di collaudo
Cap 8: Attachments
8.6 Dichiarazione CE di conformità
