GEA Niro Soavi One7TS User manual

GEA Mechanical Equipmentengineering for a better world
Instruction manual
Designation: Clarifying decanter
Type: waterMaster CF 4000
No. 8416-9001-815 | Edition 26.09.2012
Model:
S.N.:
Revision:
Translation of the original instructions
Model:
S.N.:
Revision:
GEA Niro Soavi - Instruction manual
One7TS
8066
00

Instructions for use and maintenance
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
00C100-1C0
GEA Niro Soavi1
Dear Customer,
we wish to thank you for selecting our product and ensure you our best assistance in order to enable
you to make the most of your machine.
Also, we remind you that a good understanding of the contents of this manual - through careful
reading of all sections - is essential for the correct, safe use and operation of the machine you have
purchased.
No one should operate or perform maintenance on this machine without rst having read and
understood the following Instructions for Use & Maintenance.
Yours faithfully,
For any further support or information, you may contact us at the below listed address.
GEA Mechanical Equipment Italia S.p.A.
Via A. M. da Erba Edoari 29, 43123 Parma - Italia
Tel. [phone]
Fax [phone]
e-mail: [email protected]
Internet: http://www.niro-soavi.com
Introduction

Instructions for use and maintenance
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
00C100-1C0
GEA Niro Soavi2
Introduction.................................................................................................................................1
1. General information ............................................................................. 6
1.1. Declaration of Conformity................................................................................................7
1.2. Introduction......................................................................................................................9
1.3. Warranty and testing .......................................................................................................10
1.3.1 Warranty .........................................................................................................................10
1.3.1.1 Warranty duration ..........................................................................................................10
1.3.1.2 Application mode ...........................................................................................................11
1.3.1.3 Exceptions and limitations .............................................................................................11
1.3.1.4Materialefciency..........................................................................................................11
1.3.2 Testing .............................................................................................................................13
1.4. Introduction......................................................................................................................14
1.5. How to use the manual....................................................................................................14
1.6 Reproduction and copyright terms ..................................................................................14
1.7. Revisions.........................................................................................................................15
1.8. User manual storage .......................................................................................................15
1.9. Customer in charge of the prearrangement ....................................................................15
1.10. Instructions for request actions .......................................................................................16
1.11 Instruction for ordering spare parts ................................................................................16
1.12 Operator characteristics and language used...................................................................16
2. Description of the machine, technical data ....................................... 17
2.1 General description .........................................................................................................18
2.1.1 Operating principle ..........................................................................................................18
2.2 Main components of the machine ...................................................................................19
2.2.1 Monoblock compression head.........................................................................................21
2.2.2 Homogenising unit...........................................................................................................22
2.2.3 Pressure Gauge ..............................................................................................................25
2.2.4 Compression head safety valve ......................................................................................26
2.2.5 Manifold Groups ..............................................................................................................27
2.2.6 Water plant for sanitised machine ...................................................................................28
2.2.7 Pneumatic plant...............................................................................................................29
2.2.8 Transmission assembly...................................................................................................34
2.2.9 Drive ...............................................................................................................................35
2.2.10 Housing ...........................................................................................................................36
2.2.11 Operator control panel.....................................................................................................37
2.2.12 Electrical equipment ........................................................................................................38
2.3 Standards,certications,limitsofuse,ergonomics,environmentalissues..................... 41
2.3.1 Applicable technical standards........................................................................................41
2.4 Ambient operating conditions ..........................................................................................42
2.5 Atmosphereswithriskofexplosion/re ...........................................................................42
2.6 Illumination ......................................................................................................................42
2.7 Vibration ..........................................................................................................................42
2.8 Noise ...............................................................................................................................42
2.9 Residue and environmental contamination .....................................................................43
2.10 Scrapping and disposal of materials ..............................................................................43
2.11 Disposal ..........................................................................................................................44

Instructions for use and maintenance
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
00C100-1C0
GEA Niro Soavi3
3. Safety and accident prevention .......................................................... 45
3.1 Applications, intended use ...................................................................................................46
3.2 Intended, improper and permitted uses ................................................................................46
3.3 Work area, control area, danger zones.................................................................................47
3.4 Risks, dangers and residual risks in the area .......................................................................54
3.4.1 General safety .................................................................................................................54
3.4.2 Residual risks and hazards on the machine....................................................................54
3.5 Safety equipment used .........................................................................................................55
3.5.1 Pressure relief valve........................................................................................................55
3.5.2 Protections on the main motor .......................................................................................58
3.5.3 Emergency stop button ..................................................................................................58
3.5.4 Housing ...........................................................................................................................60
3.6 Safety notices .......................................................................................................................61
4. Installation............................................................................................. 63
4.1 Shipping ................................................................................................................................64
4.1.1 Shipping by ground over medium to long distances........................................................65
4.2 Receiving and checking........................................................................................................68
4.3 Storage .................................................................................................................................69
4.3.1 Storage prior to installation..............................................................................................69
4.3.2 Storage for longer than 6 months ...................................................................................70
4.4 Setting up the installation site ...............................................................................................71
4.5 Hookup and cabling ..............................................................................................................73
4.5.1 Hookup ............................................................................................................................73
4.5.2 Electrical hookup .............................................................................................................75
4.5.3 Grounding system (provided by client)............................................................................ 76
4.6 Installation and assembly......................................................................................................77
4.6.1 Installation instructions ...................................................................................................77
4.6.2 Positioning.......................................................................................................................79
4.6.3 Levelling the machine .....................................................................................................80
4.6.4 Positioning the electrical equipment ...............................................................................81
5. Commissioning and rst startup ........................................................ 82
5.1 Procedure .............................................................................................................................83
6. Operation and use................................................................................ 88
6.1 Operator's responsibilities.....................................................................................................89
6.2 Electrical enclosure and control panel ..................................................................................90
6.2.1 Control Panel on the machine .........................................................................................91
6.3 Startup procedure .................................................................................................................92
6.3.1 Position of operator .........................................................................................................92
6.3.2 Startup.............................................................................................................................94
6.3.3 Operation and adjustment ...............................................................................................95
6.3.3.1 Regulating the homogenizing pressure - 1 stage........................................................... 95
6.3.3.2 Regulating the homogenizing pressure - 2 stages .........................................................97
6.4 Stopping the machine ...........................................................................................................99
6.4.1 Normal stop ....................................................................................................................99
6.4.2 Emergency stop .............................................................................................................99
6.5 Washing ................................................................................................................................100
6.6 Checks after starting up the machine ...................................................................................101

Instructions for use and maintenance
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
00C100-1C0
GEA Niro Soavi4
7. Maintenance.......................................................................................... 102
7.1 General Information ..............................................................................................................103
7.1.1 DenitionofSTAFFRESPONSIBILITIES .......................................................................103
7.2. Directions for correct maintenance..................................................................................104
7.2.1 Forpropermaintenance: .................................................................................................104
7.2.2 Maintenance plan ............................................................................................................104
7.3 Safety, precautions and maintenance shutdown ..................................................................106
7.3.1 General safety warnings..................................................................................................106
7.3.2 Safety symbols ................................................................................................................107
7.3.3 Maintenance shutdown ...................................................................................................108
7.4 Maintenance during running-in period .................................................................................. 110
7.5 Planned routine maintenance during operation .................................................................... 110
7.5.1 General Information.........................................................................................................110
7.6Frequencyofmaintenancework...........................................................................................112
7.7 Maintenance sheets..............................................................................................................118
SHEET 00[a]...............................................................................................................................120
GENERAL MACHINE - Check noise and vibration ................................................................120
SHEET 00[b]...............................................................................................................................121
GENERAL MACHINE - Check protections and safety devices .............................................121
SHEET 00[c]...............................................................................................................................122
GENERAL MACHINE - Tighten nuts and stud bolts...............................................................122
SHEET A.....................................................................................................................................125
COMPRESSION HEAD..............................................................................................................125
SHEET A[a] ................................................................................................................................127
COMPRESSION HEAD - Visually check for seal and gasket leakage..................................127
SHEET A[b] ................................................................................................................................129
COMPRESSION HEAD - Replace pumping piston gaskets ..................................................129
SHEET A[c].................................................................................................................................138
COMPRESSION HEAD - Check tightness of pumping pistons and nuts ............................138
SHEET A[d] ................................................................................................................................139
COMPRESSION HEAD - Check wear and if necessary renew the pumping pistons .........139
SHEET A[e] ................................................................................................................................144
COMPRESSION HEAD - Check and if necessary renew the pumping valves ....................144
SHEET A[f] .................................................................................................................................147
COMPRESSION HEAD - Visually check for leakage from the packings and from the gaskets of the head.........147
SHEET A[g] ................................................................................................................................148
COMPRESSION HEAD - Check and if necessary renew the pumping valve seats ............ 148
SHEETB ....................................................................................................................................152
HOMOGENIZING UNIT..............................................................................................................152
SHEETB[a] ................................................................................................................................154
HOMOGENIZING UNIT - Checking/renewing homogenizing valves ....................................154
SHEET C[a] ................................................................................................................................159
PRESSURE GAUGE - Check state and operation .................................................................159
SHEET D[a] ................................................................................................................................163
HEADSAFETYVALVE-Check operation ...............................................................................163
SHEET E[a] ................................................................................................................................167
MANIFOLDGROUP-Check gaskets ...................................................................................... 167
SHEETF ....................................................................................................................................169
LUBRICATIONSYSTEM............................................................................................................169

Instructions for use and maintenance
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
00C100-1C0
GEA Niro Soavi5
SHEETF[a] ................................................................................................................................170
LUBRICATIONSYSTEM-Change oil ......................................................................................170
SHEETF[b] ................................................................................................................................172
LUBRICATIONSYSTEM-Check and top up oil level ............................................................172
SHEET G[a]................................................................................................................................176
WATERSYSTEM-Clean and/or renew lters ........................................................................176
SHEET G[b]................................................................................................................................178
WATERSYSTEM-Check: piston lubrication water pipes - checkwaterowrate....................178
SHEET H ....................................................................................................................................182
PNEUMATIC PLANT ..................................................................................................................182
SHEET H[a] ................................................................................................................................185
PNEUMATIC PLANT - Clean and/or renew lters...................................................................185
SHEET I [a].................................................................................................................................188
BODYANDCRANKMECHANISM-General check of components......................................188
SHEET L.....................................................................................................................................192
DRIVE ........................................................................................................................................192
SHEET L[a].................................................................................................................................193
DRIVE - Check tension and service belts...............................................................................193
SHEET L[b].................................................................................................................................197
DRIVE - Check tightness of the transmission elements ...................................................... 197
SHEET L[c].................................................................................................................................198
DRIVE - Check V-belt wear and renew if necessary..............................................................198
SHEET L[d].................................................................................................................................200
DRIVE - Check pulley alignment .............................................................................................200
SHEET M[a]................................................................................................................................203
HOUSING - General visual check............................................................................................203
SHEET N[a] ................................................................................................................................206
ELECTRICALSYSTEMONTHEMACHINE-Check the electrical system on the machine .............206
8. Troubleshooting ................................................................................... 207
8.1 Troubleshooting ....................................................................................................................208
9. Waste disposal ..................................................................................... 212
9.1Denitionofwaste.................................................................................................................213
9.1.1 Special waste ..................................................................................................................213
9.1.2 Toxic-harmful waste.........................................................................................................213
9.2 Temporary storage ................................................................................................................213
9.3 Characteristics of the containers...........................................................................................213
9.4 Required registration.............................................................................................................214
9.5 Disposal ................................................................................................................................214
10. Spare parts.......................................................................................... 215
10.1 Recommended spare parts .............................................................................................216
10.2 How to order the spare parts...........................................................................................217
10.3 Safety warnings...............................................................................................................218

Instructions for use and maintenance
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
01C100-1C0
GEA Niro Soavi6
Index
1.1. Declaration of Conformity
1.2. Introduction
1.3. Warranty and testing
1.3.1 Warranty
1.3.1.1 Warranty duration
1.3.1.2. Application mode
1.3.1.3 Exceptions and limitations
1.3.1.4 Materialefciency
1.3.2 Testing
1.4. Introduction
1.5. How to use the manual
1.6 Reproduction and copyright terms
1.7. Revisions
1.8. User manual storage
1.9. Customer in charge of the prearrangement
1.10. Instructions for request actions
1.11 Instruction for ordering spare parts
1.12 Operator characteristics and language used
1. General information

Instructions for use and maintenance
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
01C100-1C0
GEA Niro Soavi7
1.1. Declaration of Conformity
What follows is the “Declaration of conformity” FACSIMILE. The ofcial copy will be lled in and
supplied with the machine.

Instructions for use and maintenance
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
01C100-1C0
GEA Niro Soavi8
In addition to this, GEA Niro Soavi is certied according to UNI EN ISO 9001 for Design, Manufacture
and Servicing of Homogenisers and high pressure piston pumps, therefore your machine has been
engineered and produced according to the approved quality procedures.
See the following gure for the UNI EN ISO 9001 Quality System Certicate FACSIMILE.