Users Manual for Installation, maintenance and working

Edition 01/2003

Version 03.01

Chapter 1: Introduction

1 INTRODUCTION .................................................................................................................. 3

2 Preliminary machine description ........................................................................................... 8

1.1 HOW TO USE THE USERS MANUAL...................................................................................3 1.2 Manual users..........................................................................................................................4 1.3 General information................................................................................................................5 1.4 Safety warning........................................................................................................................6 1.5 Guarantee...............................................................................................................................6 1.6 General delivery requirements................................................................................................6 1.7 Personnel professional qualification........................................................................................7 1.8 Assistance request..................................................................................................................7 2.1 Introduction.............................................................................................................................8 2.2 Supplied Components ............................................................................................................8 2.3 Attachment (Optional).............................................................................................................8 2.4 Technical data........................................................................................................................9 2.5 Standard usage....................................................................................................................10 2.6 Non-standard usage ............................................................................................................10 2.7 Worker intervention...............................................................................................................10 2.8 Risks.....................................................................................................................................10 3.1 Storage.................................................................................................................................11 3.2 Machine lifting.......................................................................................................................11 3.3 Moving packed devices.........................................................................................................11 3.4 Storage.................................................................................................................................11 4.1 Introduction...........................................................................................................................12 4.2 Required space for usage and maintenance.........................................................................12 It is recommended to use the machine inside an enclosed space in order to perform both control and maintenance easier..............................................................................................................12 4.3 Placing..................................................................................................................................12 5.1 General prescriptions...........................................................................................................15 5.2 Test.......................................................................................................................................15 5.3 Warnings...............................................................................................................................15 5.4 Process description...............................................................................................................15 5.5 Setting for work.....................................................................................................................16 5.6 Noise emission.....................................................................................................................17 5.7 Cleaning................................................................................................................................17 5.8 Maintenance and repair .......................................................................................................17

3 TRANSPORT - MOVING ..................................................................................................... 11

4 INSTALLATION ................................................................................................................. 12

5 Machine Usage ................................................................................................................. 15

6 DEMOLITION .................................................................................................................... 18 7 WORKING IN SAFETY ........................................................................................................ 19

8 ENCLOSURES ................................................................................................................... 20

7.1 General usage safety prescriptions ......................................................................................19 7.2 Safety prescriptions for service engineer ............................................................................19 8.1 Maintenance - repair ...........................................................................................................20 8.2 Main failure summary............................................................................................................21 8.3 Spare parts summary............................................................................................................22 8.4 Schema quadro elettrico.......................................................................................................23 8.5 Certificato di collaudo............................................................................................................24 8.6 Dichiarazione CE di conformit.............................................................................................25

Chapter 1: Introduction

1 INTRODUCTION
1.1 HOW TO USE THE USERS MANUAL

Chapter 1: Introduction

According to Direttiva macchine (98/37/CE) the Users 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 Users manual), are "ECOMAC S.r.l." property which reserves all rights. This Users 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 users

The 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, 12 84018 Scafati (SA) Phone: 081 850 22 16 Fax 081 856 75 63 e-mail : info@ecomacsrl.com Web : 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 warning

Operations described in the present users 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 Guarantee
A 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 requirements

On 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 Users 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 request

Service is provided by:

ECOMAC S.R.L.
Via Galileo Ferraris, 12 84018 Scafati (SA) Phone. 081 850 2216 Fax 081 856 7563 E-mail : info@ecomacsrl.com Web site : www.ecomacsrl.com

Chapter 5 Usage

2 Preliminary machine description

2.1 Introduction
Polyelectrolyte 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

STPL 12 - 60

STPL 10

Type STPL 10 STPL 12 STPL 15 STPL 20 STPL 25 STPL 30 STPL 40 STPL 50 STPL 60

A [mm]

B [mm]

C [mm]

Volume [l]

Hopper capacity [kg]

Flow rate [l/h]

Empty weight [kg]

Electric power [kW]

1600 1500 2000 2500 3000 3000 3000 3500 4000

1700 1700 1700 1700 1700 1700 2400 2400 2400

1300 1300 1300 1300 1300 1500 1500 1500 1500

1200 1350 1800 2250 2700 3430 4680 5460 6460

50 50 50 50 50 75 100 100 100

1000 1200 1500 2000 2500 3000 4000 5000 6000

420 450 480 530 560 620 680 720 750

1.28 1.28 1.28 1.28 1.28 1.68 1.68 1.68 1.68

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 users 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 intervention

The machine works automatically, worker will perform periodic controls as prescribed in users manual.

2.8 Risks
During 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 lifting

For 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 Weights
See technical attachments

3.3 Moving packed devices

Use suitable lifting device.

3.4 Storage
The 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 Introduction
During 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 users 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 Placing
The machine has to be placed on a clean basement; For machine usage only required electric and hydraulic connections are required Hydraulic connection

Ingresso acqua

Data

Chapter 5 Usage

Type Water system pressure Water system flow rate

Bar Mc/h min. 2 max. 4 >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 PHASE NUMBER FREQUENCY ELECTRIC POWER V Hz kW

400 3 50 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 prescriptions
All 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 Test
Before sending the machine has been subjected tests. Inspection report is an attachment of present users manual (see paragraph 8.4)

5.3 Warnings
Check the machine has been properly fastened Comply with ht information content in the users manual

5.4 Process description

Powder 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. 2. 3. 4. 5. 6. 7. 8. Check both hydraulic and electric connections Close bottom valve Check powder level in the charging hopper Check water pressure and if necessary tune up it using the pressure reducing valve Set all device in automatic mode working Push start cycle button Control dilution water flow rate according with hourly machine flow rate (see page 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 emission

Machine noise level is less than allowable limits.

5.7 Cleaning
5.7.1 Warnings
During 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 operation

Use 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

WARNING
Machine 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.

Warnings
In 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 unconscious o if electric disconnection is not possible aid injured using insulators like wood, PVC, leather or fabric o call immediately medical staff and hospitalize the injured

Cap 8: Attachments

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

1.1 insufficient pressure system 1.1 Try to restore correct pressure 1 Starting failure: 1.2 non-adjusted pressure switch 1.3 dirty probes level 1.2 Call Ecomac s.r.l. service 1.3 Try to clean the probes

2.1 incorrect motor direction of 2.1 Try to restore correct direction rotation 2 Excessive motors vibration 2.2 Too dense solution 2.3 Nuts and bolts loosed 3.1 Excessive powder dosage 3 Too dense solution 3.2 Insufficient water dilution flow rate 4.1 Insufficient powder dosage 4.2 Excessive water dilution flow rate 4.3 Dosage cochlea clogged 4.4 Powder charging hopper 2.2 Try to reduce density 2.3 Try to tighten 3.1 Reduce the powder dosage 3.2 Increase water dilution flow rate

4.1 Increase powder dosage 4.2 Reduce water dilution flow rate 4.3 Clean the cochlea 4.4 Fill the hopper 5.1 Reduce the powder dosage 5.2 Change product 5.3 Try to restore correct pressure

Too diluted solution

empty
5.1 Excessive powder dosage 5 Lumpy solution 5.2 low quality powder 5.3 Low operation pressure

Cap 8: Attachments

8.3 Spare parts summary

Component Water inlet filter pressure reducing valve regulation valve
Pressure switch

CODE
FTD RIDP... VRBG RPT EV FL GDAP GCDP MDP VDP RDP ELG1 ELG2 ELG3 MEAG RE1V RE2-3V VSF CDP CAP CAPR TCP ICD VBR

electric valve
Flow meter Dilution system Powder dosage system ( motor inverter reduction gear) Powder dosage motor Powder dosage inverter Powder dosage reduction gear

Electric stirrer in first dilution tank std Electric stirrer in second dilution tank std Electric stirrer in third dilution tank (optional) std Electric stirrers motors Electric stirrer reduction gear in first dilution tank Electric stirrer reduction gear in second and third dilution tanks
Bottom discharge valves Powder dosage cochlea Powder feeding line std

Heated powder feeding line std (optional)

Powder charging hopper ICD Shaker

Cap 8: Attachments

8.4 Schema quadro elettrico

Cap 8: Attachments

8.5 Certificato di collaudo

Cap 8: Attachments

8.6 Dichiarazione CE di conformit