OPERATING INSTRUCTIONS

Transcription

1 DESCRIPTION CODE DATE ORIGINAL DOCUMENT REV /05/2011 OPERATING INSTRUCTIONS SEPCOM LIVESTOCK WASTES SEPARATOR Model: 015

2 INDEX OF TOPICS 1. PRELIMINARY INFORMATION CONTENTS AND ADDRESSEES OF THE MANUAL REGULATORY CONFORMITY SYmbolS: MEANING AND USE DESCRIPTION OF THE MACHINE AND TECHNICAL INFORMATION THE MACHINE Intended Use Machine dimensions TECHNICAL INFORMATION AND OPERATING CONDITIONS Electric supply Environmental conditions of use Emissions in the atmosphere Lighting Noise, Vibrations Limits of use, operating conditions - Envisaged life SAFETY AND ACCIDENT PREVENTION GENERAL SAFETY STANDARDS Qualifications of the operators Safety prescriptions SAFETY SIGNS AND PICTOGRAMS Geometric figures and safety signs Signs used for indicating hazards Signs used for indicating prohibition Signs used for indicating obligation Signs used for safety indications Warnings regarding residual risks SAFETY DEVICES AND INDICATIONS Warning and signalling devices - Plates/signs HANDLING - INSTALLATION - START UP HANDLING, LIFTING AND UNLOADING Lifting points and methods PREPARATION OF THE INSTALLATION SITE (BY THE BUYER) INSTALLATION OF THE MACHINE FIXING TO THE SUPPORTING FRAME ASSEMBLING THE COMPENSATOR TANK CONNECTIONS TO THE PLANT Wiring diagram PUTTING INTO SERVICE Preliminary operations Testing - suitability of the machine for use PUTTING OUT OF SERVICE - CLEANING AND PRESERVING THE parts Storage and preservation Restoration after storage OPERATION AND USE...26 Page 2 of 41

3 5.1 START-UP GEAR BOX AND REDUCTION GEAR Accessories permitted and not permitted - Compatible equipment OPERATING CONDITIONS Operating environment Danger zones and exposed persons Lighting in the work area Contraindications for use MAINTENANCE SAFETY PRECAUTIONS Warning notes Danger notes QUALIFICATION of maintenance personnel Operator in charge of machine conduction Mechanical maintenance technician Electrical maintenance technician Electro-mechanical maintenance technician Mechanical technician Electro-mechanical/mechanical-electronic technician RECOMMENDATIONS CONCERNING MAINTENANCE ROUTINE AND PERIODIC MAINTENANCE PLAN Inspection of the screen Cleaning the screen Checking for leakage from the seals REPLACEMENT OF PARTS AND COMPONENTS SPARE PARTS AND CONSUMABLES Personnel authorised to act in the event of a fault Putting out of service DISMANTLING, DISPOSAL AND SCRAPPING MAINTENANCE ACTIVITIES CONTROL REGISTER Page 3 of 41

4 Manufacturer: MACHINE IDENTIFICATION DATA: WAM S.p.a. Via Cavour n Ponte Motta di Cavezzo (MO) - ITALY Machine: SEPCOM Model: 015 ANNEXES: Declaration of incorporation pursuant to Annex II B of Machinery Directive 2006/42/EC THE OPERATION AND MAINTENANCE MANUAL AND THE CERTIFICATE OF CONFORMITY ARE AN INTEGRAL PART OF THE MACHINE All the products described in this catalogue have been manufactured according to the operating methods defined by the WAM S.p.A. Quality System The corporate Quality System, which has been certified since July 1994 in compliance with the UNI EN ISO International Regulatory standards and subsequently extended to the UNI EN ISO International Regulatory standards in October 2002, is in a position to ensure that the entire production process - from formulation of the order to the technical assistance after delivery - is carried out in a controlled, adequate manner to ensure the quality standard of the product. For correct identification of the machine, refer to the code on the plates affixed on the machine. This document cancels and replaces all the other previous editions or revision. The Manufacturer reserves the right to make modifications without giving prior notice. Reproduction, even partial, without authorization is forbidden. Page 4 of 41

5 1. PRELIMINARY INFORMATION 1.1 CONTENTS AND ADDRESSEES OF THE MANUAL The sepcom 015 livestock wastes separator, hereafter commonly referred to as the machine, is designed, produced and marketed by: WAM S.p.a. Via Cavour n Ponte Motta di Cavezzo (MO) - ITALY Tel: +39 / 0535 / fax: +39 / 0535 / In consideration of the intended use - envisaged use" of the machine, the Manual contains the functional and performance technical features of the machine as well as the relative instructions for installation, use and maintenance. It addresses: the factory manager, workshop manager and work site manager the operators involved in transport, handling and installation the operators in charge of machine conduction maintenance personnel The documentation must be kept in the custody of the person responsible for the purpose, in a suitable place, preserved in the best possible state so that it is always available for consultation. If lost or damaged, replacement documentation can be ordered from the manufacturer by mentioning the code of this Manual. The manufacturer reserves the material and intellectual propriety rights to this Manual and forbids the disclosure and copying, even partial, without prior written consent. 1.2 REGULATORY CONFORMITY The machine is designed and produced taking into consideration the Essential Safety Requirements of Annex I of the Community Directive 2006/42/EC, referred to as the Machinery Directive, already transposed into Italian legislation by means of LEGISLATIVE DECREE No. 17 of 27 th January 2010 It is forbidden to use the devices unless the machine or assembly in which these are to be installed have been declared as conforming to Directive 2006/42/EC and its modifications. Page 5 of 41

6 1.3 SYMBOLS: MEANING AND USE - Certain symbols are used in this Manual to draw the reader s attention and highlight certain especially important aspects of the documentation. The Table below shows the list and meaning of the symbols used in the Manual. SYMBOL MEANING EXPLANATION, RECOMMENDATIONS, NOTES Danger Indicates danger with risk of accident, even fatal. Failure to respect the instructions marked with this symbol can lead to serious danger for the safety of the operator and/or exposed persons. Strictly follow the indications! Attention A note of caution regarding possible deterioration of the machine or another personal object of the operator. Important warning to which utmost attention is required. Warning/Note Indicates a warning or a note regarding the key functions or useful information. Visual observation Action to be taken A stylised eye may indicate to the reader that: a) It is necessary to proceed with a visual inspection. b) It is necessary to proceed in the operating sequence. c) A value must be read, a signal must be checked, etc. With reference to what has been described in this Manual, WAM S.p.a. declines all responsibility in case of: use of the machine contrary to the national laws regarding safety and accident prevention incorrect preparation of the work site and structures on which the machine is intended to work defects in electricity supply voltage and/or other energy sources failure to observe the instructions provided in this Manual unauthorised modifications to the Manual use by untrained or unsuitable persons WAM S.P.A. reserves the right to make the necessary modifications and improvements to the machine over time without any obligation to give prior notification. The Manual must be kept protected from damage in a place easily accessible to the operators. Page 6 of 41

7 2. DESCRIPTION OF THE MACHINE AND TECHNICAL INFORMATION 2.1 THE MACHINE Intended Use The machine functions as a solid-liquid separator capable of obtaining a separated solid with residual moisture not more than 80% in weight and a separation capacity such as to be suitable for use for medium and small cattle and pig-breeding farms with separation capacities between 5 m 3 /h and 10 m 3 /h. The use of inflammable and/or explosive products is forbidden Machine dimensions Page 7 of 41

8 2.2 TECHNICAL INFORMATION AND OPERATING CONDITIONS Electric supply The machine is designed to be powered with 400 V +/- 10% three-phase + neutral alternate electric current (Euro Voltage min. 360V; max. 440V) Machine weight: The weight of the packing must be added to the above weights, if the machine is packed in a crate or cage for shipment Environmental conditions of use The machine must be installed in a well ventilated place, with the safety provisions prescribed by the regulatory standards in force so that the personnel can work in the best possible conditions. Sufficient working spaces must be provided to ensure safety of the operator and maintenance personnel. Do not use the machine in an explosive atmosphere or where the use of anti-explosive components is prescribed Emissions in the atmosphere During the process the machine does not generate any atmospheric emissions Lighting The machine must be installed in a well lighted place. If maintenance activities are to be performed in poorly lit areas, additional lamps must be used, ensuring that the activities are carried out in safety conditions in compliance with the legal provisions in force Noise, Vibrations The noise level depends on various factors such as dimensions, kind of material and filling coefficient. In conformity with the prescriptions of the legal provisions in force, it is the Buyer s duty to measure the noise level during the working of the machine in the worst operating hypothesis, after installation and before start-up to make sure that, in the actual operating environmental conditions, reverberation of the noise produced by the machine does not create hazardous situations for the operator. Page 8 of 41

9 The vibrations produced by the machine are not hazardous for the health of personnel working on it. Excessive vibration may be caused by a fault which must be reported immediately so that it does not affect the reliability of the machine Limits of use, operating conditions - Envisaged life Appropriate definition of the operating limits of the machine is the condition necessary to ensure correct working and total compliance with the operating conditions for which it is meant. The machine is designed and constructed also for use outdoors. It is the Customer's responsibility to equip the assembly area in compliance with the regulations in force and the safety requisites: aeration, earthing, etc... - If the machine is used and maintained correctly, its life in complete safety is expected to be 20 years. Page 9 of 41

10 3. SAFETY AND ACCIDENT PREVENTION 3.1 GENERAL SAFETY STANDARDS The machine is designed and constructed on the basis of the most modern technical know-how and can be used safely. The hazards for the personnel can be completely eliminated and/or considerably reduced only if the machine is used in accordance with the instructions given in this documentation by authorised personnel with sufficient training for the job. The personnel are responsible for the following operations: Putting the machine into service or management of its operation. Executions of different kinds of operations on the machine, especially in relation to maintenance, checking and repair of any of its components before starting up the machine, during its working or after it stops. The personnel must be absolutely informed regarding the potential hazards that may be encountered during the performance of their duties regarding the working as well as correct use of the safety devices provided on the machine. This personnel must also carefully observe the following safety standards in order to avoid hazardous situations. Page 10 of 41

11 3.1.1 Qualifications of the operators In order to better define the field of action and the consequent assumption of responsibilities by each OPERATOR, given by the specific training and qualification obtained, as well as to make it easy to read and understand this Manual, the following Table of professional profiles was prepared with the relative pictogram, necessary in every kind of action: PICTOGRAM OPERATOR PROFILE OPERATOR IN CHARGE OF USING THE MACHINE: Person qualified for carrying out simple tasks, i.e. conduction of the machine by using the controls and the operations for loading/unloading the materials used during the process. MECHANICAL MAINTENANCE PERSONNEL: Qualified personnel capable of acting in normal conditions for carrying out normal adjustments, minor routine maintenance and the necessary mechanical repairs on the mechanical parts ELECTRICAL MAINTENANCE PERSONNEL: Qualified personnel capable of acting in normal conditions for electrical operations, adjustments, maintenance and repairs. MECHANICAL TECHNICIAN: Specialist technician authorised to carry out complex and extraordinary mechanical operations Safety prescriptions Before starting up the machine, carry out the following operations: Read the technical documentation carefully; Obtain information regarding the working and positioning of the emergency stop devices; Become familiar with the protection and safety devices available on the machine, their location and working; Execution of specialist activities (for example: checking the working of the drive organs) to be done with the machine or some of its components running exposes the personnel and operator to serious hazard. The personnel must be authorised and specially trained regarding the operating procedures to be followed, the hazard situations that may have to be faced and the correct methods to avoid these. The personnel must always work with extreme caution taking utmost care. If the guards are to be opened or removed to carry out a special technical action in exceptional circumstances for maintenance, inspection or repair, the personnel in charge must restore these guards immediately once the operations are completed. The personnel responsible must also make sure that at the end of operations, foreign objects which could cause damage or malfunctioning, particularly mechanical parts, Page 11 of 41

12 tools or devices used during the operating procedure, are not left inside the machine by oversight. The personnel in charge of maintenance, inspections, and repairs must deactivate the power supply to the machine and implement all the necessary preventive safety measures, before commencing with their activities and within the possible limits, to ensure their own safety. Specifically, utmost care must be taken before acting if: The action is to be performed in an area of the machine that has not been deactivated; The point of action is near powered devices; Before acting, the personnel in charge must first check to make sure: The machine is deactivated and the preventive measures have been adopted (signs, blocking devices, etc.) to prevent accidental start-up of the machine or a part of it during the action; If it is found to be necessary to perform a technical action on a electrical device in the presence of power, take utmost care and proceed with extreme caution. 3.2 SAFETY SIGNS AND PICTOGRAMS The Manual contains signs and pictograms used to highlight or mention possible hazard situations due to residual risks or actions which MUST be conducted according to the safety procedures indicated in this Manual Geometric figures and safety signs The signs and pictograms assume different meanings depending on the geometric shape within which they are contained, i.e.: GEOMETRIC FIGURE MEANING Danger sign Prescription sign FORBIDDEN (RED) - OBLIGATION (BLUE) Safety information sign Page 12 of 41

13 3.2.2 Signs used for indicating hazards SIGN MEANING GENERAL HAZARD Caution! general hazard (complete with caption which indicates the type) ELECTRIC SHOCK HAZARD Indicates presence of electricity and is affixed on electrical equipment, pushbuttons, electric motors, electro-hydraulic drives and all other structures inside which electricity is present DANGER OF CRUSHING HANDS Danger of crushing hands because of moving mechanical surfaces or organs DANGER OF ENTANGLEMENT OR DRAGGING Danger of entanglement or dragging by moving parts (chains, gears, etc.) SCREW CONVEYOR HAZARD Caution! screw conveyor in operation Signs used for indicating prohibition SIGN MEANING GENERAL PROHIBITION General prohibition sign (completed with caption which indicates the type) NO ACCESS Sign forbidding access to an operating area of the machine for all unauthorized personnel NO ACCESS BY UNAUTHORISED PERSONS Sign forbidding access to an operating area of the machine, during technical intervention, for all unauthorized personnel. DO NOT REMOVE THE GUARDS It is forbidden to remove the safety guards with the machine running. DO NOT ACT ON MOVING PARTS It is forbidden to carry out technical actions for repair, maintenance or adjustment with organs, parts or components in motion. DO NOT SMOKE It is strictly forbidden to smoke in all areas where this sign is present to prevent fire or explosion hazard DO NOT PUT OUT FIRES USING WATER It is forbidden to use water to put out fires on electrical parts Page 13 of 41

14 3.2.4 Signs used for indicating obligation SIGN MEANING OBLIGATION TO CONSULT THE MANUAL Every time this sign appears, preceding or inside an indication (instructions, adjustments, maintenance, etc., consult the SAFETY MANUAL. GLOVES COMPULSORY It is compulsory to wear protective gloves. GLASSES COMPULSORY It is compulsory to wear eye protection (glasses or mask) MASK COMPULSORY It is obligatory to wear a protective respiratory mask. PROTECTIVE FOOTWEAR COMPULSORY It is obligatory to use protective slip-proof footwear. PROTECTIVE WORK CLOTHES COMPULSORY It is obligatory to use suitable work clothes for operation and maintenance, to prevent risk of entanglement Signs used for safety indications SIGN MEANING AUXILIARY LIGHTING The use of auxiliary lighting is recommended for the activities indicated Page 14 of 41

15 3.3 WARNINGS REGARDING RESIDUAL RISKS After carefully considering the hazards present in all the machine operating phases, the necessary measures have been adopted to eliminate the risks for the operators, as far as possible, and/or to limit or reduce the risks deriving from hazards which cannot be completely eliminated at the source. However, in spite of all the precautions adopted, the following residual risks persist on the machine and they can be reduced by means of the relative prevention activities. RISKS DURING USE DANGER/RISK PROHIBITION/WARNING OBLIGATION/PREVENTION Risk from danger of entanglement and/or crushing following contact with chains and mechanical parts in motion. Attention! Exposure to moving parts can lead to hazard situations. It is forbidden to touch the moving chains and gears Obligation to use protective gloves while positioning the load RISKS DURING MAINTENANCE DANGER/RISK PROHIBITION/WARNING OBLIGATION/PREVENTION Risk due to electric shock in case of access during maintenance to electrical equipment without deactivating the electric supply It is forbidden to act on the electrical equipment without disconnecting the power supply to the machine or its parts Entrust electrical maintenance operations to qualified personnel Carry out the checks on the electrical equipment as prescribed in the Manual. Risk from hazards of entanglement and/or crushing following access to moving parts during maintenance operations Attention! Exposure to moving parts can lead to hazard situations. It is forbidden to restart the machine if the guards have not been refitted Entrust the maintenance operations to specialist technicians Obligation to use protective gloves Page 15 of 41

16 3.4 SAFETY DEVICES AND INDICATIONS Access to inspection hatches is normally not required while using the machine; they are used for routine and/or extraordinary maintenance. It is compulsory to close these by refitting the screws in their original place to avoid accidental opening, before starting up the machine. The inspection hatches can only be opened by means of a tool for unlocking them. The machine is provided with appropriate signage: Warning and signalling devices - Plates/signs The machine is provided with Machine data plate with manufacturer s logo. warning plates regarding residual risks The warning plates must always be legible as regards all the data they contain, and must be cleaned periodically. If a warning plate is damaged and/or is no longer legible, even as regards one of the informative elements shown, contact the Manufacturer for a replacement, mentioning the data contained in this Manual or on the original plate. Page 16 of 41

17 4. HANDLING - INSTALLATION - START UP 4.1 HANDLING, LIFTING AND UNLOADING The personnel in charge of the following operations must be trained and authorised for carrying out these activities to avoid incorrect manoeuvres which could lead to hazardous situations and/or damage the machine, and must have understood these instructions regarding handling operations Lifting points and methods On receiving the goods, check to make sure the type and quantities correspond to the data in the order confirmation. Avoid all types of damage during unloading and handling operations. The mechanical material must be handled with care. HOIST THE MACHINE USING SUITABLE LIFTING BELTS SLACKEN THE FIXING SCREWS ON THE PALLET AND LIFT THE MACHINE DO NOT PULL OR PUSH THE MACHINE Page 17 of 41

18 All the operations must be performed by qualified authorized personnel. Those authorized to carry out the handling operations must have the capabilities and experience required to adopt all the necessary measures to guarantee one's own safety and the safety of persons directly involved in the operations. Use lifting systems suitable for the weights, dimensions and movements to be carried out. It is forbidden to use systems that do not guarantee the same degree of safety. Hook the machine to the eyebolts by means of shackles or type-tested hooks. Pay attention in the lifting phase to balance the load to avoid uncontrolled movements which could cause accident to persons. 4.2 PREPARATION OF THE INSTALLATION SITE (BY THE BUYER) To allow for correct installation of the machine, the Buyer must carry out the preliminary operations indicated in the order confirmation as regards: Checking the suitability of the supporting surface and load-bearing structures on which the machine is to be installed. Checking the suitability of the clearances, paths, corridors, walkways, and the escape areas surrounding the machine installation area. Checking the suitability and correct working of the electrical system: power supply line, power socket, distribution board, cut-out switches, which must be capable of cutting off the short-circuit current, disconnect, power, length of line cable and earthing system cable (standard EN ). Checking the suitability and correct working of the power supply, distribution, intake of other energy sources if any. Preparation of the installation area in such a manner that it complies with the safety standards as regards safety of the energy supply sources, products/substances and all working equipment provided for the installation; specifically the Buyer must ensure suitable earthing of the metal structures, electrical apparatus/equipment. Installation of appropriate signs to signal the presence of assembly operations using handling means. Page 18 of 41

19 4.3 INSTALLATION OF THE MACHINE The installation, assembly, first start-up and testing are done by specialist highly trained personnel employed by and/or instructed by the Manufacturer. This section of the Manual therefore only contains instructions regarding the operations concerning the user. For assembling the parts, strictly follow the instructions contained in this Manual, and specifically, make sure: the instruction manual concerns the machine to be installed the machine features conform to the use for which it is intended the machine capacity is equal to or more than the loads to be handled FIXING TO THE SUPPORTING FRAME Prepare the machine installation area by providing a suitable supporting structure having dimensions and features suitable for the machine dimensions and weights, as well as the type of foundation underneath. The machine is already completely assembled, therefore it only has to be placed on the ground and fixed to the floor as described earlier by means of bolts. The machine must be fixed firmly and safely; therefore use fixing bolts having the required dimensions. Installation with the relative supporting systems, hook-up and/or connecting systems by the user must be done in compliance with the safety standards applicable. STATIC LOAD 400 kg Page 19 of 41

20 4.3.2 ASSEMBLING THE COMPENSATOR TANK Use only suitable lifting equipment during installation and all maintenance work. Apply the silicone on the flange of the separator inlet spout Place the compensator tank on the separator inlet spout flange Fix and bolt the compensator tank to the inlet spout of the machine by means of bolts; fix it safely and firmly Screw the atmospheric vent. Page 20 of 41

21 4.3.3 CONNECTIONS TO THE PLANT The separator must be connected to the plant using the connections provided: 1. Product inlet 2. Product overflow 3. Atmospheric vent 4. Main separated fluid drainage The machine must be fixed firmly to a sturdy brickwork base or a heavy structural steel framework, by means of a supporting frame which is an integral part of the machine, and made operative at a height sufficient to be able to accumulate material under the outlet spout Wiring diagram The connection between the motor and electricity mains, and all work on the terminal junction box of the motor must be done by specialist personnel. DISCONNECT THE ELECTRIC POWER SUPPLY BEFORE CARRYING OUT ANY OPERATION. Always pay attention to the safety standards. Before making the connection, make sure the mains supply voltage corresponds to that indicated on the motor rating plate. Never insert your hands into the machine while it is running. Never open the hatches or remove the covers without disconnecting the power supply. Page 21 of 41

22 FEATURES OF MOTORS INSTALLED The motor must be connected on its terminal board in Pos.L. DISCONNECT THE ELECTRIC SUPPLY BEFORE CARRYING OUT MAINTENANCE OPERATIONS ON THE MACHINE! Motor 4 Poles Power 2.2. kw Voltage V 50Hz V 50Hz V 60Hz Power input 5.2 A Protection degree IP55 MOTOR INTERNAL TERMINAL CONNECTION During the initial machine start-up phases check to ensure the direction of rotation is correct. If the rotation is in reverse, after disconnecting the current, invert the position of the supply cables on the terminal board. Page 22 of 41

23 Direct start up from mains - In direct start up the motor may be used with star as well as delta connection (obviously with different voltages). - For example 660 VY, 380V indicate that the motor can have a star connection for 660V and delta connection for 380V. Star/delta start-up (Y/ ) - The line voltages must be equal to the rated voltage of the motor with delta connection. - For connecting double speed motors, special and single-phase motors, follow the instructions given inside the terminal boxes. Terminals and direction of rotation The direction of rotation is clockwise seen from the control side when the L1, L2, L3 phase sequence is connected to the terminals as shown in Figure 1. To invert the direction of rotation, switch any of the two terminal connections If the motor has a fan that rotates in a single direction, check to make sure the rotation is as indicated by the arrow present on the motor. Operating conditions - The motors are designed for use in industrial applications. - The environmental temperature limits are 25 C C. - The maximum altitude is 1000m at sea level Page 23 of 41

24 4.4 PUTTING INTO SERVICE Preliminary operations Carry out the following operations before putting the machine into service Check the suitability of the clearances available: check the working spaces which must allow for correct operation of the machine. check the manoeuvring spaces of the mobile parts which must not encounter any obstacles. Lubrication of the mechanisms: Make sure the reduction gears are lubricated and that there is no lubricant leakage. Checking the suitability of the electrical system: Check to make sure the voltage corresponds to that envisaged for the operation. Check to make sure the voltage value at the motors is within the +/- 10% limits of the rated value Testing - suitability of the machine for use The machine has been tested by the Manufacturer to ensure functional compliance. However, certain testing phases must be repeated together with others typical of the process by the installer in order to ensure that their performance and function correspond in complete safety of the machine in its installation site. 4.5 PUTTING OUT OF SERVICE - CLEANING AND PRESERVING THE PARTS Storage and preservation If the machine and/or its component parts are to be stored and preserved for a certain period of time before putting into service, in order to avoid damage or deteriorations, check to make sure: There is no damage to the electrical mechanisms, structural parts and avoid scratching the painted parts and machined surfaces. Before proceeding with storage, apply rust-proof products to protect the structural parts and machined surfaces. The material storage areas must be fenced off and marked with signs. For all the operations, always use suitable personal protection equipment (P.P.E. = gloves) Page 24 of 41

25 4.5.2 Restoration after storage Before starting operations with machines which have been stored away for a long period of time, carry out the following operations: For the structural parts: - remove traces of lubricants or protective rust-proof coats - go over the thread of the joining holes to remove grease residue, if any - clean the joining surfaces of the joints - repair damage if any to the structure (bent corners, scored surfaces, flaking paint, etc.) For the mechanisms: - check for leakage of lubricants and replace defective gaskets - check to ensure bolted joints are locked tight - remove traces of lubricants or protective rust-proof coats - remove traces of rust from accessory sliding parts of drive organs - check the condition of the chains and relative pinions and clean and lubricate these - lubricate the unpainted mechanical parts - remove traces of water present in the concave parts of the structure and mechanisms. Page 25 of 41

26 5. OPERATION AND USE 5.1 START-UP For the first start-up, and in general for reusing the machinery after a long shutdown period, follow the procedure described below, implementing it after ensuring electrical and hydraulic connections to the machine: a) Start up the sewage feed pump; let the pump run until the product reaches the compensator tank. b) Switch off the sewage feed pump and start up the machine, letting it run for 1 minute so that the screw conveyor can remove the separated solid from the filter, convey it towards the outlet spout and press it, forming the solid plug of material necessary for the working of the separator. In this step, the diaphragm of the outlet spout opens gradually as the solid builds up to form the plug. Switch off the separator after about 1 minute of operation. c) Repeat the actions described at points a and b above until the plug of solid material is formed in the outlet module. The plug is fully operative if the diaphragm is opened completely. Page 26 of 41

27 5.2 GEAR BOX AND REDUCTION GEAR The oil level must be checked with the motor cold. After a brief period of operation, the oil needs a longer standing period to allow air bubbles, if any, to come out. Check the oil level in the gearbox Quantity of oil - The gearboxes and reduction gears are filled with oil and are provided with level, drainage and venting plugs. - The lubricant used is of the long-life type and does not have to be changed. - Check periodically to make sure there are no oil leaks. - The exact quantity of oil is indicated on the technical data plate of the controls. Unscrew the screw cap in the position indicated by this symbol. QUANTITY OF OIL FILLED EACH TIME Synthetic Indication: When the oil level is correct, there may be leakage of a minimum quantity of oil; the oil level must at least reach the lower edge of the hole. Oil Level Page 27 of 41

28 5.2.1 Accessories permitted and not permitted - Compatible equipment The use of lifting accessories and/or handling equipment must conform to the prescriptions provided by the manufacturers. - The following accessories are generally not permitted: the functional/performance features of which can cause dynamic stresses on the machine greater than those permitted or those which are not provided with suitable gripping and handling systems. those which allow immediate release of the load and which can cause dynamic over-stresses and/or accidental overloads. 5.3 OPERATING CONDITIONS Operating environment The machine must not be used in environments or areas: where vapours, fumes or highly corrosive and/or abrasive dusts are present. In the presence of flames and/or heat exceeding the permitted temperatures. With risk of fire or explosion and where the use of explosion-proof and spark-proof components is prescribed Danger zones and exposed persons It is obligatory for the Buyer to provide adequate signalling and warning systems, or systems for segregation of the danger areas, to prevent access by untrained personnel or outsiders and/or those not concerned with the operations in areas where the machine operates, as envisaged by the legislative provisions in force Lighting in the work area The machine is not provided with its own functional lighting system for operation, while a lighting system is provided inside the electric control equipment. The operator must, however, always check before any start-up or manoeuvre that the environmental lighting is sufficient to ensure functionality of the machine in the maximum possible safety in relation to the use for which it is meant. In case of localised maintenance operations in areas and/or parts of the machine which are not sufficiently lit up, it is obligatory to use portable lighting systems, avoiding shadow cones, which prevent or reduce visibility of the operating area or the surrounding area. Page 28 of 41

29 5.3.4 Contraindications for use NEVER use the machine unless you are mentally-physically capable. NEVER operate without the appropriate personal protection equipment. NEVER operate without taking utmost care during manual handling operations. NEVER operate with two simultaneous movements during operation in manual mode; wait for the movement to stop completely before starting another. NEVER use the machine or carry out maintenance on it if lighting and/or visibility is insufficient. NEVER use the machine in the presence of a strong voltage drop on the mains or in the event of accidental failure of one of the three phases. NEVER carry out temporary or improvised repairs not conforming to the instructions. NEVER use spare parts that are not genuine or are not recommended by the manufacturer. NEVER entrust maintenance and repairs to personnel not trained by the manufacturer. NEVER leave the machine at the end of the day s work without activating the safety procedures NEVER carry out routine maintenance, inspections or repairs without putting the machine out of service and activating the relative procedure. During the maintenance phase, NEVER: - use unsuitable means - place ladders against moving elements, handling components or material handled - operate without appropriate personal protection equipment - act unless the materials handled have been removed. NEVER use the machine unless all its operating functions are compliant. Page 29 of 41

30 6. MAINTENANCE 6.1 SAFETY PRECAUTIONS The safety precautions contained in this paragraph must always be strictly observed during maintenance in order to avoid damage to the personnel and the machine. The machine maintenance personnel must be properly trained, must have read this Manual and must have a detailed knowledge of the safety standards. Unauthorised personnel must stay outside the work area during operations These precautions are mentioned and described in detail in this Chapter every time a procedure is required which involves risk or damage or accident, by means of WARNING and DANGER notes: The WARNING notes precede an operation which, if not performed correctly, can cause damage to the machine. The DANGER notes precede an operation which, if not performed correctly, can cause accident to the operator. Page 30 of 41

31 6.1.1 Warning notes Pay attention to the following warnings during the machine maintenance phases! Before resuming machine operation, it must be checked carefully and the start-up - test procedure must be repeated. Unless expressly required for elimination of a fault, never act on the adjustments or positioning of the safety devices as tampering with these can cause severe damage to the machine Danger notes Pay attention to the following hazards during the machine maintenance phases! Always disconnect all the energy supplies to the machine before carrying out maintenance operations. Affix the sign saying: MACHINE UNDER MAINTENANCE - DO NOT CONNECT POWER SUPPLY Never disconnect the safeties and protection devices installed on the machine. If this is found to be necessary, indicate the status by means of warning signs and work with utmost care. Always ensure earthing connections are present and comply with the regulatory standards. Lack of earthing connection of electrical equipment can cause serious harm to persons. Avoid using toxic and inflammable solvents (petrol, ether, alcohol, etc.). Avoid prolonged contact with solvents and inhalation of their vapours. Avoid use near naked flames, ensure adequate ventilation Before starting up the machine, always ensure that the maintenance personnel are at a safety distance and that tools and materials are not left onboard the machine or in the equipment. Page 31 of 41

32 Always use protective gloves during maintenance operations. All the moving parts and drive organs must be protected against accidental contact. Therefore, make sure the guards are refitted correctly before restarting the machine Never use water jets to put out a fire; disconnect all power supplies and use appropriate fire extinguishers. Make sure the tools to be used are in perfect condition and are provided with insulated grips, where required. 6.2 QUALIFICATION OF MAINTENANCE PERSONNEL In order to be able to solve all kinds of problems regarding machine maintenance, the maintenance personnel must: be familiar with the laws in force regarding accident prevention while carrying out work on machines with motor drive and must be capable of applying these have read and understood Chapter 3 Safety and Accident prevention know how to consult and use this documentation be involved in the working of the machine check operating irregularities and adopt the necessary measures - The professional figures responsible for and authorised to act on the machine are: Page 32 of 41

33 6.2.1 Operator in charge of machine conduction Activities: using the machine in its normal operating status (automatic operation) and restoring operation after activation of an emergency adopting the necessary measures for maintaining the performance quality cleaning and lubricating the parts of the machine with which he is normally in contact and carrying out ordinary simple maintenance activities (lubrication) collaboration with personnel involved in periodic and extraordinary maintenance activities Mechanical maintenance technician Activities: adjustment of mechanical play of the kinematic chains checking the execution of the movements and mechanical adjustment of safety devices checking the mechanical play and wear of the components (racks, pinions, etc.) repairing mechanical units prior to replacing parts with original spares Electrical maintenance technician Activities: acts on electrical equipment starting with the functional diagrams. checking the execution of the movements and electrical adjustment of safety devices checking wear of the electrical components (contacts of electrical equipment) repairing electrical units prior to replacing parts with original spares Electro-mechanical maintenance technician This is an operator whose professional profile combines and summarises the technical duties and skills required of the mechanical maintenance technician and those typical of the electrical maintenance technician Page 33 of 41

34 6.2.5 Mechanical technician Activities: SEPCOM 015 mechanical adjustments of safety devices, calibration and tests (load tests) routine maintenance operations prior to replacement of complex and/or critical mechanical components for purposes of safety repairing mechanical units prior to extraordinary maintenance operations (repairs on structural parts with weld filling material, mechanical processes onboard the machine, etc.) Electro-mechanical/mechanical-electronic technician This is a highly specialised operator whose professional profile combines and summarises the duties and skills required of the mechanical maintenance technician in addition to those typical of the electrical/electronic maintenance technician 6.3 RECOMMENDATIONS CONCERNING MAINTENANCE It must be noted that maintenance actions performed correctly can reduce downtimes due to a fault to the minimum. Timely repair will avoid further deterioration. As far as possible, use genuine spare parts. Follow the indications given below for setting in maintenance status: Personnel responsible for carrying out routine and extraordinary maintenance activities must have read and understood all the indications given in this chapter and in chapter 3. Routine and extraordinary operations must be performed only by authorised qualified personnel. Maintenance activities must be carried out with the machine disconnected from the power supply, and in safety conditions, using the appropriate personal protection equipment in accordance with the regulatory standards in force, after affixing a notice bearing the warning: "MACHINE UNDER MAINTENANCE". In case of problems or to order spare parts, contact WAM S.P.A. Page 34 of 41

35 6.4 ROUTINE AND PERIODIC MAINTENANCE PLAN The maintenance plan comprises ordinary actions which involve inspections, checks and tests conducted by the operator responsible for machine conduction and/or personnel qualified for normal maintenance and periodic maintenance which include replacement and adjustment by technical personnel trained for the purpose by means of special training courses. When the maintenance operations are performed at a hazardous height off the ground, the personnel must use suitable means (scaffolding, platform, ladders, etc.) to be able to carry out the activities in safety conditions. The personnel must also be provided with appropriate personal protection equipment (P.P.E.) as envisaged by the laws in force. - Every week, check to make sure the drainage unit and compaction unit are free of material residues. - Every two months, clean the separation screen. - Every year, check the conveyor screw and screen for wear. The indications given above are general; wear is proportional to the type of product treated and the operating time. BEFORE CARRYING OUT ANY OPERATION, DISCONNECT THE MACHINE FROM THE ELECTRICITY SUPPLY! Inspection of the screen To check the condition of the screen: 1.UNSCREW THE NUTS Page 35 of 41

36 2. LIFT THE GUARD 3. THEN CHECK THE SCREEN TO MAKE SURE IT IS CLEAN Cleaning the screen To clean the screen, first of all, disconnect the power supply to the electric motor. Slacken the locking nuts of the outlet module and rotate the module to remove it Page 36 of 41

37 Remove the 6 flanged nuts unscrew the nuts on the guards. Remove the guards Then wash the screen with running water If the operation described above is not sufficient to clean the screen, unscrew the fixing nuts and remove the screen. Page 37 of 41

38 Remove the screw, pulling it from the end. Remove the screen. If necessary, refit a new screen using the alignments provided. Refit the drainage module according to the instructions at the previous points and restore the working of the machine Checking for leakage from the seals In case of evident leakage in the point indicated in the photo, stop the machine and call assistance. Page 38 of 41

39 6.5 REPLACEMENT OF PARTS AND COMPONENTS For all parts or components replacement contact WAM S.P.A. 6.6 SPARE PARTS AND CONSUMABLES The machines are designed and constructed in such a manner that they do not normally require spare parts due to faults or breakages, if used correctly and with adequate and correct maintenance as described in this Manual. If faulty parts need to be replaced, it is compulsory to use genuine spare parts. Do not hesitate to replace the part and/or component concerned if it is incapable of offering sufficient guarantee of safety and/or functional reliability. Never carry out improvised repairs. The use of spurious spare parts, apart from invalidating the warranty, can also affect the working of the machine Personnel authorised to act in the event of a fault The personnel authorised to act in most cases of fault, or where not indicated otherwise, is an expert qualified maintenance technician with specific training regarding the mechanical, electrical and electronic parts. Where highlighted, intervention by specialist or duly trained technical personnel from the manufacturer is necessary Putting out of service If it is not possible to restore the correct working of the machine following a fault, proceed with the operations for putting it out of service, indicating the fault by means of a notice and contact the WAM S.P.A. assistance service. Page 39 of 41

40 6.7 DISMANTLING, DISPOSAL AND SCRAPPING If the machine or its components, broken, worn or at the end of the life cycle, are no longer usable or repairable, they must be demolished. Demolition of the machine and its parts must be done using suitable equipment selected according to the nature of the material on which action is to be taken (for e.g. shears, oxy hydrogen flame, saw, etc.). All the components must be dismantled and scrapped after being reduced to smaller pieces in such a manner that none of these can be reasonably reused. If the machine is to be scrapped, dismantle it, separating the different parts according to the type (for e.g. metals, oils and lubricants, plastic and rubber, etc.) and contact specialist collection centres for their disposal, in compliance with the legislation regarding disposal of solid industrial wastes. Do not try to reuse the parts or components of the machine which apparently still seem to be intact once they have been declared as no longer suitable after inspections and checks and/or replacements by specialist personnel or by the manufacturer. 6.8 MAINTENANCE ACTIVITIES CONTROL REGISTER - To prove that all the checking and maintenance activities have been conducted on the machine, and to retain a trace of responsibilities for the actions, if any, as described in this Manual, it is advisable to prepare, regularly fill in and keep a Control Register throughout the life of the machine. - In addition to all the activities regarding the life and use of the machine (parts replacement, overhauls, faults of a certain entity, etc.) all the operations envisaged in the maintenance plan must be noted down on a three-monthly and yearly basis as indicated in the Periodic Maintenance and Lubrication Table. - It shall be the responsibility of the maintenance personnel entrusted by the Buyer to fill in this register, noting down the results and notes in the spaces provided. The chart must also clearly indicate the name of the maintenance technician and the safety representative (responsible for occupational safety) who countersigns the notes in the register, as well as the date of each inspection and maintenance activity. Page 40 of 41

41 Date Type of action Operator Page 41 of 41