10112677

1Index

1 General information ............................................................................................................... 3- Introduction - ................................................................................................................................ 31.1 How to use this manual .......................................................................................................... 3

- 1.1.1 Symbols description - ............................................................................................... 3- 1.1.2 Keeping this instructions manual- ........................................................................... 3

1.2 Machine identifying data ........................................................................................................ 4- 1.2.1 Marking - .................................................................................................................... 4

1.3 Technical features................................................................................................................... 5- 1.3.1 Overall dimensions - ................................................................................................. 5- 1.3.2 Consumption according to use - ............................................................................. 5- 1.3.3 Electrical features - ................................................................................................... 6- 1.3.4 Environment features - ............................................................................................. 6- 1.3.5 Noise emission - ....................................................................................................... 6- 1.3.6 Technical data ........................................................................................................... 7

1.4 Description of the machine ................................................................................................... 8- 1.4.1 Intended use - ............................................................................................................ 8

1.5 Safety devices and protections ............................................................................................ 9- 1.5.1 Preventive measures to be carried out - ............................................................... 9- 1.5.2 Safety valve - ...........................................................................................................10- 1.5.3 Emergency stop push button - ............................................................................... 11

1.6 Warranty conditions ..............................................................................................................122 General instructions ............................................................................................................132.1 Machine delivery...................................................................................................................13

- 2.1.1 Moving the machine - .............................................................................................13- 2.1.2 Storage of the machine - ........................................................................................15

2.2 Installing the machine ...........................................................................................................16- 2.2.1 Instructions for placing the machine - ....................................................................16- 2.2.2 Connecting between Product and fluids piping- ..................................................16- 2.2.3 Electric connections - .............................................................................................18

2.3 Disposal ................................................................................................................................203 Instructions for the operators ...........................................................................................213.1 Instructions for the use .........................................................................................................21

- 3.1.1 Description of the control devices - ......................................................................21- 3.1.2 Machine starting up - .............................................................................................22- 3.1.3 Emergency stop - ....................................................................................................22- 3.1.4 Instructions for the washing procedure - ...............................................................23

3.2 Troubleshooting ...................................................................................................................24- 3.2.1 Function anomalies - ..............................................................................................24- 3.2.2 Safety valve operation - ..........................................................................................25

NOTES.........................................................................................................................................26- 3.2.3 Signalling pilot lamps and electric anomalies - ...................................................26

4 Maintenance...........................................................................................................................274.1 General principles ................................................................................................................27

- 4.1.1 List of recommended spare parts to be kept in store - ......................................27- 4.1.2 Instructions for checks and ordinary maintenance - ............................................28- 4.1.3 Programmed maintenance - ..................................................................................29

4.2 Transmission belts ...............................................................................................................35- 4.2.1 Replacing the belts .................................................................................................35

2- 4.2.2 Tensioning the belts - ..............................................................................................36- 4.2.3 Attention - .................................................................................................................36- 4.3 Lubrication oil change - .............................................................................................37

- 4.3.1 Reducers - .......................................................................................................................38- 4.3.2 Pump body - ............................................................................................................39

4.4 Maintenance special equipment .........................................................................................404.5 Ordinary maintenance: pumping group ..............................................................................41

- 4.5.1 Pumping group composition - ...............................................................................41- 4.5.2 Components of pumping group that get worn out - .............................................42- 4.5.3 Maintenance of pumping pistons, gaskets ch and guiding bands - ..................43

4.6 Valve groups .........................................................................................................................46- 4.6.1 Composition of the valve group - ..........................................................................46- 4.6.2 Components of the valve group that can get worn out- .......................................47- 4.6.3 Maintenance of the supply valve group - ..............................................................48- 4.6.4 Maintenance of the suction valve group - .............................................................50

4.7 Safety valve ...........................................................................................................................52- 4.7.1 Composition of safety valve - ................................................................................52- 4.7.2 Components of the safety valve that can get worn out - ......................................52- 4.7.3 Maintenance of the safety valve - ..........................................................................53

5 Spare parts tables and instructions for replacing the components .......................545.1 How to read the spare parts tables - ..................................................................................545.2 Spare parts order form - ......................................................................................................555.3 Spare parts tables ................................................................................................................56

- 5.3.1 Pistons and head table - ........................................................................................56- 5.3.2 Homogenizing chamber table - .............................................................................58- 5.3.3 Safety valve table - ..................................................................................................59- 5.3.4 Pump body table - ...................................................................................................60- 5.3.5 Motor table - ............................................................................................................62

Notes ............................................................................................................................................63- 5.3.6 Hydro-pneumatic system table - ............................................................................64- 5.3.7 Inlet product union group table - ............................................................................66- 5.3.8 Outlet product union group table - .........................................................................67

5.4 Recommended torque for fastening studs - ......................................................................685.5 Electric system .....................................................................................................................69

2

31 GENERAL INFORMATION

- INTRODUCTION -Dear Client,We thank you very much for your preference and with the occasion we are please to

assure our complete disposal in order to allow you to use our machine in the best possibleway.

1.1 HOW TO USE THIS MANUAL

This manual contains all information the user needs to install correctly and safely the ma-chine, to start it up and use it, to localize any eventual trouble and to carry out maintenance opera-tions on the machines manufactured by FBFITALIA s.r.l. This manual is divided into chapterscontaining paragraphs relative to the argument treated in the chapter.All our technical staff remains at your complete disposal for any further information.

- 1.1.1 Symbols description -

Follow carefully the instructions contained in this instructions manual,paying PARTICULAR ATTENTION to that information bearing DANGERwarning and the symbol here by, in order to assure the operators safety.

Read carefully the notes introduced by this symbol bearing the writeATTENTION! in order to avoid dangerous operations for the machinesequipment.

This symbol accompanies warnings and important information, further-more suggests to use the machine in the best possible way.

D A N G E R

!

iATTENTION

!

This symbol is positioned on the machine casings. It means thatmanual cleaning, greasing, repair and adjustment of the movingdevice are prohibited.

This symbol is positioned on the machine compression head.It informs the operator that the use of protective gloves is compulsory,in order to avoid any injury to hands due to high temperatures.

This symbol is positioned on the machine compression head.It indicates the high temperature of the surfaces on which it is located.

This symbol is positioned on the machine casings. It means that themachine safety protections must not be removed.

This symbol is positioned on the electric panel cover of the machine.It indicates the presence of possible electric discharges.

41.2 MACHINE IDENTIFYING DATA

- 1.2.1 MARKING -

The machine is supplied free from identifying label and without electrical board.

Therefore you are not allowed to install the machine untill the machine or the plant ofwhich it will become part is identified or declared in accordance with the regulations in force.

- 1.1.2 KEEPING THIS INSTRUCTIONS MANUAL-

Keep this manual safe for any future reference in a safety place and always at the opera-tor disposal. In case the machine should be sold, remember to handle this manual to the newowner, since this manual is an integral part of the machine.

51.3 TECHNICAL FEATURES

- 1.3.1 OVERALL DIMENSIONS -

- 1.3.2 CONSUMPTION ACCORDING TO USE -

Fig. 1.3.a Dimensioni dingombro - Overall dimensions -

DIMENSIONI INGOMBRO - OVERALL DIMENSIONS

A B C

1.280 mm 990 mm 970 mm

PESO TOTALE - TOTAL WEIGHT - Kg 420

CONSUMI - CONSUMPTIONS

OGGETTO - SUBJECTUNITA' DI MISURA -

MEASURE UNIT VALORE - VALUE

Acqua - Water m3/h 0,12

Forza motrice - Motive power kW 8,6

Aria compressa - Compressed air Nl/h Irrilevante - Irrelevant

6Machine front rear

72 db A

70 db A

70 d

b A

71 d

b A

H from ground =1,6 m

1 m 1 m

1 m1 m

- 1.3.3 ELECTRICAL FEATURES -

- 1.3.4 ENVIRONMENT FEATURES -The machine has to be installed in a suitable and covered place (at temperature be-

tween +5...+45 C, with relative humidity

7- 1.3.6 TECHNICAL DATA

CAPACITY...........................................................................................LpH

MAXIMUM WORKING PRESSURE ................................................Kg/Cm2 (bar)

N REV/MIN. CRANKSHAFT

PUMPING PISTON STROKE ..........................................................mm

PUMPING PISTON DIAMETER ......................................................mm

SUPPLY MINIMUM PRESSURE REQUESTED ...........................Kg/Cm2 (bar)

ELECTRIC MOTOR PULLEY

REDUCER PULLEY

TRANSMISSION BELT

PRODUCTS TREATED

MAIN ELECTRICAL MOTOR

SIEMENS 1LE10021CB222AA4 - 3 Phases - 60 Hz - 8,6 kW - 460 Vac - 1.750 Rpm - 14,7 A - Cl.Is. F - IP55 - Poles 4

SERVOFAN FOR MAIN MOTOR

-

SECONDARY FAN MOTOR

WINSTRO C35 IL 2 2 - 3 Phases - 60 Hz - 148 W - 380/575 Vac - 0,24 A - Cl. Is. F - IP66 - Poles 4

OIL PUMP MOTOR

-

REDUCER

ROSSI RI080 UP3A /4,17

TEST AND INSPECTION CERTIFICATE

Test method used: The machine is tested with water at operating pressure and capacity, fed at a constantpressure of 2 bar for a period of 12 hours

SURVEY VALUE

ACTUAL CAPACITY IN ABSENCE OF PRESSURE

ACTUAL CAPACITY IN PRESENCE OF PRESSURE

N REV/MIN. IN PRESSURE ON THE REDUCER

OIL PRESSURE ON THE LUBRICATING SYSTEM

AIR PRESSURE ON THE PNEUMATIC SYSTEM

POWER IN THE LINE WITH MACHINE IN ABSENCE OF PRESSURE

POWER IN THE LINE WITH MACHINE IN PRESENCE OF PRESSURE

N REV/MIN. OF MAIN MOTOR WITH MACHINE IN PRESSURE

SUPPLY VOLTAGE

H.P. PUMP MODEL FBF008/P - SERIAL NUMBER 10112677

NOTES: MACHINE TESTED AT 400 VAC 60 HZ CONTROL SIGNATURE

900

200

178

48

28

2

116.SPZ118-3/C

116.SPZ280-3/C

115.SPZ1287/A

Eggs

81.4 DESCRIPTION OF THE MACHINE

The positive-displacement pump has the specific function of conveying the product inside theplant assuring a volumetric capacity at a constant pressure.The machine is covered by stainless steel panels that provide to fair and to eliminate the noiseprovoked by the rotating parts of the moving organs of the machine (such as electrical motors,transmission belts, pulley, etc.) and specially they provide to avoid any danger for thepersonnel in charge of operations.

The uncovered part of the panels is called compression head where the product to betreated will be conveyed into.

The pumping pistons are installed in the inner part of the compression head and theirfunction is that of pumping the product under pressure; the suction and delivery valves andthe homogenizing valve, where the product is homogenized, are also installed inside thecompression head.

The control panel bears the start and stop controls, the control to regulate the homog-enizing pressure and the pilot lamps.

The machine always bears an emergency stop push button on the front rear.The main switch is placed on the electric board; it can be used both to cut off power

supply to the machine and to stop the machine in case of emergency.The machine is supplied with a complete set of gaskets for the compression head and

safety valve, N 6 Recovery springs for heads valves, N1 safety valve seat, N1 safety valveball, a set of wrenches and tools to carry out regular maintenance operations.

- 1.4.1 INTENDED USE -

This machine has been calibrated to treat the product indicated in the technical card,such product must not contain hard particles or strange bodies. It is convenient to install afilter upstream the machine for filtering adequately the product treated.

Never use the machine to treat products different from those indicatedin the paragraph 1.3.6 TECHNICAL FEATURES - TECHNICAL DATA -(density, dimension of subparticles, viscosity, etc...). Furthermore, theoperating conditions have to be fully respected, as indicated in thetechnical card.

FBF ITALIA srl will not to be hold responsible for damaged caused for having treatedother product than those indicated in the technical card. The constructor, in any case, re-mains at your complete disposal for any further information regarding this argumentation andwill suggest the eventual modifications that needs to be carried out in case the user intendsto process other product different from the initial one for which the machine was originallycalibrated.

ATTENTION!

!

91.5 SAFETY DEVICES AND PROTECTIONS

- 1.5.1 PREVENTIVE MEASURES TO BE CARRIED OUT -

Only qualified personnel is to be allowed to operate this machine, according to the regu-lation in force.

The machine is not at all dangerous for the operator when used cor-rectly and according to the instructions contained in this manual. Nevertamper or disengage safety devices.

When carrying out maintenance operations on electrical or mechanicalparts it is COMPULSORY to cut off the power to the control board bymeans of the main switch (see paragraph 3.1 INSTRUCTIONS FOR THEOPERATORS - DESCRIPTION OF THE CONTROL DEVICES - to locatethe afore mentioned switch).

All rotating and moving elements are equipped with protections, whichcan be removed only by means of special tools and ONLY after havingSWITCHED OFF the power supply to the machine by using the specialexternal handle of the main switch.

When the machine operates with products at high temperatures, the feed-ing and sending piping (which has to be installed by the installer or user)and those machines parts where the product get conveyed in, reachsuch high temperatures as to provoke burns when touched. Should thisbe the case, the user has to install suitable protections in order to avoidthe operator to get burnt or, otherwise, to install the machine in such away so to avoid any damage to the operator.

Our technical staff remains at your complete disposal for any further information.

ATTENTION!

!

D A N G E R !

!

D A N G E R !

!

D A N G E R !

!

Before to proceed to any maintenance operation, wear the safety devices(Ex.: glowes, glasses, masks, etc...) in the way to avoid every damage forthe operators.

D A N G E R !

!

10

- 1.5.2 Safety valve -

This valve, located on the sending piping of the compression head, is already calibratedto a value higher than the maximum pressure admitted and operates only in case ofoverpressure by draining the product out.

For further information regarding this valve operating mode see the paragraph 4.8.3.

i

Never tamper/modify the calibration of the valve!

This valve protects the integrity of the head; for the product drainingpiping mounted in the user premises it will be convenient to install , incase of risk of overpressure, a suitable safety device in order to avoidany danger.

Make sure the final part of the valve A draining pipe is always directedto any area far from the operators.

The product discharged by the valve has to be collected and disposedoff according to the regulations in force in the Country where the ma-chine is installed in; particular attention need to be paid in case of toxicand/or polluting substances.

ATTENTION

!

ATTENTION

!

Fig. 1.5.a Product safety valve

A

D A N G E R

!

11

- 1.5.3 EMERGENCY STOP PUSH BUTTON -

The machine is equipped with one or more emergency stop push-buttons. The mush-room head push-button is red and surrounded by a yellow ring. This push-button is self-blocking, that is to say that when pressed it remains blocked in this position. To unblock thepush-button pull it.

The operator must press, IMMEDIATELY and WITHOUT HESITATION, theemergency stop push-button every time a dangerous situation, no matterif for the operator and/or for the machine, occurs.

In case any other machine or equipment have to be installed near themachine, the operator needs to make sure the push-button area remainseasily accessible in case of dangerous situation.

D A N G E R !

!

ATTENTION!

!

Fig. 1.5.b Pulsante di emergenza - Emergency stop button -

12

1.6 WARRANTY CONDITIONSThis document certifies that FBF ITALIA srl warrants that its product(s) are free from defects

of materials used and are manufactured under the conditions and limitations here below speci-fied.

FBF ITALIA srl will not to be hold responsible for latent defect or malfunctioning of anycommercial components used, no matter that the manufacturer might be a national or inter-national leader company, which are not constructed by FBF ITALIA srl .

Should this case happened, FBF ITALIA srl will recognize to the Client the same war-ranty that the manufacturer of the components supplies and will provide to supply all the nec-essary assistance to the users.

The pieces to be repaired or replaced will have to be sent to our factory by the Client,free of charge, only after having received acceptance of warranty from our company.

What is covered by the warrantyThe warranty covers the costs for replacing faulty parts, for repairing or replacing them with

equivalents parts according to the convenience of every single case.A part or product have to be considered faulty, and therefore covered by the warranty, when

it has been proved that the congenital defects of the part(s) already existed at the time of thedelivery.

What is not covered by the warrantyThis warranty does not cover parts or products which become damaged during trans-

port, installation or repairing, or those that become damaged due to not regular use of theparts or products, overload, negligence, insufficient lubrication, normal wear of parts, use ofnot original FBF ITALIA srl spare parts, or any other damages caused by improper use,accident or negligence on having follow the instructions contained in this use and mainte-nance instructions manual.

The warranty does not cover also any damage caused by irresponsible users or in case ofmodifications that FBF ITALIA srl considers might have caused or worsen the eventual dam-ages or in case the eventual seals have been removed or regulations modified.

The warranty does not cover any other accidental costs, should those be consequentialor connected costs: for example transport expenses for any eventual spare parts shippedcovered by warranty, travel expenses of technical assistance personnel, extraordinary ex-penses due to difficult accessibility of the installed machinery, missing profit, waste of time,harm or damages caused to other parts or goods that are not of FBF ITALIA srl manufactureindicated in this warranty.

FBF ITALIA srl does not authorize third parties to charge other responsibilities regard-ing the sale of FBF ITALIA srl s products than those established in this warranty.

Period of warrantyFBF ITALIA srl warrants the machine for a period of twelve months both mechanic and

electric parts.The warranty starts from the date the machine is tested on the production line or, at the latest,

after 4 months from the delivery date to the first owner.

Operations carried out before deliveringBefore leaving our factory all our products are carefully tested to make certain they sat-

isfy all FBF ITALIA srl s specifications and quality standards.

Production modificationsFBF ITALIA srl reserves the right to modify, any time, the products manufactures and

sold, without any previous notice and without any obligation to update the products alreadyconstructed or sold.

13

Fig. 2.1.b Movimentazione macchina - Machine transport -

2 GENERAL INSTRUCTIONS

2.1 MACHINE DELIVERY

- 2.1.1 MOVING THE MACHINE -To transport and move the machine is required the use of a fork lift truck with such a

loading capacity as it will be suitable to lift and handle the machine. Refer to the figure 2.1.afor information on the machines dimensions and weight.

The length of the forks must be the same or even longer than the machines depth or thatof the packaging containing the machine itself.

To move the machine carry out the following instructions.

Machine without packagingCarry out the following operations:

- The forks have to be positioned between the supporting feet and as near to them aspossible.

- The homogenizing head will have to be positioned facing the lift truck so to balancebetter the load.

- The machine hasto be suitablyprotected (for ex-ample with plas-tic protections)against anyeventual collisionor abrasioncaused by a fron-tal impact withthe lift truck. The forks have to be positioned be-tween the feet and as near to them as

possible

The

fork

has

to p

roje

ctov

er th

e m

achi

ne

The head is to be posi-tioned facing the lift truck

Fig. 2.1.a Dimensioni imballo - Packing dimensions-

DIMENSIONI IMBALLOPACKING DIMENSIONS

A B C

1.600mm 1.150 mm 1.300 mm

PESO - WEIGHT Kg 165

14

Fig. 2.1.c Movimentazione imballo - Packing transport -

Packed machine.Carry out the instructions described here bellow:

- The forks have to be inserted under the packaging, between the supporting beamsand as near to them as possible.

In both cases the machine has to be hoisted and transported only after being sure theway is free from any obstacle.

The forks have to be positionedbetween the beams and as nearto them as possible

The

fork

has

to p

roje

ctov

er th

e m

achi

ne

15

Fig. 2.1.d Movimentazione con gru - Transport with crane-

ATTENTION!

!

Handling with a crane or bridge crane.In case the machine will be moved by means of a crane or bridge crane, the loading

capacity of transport means will have to be suitable to lift the machine itself (refer to Fig.2.1.a); it is also compulsory to tighten the machine by using ropes or belts, as shown in theFig. 2.1.d.

To lift the machine it will be necessary to use a rocker arm which will be fixed to themachine by means of ropes or belts; following this procedure you will avoid any possibledamages to the machines framework.

In case the machine is packed it will be enough to fix ropes or belts, as shown in thefigure, having a vertex angle not bigger than =60. The typology (diameter, material etc.,) ofrope or belt has to be selected according to the admitted safety load which is punched markedon approved lifting equipment.

- 2.1.2 STORAGE OF THE MACHINE -

In case the machine has to be stored longer than 3 months before being installed, it isnecessary to keep it in a covered and dry place (free from humidity), mainly to protect electricand electrical components mounted within the machine.

Further more you need to:- disassemble the pumping piston placed within the compression head in order to avoid

that the pistons, remaining in static contact with their relative gaskets CH, could get worn out.- loosen the transmission belts by means of the tightening devices.

Pistons should be mounted back when installing the machine and soshould the belts be tightened.

Read carefully the paragraph 4.3 REPLACING THE COMPONENTS in order to carryout the correct operations.

= 60

Rocker arm

Rocker arm

Rope or belt

Machinehoisting

Hoisting withpackaging

16

ATTENTION!

!

ATTENTION!

!

D A N G E R !

!

D A N G E R !

!

2.2 INSTALLING THE MACHINE

- 2.2.1 INSTRUCTIONS FOR PLACING THE MACHINE -The machine has to be installed in a suitable place (temperature +5...+45 C, relative

humidity

17

A - Product intlet SMS 1,5 -B - Product outlet counterflange D.26 -C - Electric cables inlet -E - Water inlet, internal thread G1/4 -F - Water drain, internal thread G1/4 -G - Adjustable foot -H - Control panel -

Fig. 2.2.a Connections placement and overall dimensions -

A B

H E

C

G F

Vista posteriore - Rear view

Vista da sotto - Bottom view

18

- 2.2.3 ELECTRIC CONNECTIONS -

The machine is equipped without electrical board.All its electrical components (motor, electrovalves, push button. etc..) have beenconnected into a suitable shunting box to faciloitate the connection with therelative electrical board (see chapter relative to the electrical scheme).The connection between machine and electrical board have to be effected inaccordance to regulations in force.

ATTENTION!

!

THE MACHINES FRAME MUST BE CONNECTED TO THE MAIN OF THE ELECTRICAL BOARD.USE THE CONNECTIONS POINT ON THE SHUNTING BOX (REF. CH.5.5 MACHINES ELECTRICAL BOARD PAGE 01)

Fig. 2.2.b - Connessione TERRA - Connection EARTH -

19

ATTENTION!

!

D A N G E R !

!

D A N G E R !

!

When the machine has been connected to the supply system, make sure thesense of rotation of the electric motors is correct.

To carry out this check it is necessary to remove the machines externalprotections (panels). This way the moving mechanical componentsrepresent a serious danger for the personnel in charge. It isrecommended to pay particular attention while carrying out thisoperation.

Carry out a general check of the machine functioning and test the protectionsfunctioning conditions (emergency, irregular oil pressure, magneto-thermicswitch, etc.)

To carry out this check it is necessary to operate with the control boardopen. This way the voltage represents a real danger for the personnelin charge. It is recommended to pay particular attention while carryingout this operation.

i

ATTENTION!

! Electric connections have to be carried out by electricians only.

20

- 2.2.4 TROUBLE-SHOOTING FOR SERVOVENTILATION -

In case the servoventilator of the main motor (M1) fails it is possible to execute an emergencyprocedure which allows to run the machine from the maxicum capacity to half therevolutions of the motor maintaning thecorrect safety conditions.

To execute the said emergency procedure carryout the following operations:- Cut off power supply to the machine.- Remove the machines protection panels(See figure 3.1.1).- Remove the protection cap B (see fig-ure 2.2.4b) of the forced ventilation (which youfind on the opposite side of the pulley) of themain motor (M1) (see figure 2.2.4b). Discon-nect the electrical connections of theservoventilation motor, insulate the electricalcables and remove the servoventilation kit(motor+fan).- Assemble the original cooling fan A (seefigure 2.2.4b) (which you find in the maintenancebox supplied with the machine) on the shaft ofthe main motor (M1); then assemble back in position the protection cap B (see figure 2.2.4b).- Assemble back in position the machines protection panels and fasten them correctlyby means of the relative fastening screws.- Start up the machine again paying good attention at the litimitions afore described.

Fig.2.2.4b Main motor M1 + servoventilation kit -

C

B

Fig.2.2.4a Original cooling fan supplied with theservicing box -

A

21

NOTES

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22

i

2.3 DISPOSAL

PremiseThe FBF ITALIA srl machines do not contaminate and do not cause any harm to the

environment, but during the phase of installation, maintenance or disposal there can be pro-duced some waste that if not correctly disposed of can be actually harmful for the environ-ment or can not be used to produce raw material.

Therefore assuring the maximum preservation of the environment hasto be the first main goal

Mineral or synthetic oil usedThese are special wastes that must be given directly to those special societies in charge

for the disposal of this kind of waste.

Machinery and appliances deteriorated and obsoleteThese are special wastes that must be given for scrapping according to the different

type of waste, metal alloys or plastic.

PackagingThese type of waste are assimilable and can be disposed in the installations in charge of

disposing of urban waste (first category dumps) without causing greater damage to men andenvironment.

23

A - Safety valve with drain pipe -B - Product inlet -C - Compression head -D - Oil level control -E - Pressure gauge -H - Emergency Stop push-button -F - Product outlet -I - Casing -G - Adjustable foot -

Fig. 3.1.1 Identificazione componenti - Identification of components

3 INSTRUCTIONS FOR THE OPERATORS

3.1 INSTRUCTIONS FOR THE USE

- 3.1.1 DESCRIPTION OF THE CONTROL DEVICES -

GC

F

D

A

E

I

B

H

24

How to start the machine

- Open the water supply valve upstream the machine.

- Make sure the machine is correctly fed airless and must have a constant minimumpressure of at least as indicated in the technical data table cap. 1.3.

- Start the machine by your command pannel.

- Make sure that the whole surface of the pumping pistons, in the rear part of the com-pression head, is covered by a film of water in order to assure the correct cooling andlubrication of the pistons.

Should it become necessary to regulate the water flow, use the tap installed in-side the machine (see chap.5.3.7).To avoid the water entering in contact with the oil in the pump body, the shaft ofthe guiding piston must not be wet.

How to start the machine

- Stop the machine by your command pannel.

i

- 3.1.2 MACHINE STARTING UP -

Fig. 3.1.2 Command devices on the machinery

EMERGENCY STOPPUSH BUTTON

AB

MACHINE INTENSION

25

- 3.1.3 EMERGENCY STOP -

If, in case of emergency, the machine has to be stopped, press the emergency stoppush-button located on the machine or on the electric board.

Please remember that the above mentioned devices have to be usedonly in case of real emergency and not to stop the machine duringregular functioning operations.

At the end of the emergency, after having made sure no part of the machine is failing, resetthe emergency stop push-button by turning it counter clockwise, and start up the machineagain.

ATTENTION!

!

Fig. 1.5.b Pulsante di emergenza - Emergency stop button -

26

NOTES

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..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

..........................................................................................................................................................

27

- 3.1.4 INSTRUCTIONS FOR THE WASHING PROCEDURE -

This chapter contains important information, therefore you have to readit very carefully.

The machine must be washed periodically, taking in consideration the product treatedand the working needs. However we advise to do it at the end of every productioncycle.

The washing is normally a close cycle carried out while the machine is running andonly after having set to zero the homogenizing pressure. This procedure helps toavoid possible damages to the homogenizing heads.

If the machine is equipped to be used at variable capacities, the washing will becarried out at the maximum speed.

The operator must wear suitable clothes and/or accident prevention protectionsrelated to the temperatures and the products used.

To carry out washing cycle there could be used both acid and basic solutions, butwhat is more important is to make sure that the solutions do not contain a quantityof nitric acid superior to 2%.

We recommend not to use washing solutions containing chlorine, specially withsodium hypochlorite, since in presence of acid (even very weak ones) the chlorinedecomposes and has an oxidating effect. This oxidating effect, favoured by the tem-perature, the time, the light and by the presence of heavy metals (such as nickel,chromium, etc..), increases the concentration of the Cl- ions and tends to lower thePH from basic values towards neutral values. This condition favours the pittingcorrosion and the danger increases when the environment becomes a little acid.So in consideration to these facts, we are compelled to decline any responsibilityfor any relevant damages caused by the use of solutions containing chlorine, evenduring the period the machine is still covered by warranty.

We recommend to respect the norms in force in the Country where the machine willbe installed for that what regards the biodegradability of the washing product andthe discharging of waste water.

PRODOTTI PER LAVAGGIO - WASHING PRODUCT

PRODOTTO - PRODUCT max concentr. max temper.

Soda caustica - Caustic soda 3 % 90 C

Vapore - Steam - 130 C

Acido nitrico - Nitric acid 2 % 72 C

Acido fosforico - Phosphoric acid 3 % 86 C

Acqua - Water - 90 C

ATTENTION!

!

28

3.2 TROUBLESHOOTING

- 3.2.1 Function anomalies -

TROUBLE-SHOOTING

TYPE OF ANOMALY CAUSE REMEDY OR CONTROL

THE MACHINE DOES NOT STARTUP

The emergency stop push-buttons are engaged

Control the relative push-buttons on the controlpanel of the machine and on the electrical board.

THE MACHINE SUDDENLYSTOPS

The electric protection has beenenergized due to a short circuitor to a thermal over-heating.

Check inside the electric board, having as areference the electrical diagram:- the protection devices.

The oil pressure inside thelubricating circuit is notsufficient.

Control in the lubricating circuit the followingitems:-Piping and joints for oil leaking.-The level of oil when the machine is notrunning.-If the filter is clogged.-That the pump works properly .-That the heat exchanger does not leak or isnot clogged.

Control furthermore that the secondary faninside the machine is working correctly.

If, once these controls have been carried out,the malfunctioning continues, control that themechanical rotating parts are not abnormallyworn out.

NOT ENOUGH CAPACITY

Insufficient feeding to themachine

Control the capacity upstream the machine: it has tobe slightly superior to the nominal capacity of themachine itself.

Control if the feeding pressure to the machine isenough (paragr. 1.3.6).

Control if the product fed to the machine is airless.

The rotating speed of the mainmotor is lower than normal

Control the number of revolution of the main motorcomparing this value to the main test values(paragr. 1.3.6)

The seals of the valves insidethe compression head areleaking.

Control that the sealing surfaces of the valves(chap. 4.6.3 - 4.6.4) and the valves' seats (chap.4.6.5) are not worn out.Control that there are no strange bodies betweenthe valves and seats afore mentioned. Should bethis the case, remove the strange bodies and cleancarefully the surfaces.

Control the return valves springs (chap. 4.6.1).

29

- 3.2.2 Safety valve operation -

This valve, located on the supply pipe of the compression head, is already calibrated toa value superior to the maximum pressure admitted and operates only in case of overpres-sure by draining out the product. The safety valve starts operating whenever the machinegoes overpressure due to:

- Under feeding of the machine or air bubbles inside the product. In this case the safetyvalve will automatically stop operating as soon as the regular conditions are reset.Nevertheless is most important to reset the underfeeding situation as soon as possi-ble since many parts of the machine get stressed by this conditions and could beprematurely worn out (pressure indicator, valves and valves seats, springs, etc...).

- Extreme working pressures. To reset the right safety valve functioning can benecessary to stop the machinery for few seconds.

Fig. 3.2.a - Safety valve

30

- 3.2.3 SIGNALLING PILOT LAMPS AND ELECTRIC ANOMALIES -

The control panel, with all controls, pilot lamps and control devices, is placed in the frontside of the machine (see paragraph 3.1.1 DESCRIPTION OF THE CONTROL DEVICES ).

CONTROL FOR SIGNALLING PILOT LAMPSDENOMINAZIONE

DESCRIPTION

DESCRIPTION OF PILOTLAMPS INDICATIONS CONTROLS TO BE CARRIED OUT

WHITE PILOT LAMP 'TENSION' ON The machine is intension

None - All is correct

31

D A N G E R !

!

4 MAINTENANCE

4.1 GENERAL PRINCIPLESAn accurate maintenance program will allow to obtain best performance of the machine

with minimum costs:We recommend to follow the base maintenance diagrams described below, mean for

the normal use of the machine.

Before carrying out any maintenance operation, it is compulsory to cutoff the power supply to the machine by means of the main switch (seeparagraph 3.1.2 - DESCRIPTION OF THE CONTROL DEVICES - to locatethe afore mentioned switch).

- 4.1.1 LIST OF RECOMMENDED SPARE PARTS TO BE KEPT IN STORE -

PEZZI DI RICAMBIO CONSIGLIATI - LIST OF RECOMMENDED SPARE PARTS

Q.TA'Q.TY

DENOMINAZIONE - DESCRIPTIONCODICE NCODE No

3 PISTONE POMPANTE - PUMPING PISTON 001.04318/C

3 GUARNIZIONE CH - CH GASKET 004.0006/MRR

1

SERIE COMPLETA GUARNIZIONI TESTATA E VALVOLA DISICUREZZA

COMPLETE SET OF HEAD AND SAFETY VALVE GASKETS

212.PST028BCTSTD

6 SEDE VALVOLA - SEAT VALVE 001.00016/T

6 VALVOLA - VALVE 007.0018

6 MOLLA - SPRING 001.00043

1 INDICATORE DI PRESSIONE - PRESSURE GAUGE 015.0020

1SERIE COMPLETA GUARNIZIONI CORPO POMPA -COMPLETE SET OF PUMP BODY GASKETS

213.FBF008/080

3 CINGHIA DI TRASMISSIONE - TRANSMISSION BELT 115.SPZ1287/A

32

i

- 4.1.2 INSTRUCTIONS FOR CHECKS AND ORDINARY MAINTENANCE -

We recommend to follow the following base maintenance programs (forseen fora normal use of the machine) paying particular attention to the expiries of thelubricating oil of the rotating parts. An accurate maintenance program will allowto obtain best performance of the machine with minimum costs.In case of doubts regards the necessity to replace or not a part of the machine,we advise to proceed with the replacement of it because the sudden impossibilityto start or to conclude a production implies very higher costs to the user.

The fastening of the above mentioned flanges has to be carried out bymeans of a dynamometric wrench; it will be necessary to respect thevalues given in the table you find at the beginning of the paragraph 5.4REPLACING AND ASSEMBLING OF COMPONENTS.D A N G E R !

!

CONTROLS

Frequency Controls

Dailychecks

Check the oil level and if necessary refill by means of thespecial observation glass located in the frontal part of themachine.

Verify that no noise and/or anomalous vibrations are emittedby the machine equipment.

Verify that no fluids and/or product leak from the gaskets.

Weeklychecks

Make sure the seal of the pumping pistons works correctly

Verify that the fastening elements (screws, bolts, etc.) are notloosen, paying particular attention to the heads closingflanges.

After thefirst 100hours

Control belts tightening

Before to proceed to any maintenance operation, wear the safety devices(Ex.: glowes, glasses, masks, etc...) in the way to avoid every damage forthe operators.D A N G E R !

!

33

- 4.1.3 PROGRAMMED MAINTENANCE -

PROGRAMMA DI MANUTENZIONE - MAINTENANCE PROGRAM

Intervallofrequency

Operatoreoperator Controlli - check-in list

1500ore - hours

Data - date

............................Firma - signed

............................

Replacing lubricating oil of pump body

Worn out and tensioning control and eventual replacing ofthe transmission belts

Check/replacing the valves and valves seats

3000ore - hours

Data - date

............................Firma - signed

............................




Raplace springs of valve groups

4500ore - hours

Data - date

............................Firma - signed

............................




6000ore - hours

Data - date

............................Firma - signed

............................




Raplace springs of valve groups

7500ore - hours

Data - date

............................Firma - signed

............................




34


Intervallofrequency


9000ore - hours

Data - date

............................Firma - signed

............................




Replacing springs of valve groups

Replacing the motoreducer oil

10500ore - hours

Data - date

............................Firma - signed

............................




Check and replacing of homogenizing valve

12000ore - hours

Data - date

............................Firma - signed

............................





13500ore - hours

Data - date

............................Firma - signed

............................




35


Intervallofrequency


15000ore - hours

Data - date

............................Firma - signed

............................




Check and replacing of homogenizing valve

16500ore - hours

Data - date

............................Firma - signed

............................





18000ore - hours

Data - date

............................Firma - signed

............................





19500ore - hours

Data - date

............................Firma - signed

............................





21000ore - hours

Data - date

............................Firma - signed

............................




36


Intervallofrequency


22500ore - hours

Data - date

............................Firma - signed

............................





24000ore - hours

Data - date

............................Firma - signed

............................




25500ore - hours

Data - date

............................Firma - signed

............................





27000ore - hours

Data - date

............................Firma - signed

............................





37


Intervallofrequency


28500ore - hours

Data - date

............................Firma - signed

............................




30000ore - hours

Data - date

............................Firma - signed

............................





31500ore - hours

Data - date

............................Firma - signed

............................




33000ore - hours

Data - date

............................Firma - signed

............................





38


Intervallofrequency


...........ore - hours

Data - date

............................Firma - signed

............................




..........ore - hours

Data - date

............................Firma - signed

............................





..........ore - hours

Data - date

............................Firma - signed

............................




..........ore - hours

Data - date

............................Firma - signed

............................






..........ore - hours

Data - date

............................Firma - signed

............................




39

4.2 TRANSMISSION BELTS

The transmission used is the trapezoidal belts type. Follow the operation describedbelow to carry out correct and safe assembling operations.

We recommend to carry out assembling/disassembling operations andthe check of the belts state, only when THE MACHINE IS OFF and thestarting device blocked with the key.

- 4.2.1 REPLACING THE BELTS

- Loosen the nut A

- Loosen the nuts B and C

- Turn the tension rod Dcounter clockwise toloosen tension and beable to disassemble thebelts.

- Remove the belt and re-place it with the new onethat will be placed into thepulley seat

- Turn the tension rod Dclockwise to tighten thebelts.

- Tighten the belts correctly,as described, and thentighten the bolt A and nuts B and C, as in figure 4.3.b.

ATTENTION!

!

Fig. 4.3.a Trasmissione a cinghie Belts transmission -

A

B

C

D

Fig. 4.3.b Tensionatore cinghie - Belts stretcher-

40

i- 4.2.2 TENSIONING THE BELTS -

The ideal tensioning is slightly bigger than the sliding limit of the belts. The over-tensioning reduces the belts and shafts bearings life.Before tightening as described later on, identify the installed belt type in the technicalcard (Chapter 1.3.6)

Tensioning used belts

See fig.4.3.c and carry out the following in-structions:- Find out where the free space T of the belt is- Apply a force M (by means of a dynamometer) of 2 - 3 Kg for belts SPZ- Tension the belts, by means of the reaction arm, so that the flection of beltF be of 6 mm.

Tensioning new belts

See fig.4.3.c and carry out the following instructions:- Find out where the free space T of the belt is- Apply a force M (by means of a dynamometer) of 3 - 4 Kg for belts SPZ .- Tension the belts, by means of the reaction arm, so that the flection of belt F be of 6 mm.

- 4.2.3 ATTENTION -

Before mounting the belts check the alignment of the pulleys by using a limit block andthen make sure they are clean.Furthermore to assure good performance and reliability:

- Mount only new belts, never combine new ones with old ones, since it will be notpossible to tension them correctly so endangering the reliability of the transmission.

- Mount belts of the same trademark and check on the belt back that they belong thesame production lot. In fact, belts of the same trademark, with the same nominaldevelopment, but belonging to different lots, may present little dimension differenceswhich will reduce the transmission life.

Tab. 4.3.c Belts tension values

M

Lenght of thefree space T

Force

F

BELT TENSIONING TABLE

Flexion f Belt SPZUSED

Belt SPZNEW

6 mm 2 - 3 Kg 3 - 4 Kg

41

iFBF ITALIA srl will not to be held responsible for any eventual damagescaused by oil having characteristics different from those indicatedafore.

Make sure to use the quantity of oil recommended since too much oil couldresult in over heating the oil while if the oil is not enough the rotating compo-nents will not be correctly lubricated.

ATTENTION!

!

- 4.3 LUBRICATION OIL CHANGE -The oils provided into the reducer and into the pump body are for a functioning withenvironmental temperatures of 0 - 45 C.In presence of different evironmental temperatures, please contact our technicaldepartment.

- CHARACTERISTICS OF LUBRICATION OILS -

SHELL OMALA HDCARATTERISTICHE TIPICHE (VALORI MEDI INDICATIVI)TIPYCAL FEATURES (INDICATIVE AVERAGE VALUES)

GRADAZIONE ISO 220

POUR POINT C -48

FLASH POINT C 268

VISCOSIT cSt A 40C 218

INDICE DI VISCOSITA' 162

SHELL TELLUS S100CARATTERISTICHE TIPICHE (VALORI MEDI INDICATIVI)TIPYCAL FEATURES (INDICATIVE AVERAGE VALUES)

GRADAZIONE ISO 100

POUR POINT C -27

FLASH POINT C 230

VISCOSIT cSt A 40C 100

INDICE DI VISCOSITA' 98

- EQUIVALENTS OF LUBRICATION OILS -

CORRISPONDENTI OLIO DI LUBRIFICAZIONE SHELL OMALA HDEQUIVALENTS LUBRICATION OILSHELL OMALA HD

MARCACOMPANY

TIPO OLIOOIL TYPE

MOBIL SHC 630

BP ENERSYN EPX 220

CASTROL ALPHASYN EP 220

ELF REDUCTELF SYNTHESE 220

KLBER KLBERSYNTH EG4

CORRISPONDENTI OLIO DI LUBRIFICAZIONESHELL TELLUS S100EQUIVALENTS LUBRICATION OIL SHELL TELLUS S100

MARCACOMPANY

TIPO OLIOOIL TYPE

BP BARTRAN HV100

ESSO NUTO HP100

CASTROL HYSPIN ZZ100

MOBIL DTE EXCEL 100

OILS QUANTITIES TABLEUSAGE QUANTITY KIND OF OIL USED

REDUCER'S OIL 1,5 Lt. SHELL OMALA HD

PUMP BODY'S OIL 4 Lt. SHELL TELLUS S100

42

- 4.3.1 REDUCERS -

Change the oil every 9000 hours; quan-tity of oil needed: 5 litres.

See fig.4.3.d, to change the oil carry out thefollowing operations :- Cut power supply to the machine by means

of the main switch.

- Remove the upper, back and left side pan-els.

- Remove the transmission belts (seechap.4.2) from pulley A.

- Unscrew screws E and screw them onholes F until pulley A is free on the re-ducer shaft.

- Remove pulley A.

- Remove upper cover B by unscrewingscrews C.

- Place a suitable container under tap D to collect the oil and remove the tap by unscrew-ing counter clockwise.

- Once the oil has been completely emptied screw in position tap D and refill the reducerusing oil Shell Omala HD or another one having the same features through hole B.

- Assemble back the cover B and apply the special sealing paste between the cover andthe reducer seat.

- Tighten the screws as indicated in table of chap.5.4

- Assemble the pulley and block it on the reducer shaft by screwing the screws E clock-wise; make sure the pulley is in line with the other one mounted on the electric motor.

- Assemble the belts by following the procedure described in chapter 4.2.

- Assemble back in position the panels, be sure to screw em with the bolts before to restartthe machine.

Fig. 4.3.d Reducer

C

A

B

D

E

F

Before to proceed to any maintenance operation, wear the safety devices(Ex.: glowes, glasses, masks, etc...) in the way to avoid every damage forthe operators.

D A N G E R !

!Before to proceed with these operations: oil change in the reducer, oilchange in the pump body, pump body oils cartridge substitution andpump body oils pipes substituion, waiting untill the lubrication oils tem-perature cant be dangerous for for the operator.D A N G E R !

!

43

- 4.3.2 PUMP BODY -

The machine is supplied already with Shell Tellus S100.Change the oil for the first time after 1.500 working hours, and then every 1.500working hours at least.

To change the oil carry out the following operations:

- Cut power supply to the machine by means of the main switch.

- Remove the upper, back and theleft side panel, remove the rubber pipe form the blockfig.4.3.e , unscrew the conical tap A and place a suitable container under it to collect theoil.

- Once the oil discharge is completed screw down in position the tap A and mount thepipe in the block; then fill up with oil SHELL TELLUS S100 or another one having the samefeatures the pumping body, fig. 4.3.f, by unscrewing the orange plug B.

- Make sure the oil reaches the black mark (which corresponds to the maximum level admit-ted) by means of the level control on the frontal side of the machine.

- Assemble back in position the panels, be sure to screw em with the bolts before to restartthe machine.

Fig. 4.3.e

A

B

Fig. 4.3.f

44

D A N G E R

!

4.4 MAINTENANCE SPECIAL EQUIPMENT

Every machine is equipped with a tool box containing the tools necessary to carry out main-tenance operations. The table here bellow contains a list of the tools.

Remember that before carrying out any maintenance operation it willbe compulsory TO STOP THE MACHINE by cutting off power supply.

Fig. 4.4.a - Utensili in dotazione - Tool kit -

1

2

4

6

8

7

5

3

LISTA UTENSILI - DOTAZIONE STANDARDTOOLS LIST - STANDARD EQUIPMENT

1 SERIE CHIAVI A FORCHETTA - FORK KEY TOOLS 17 - 19 - 24

2 SERIE CHIAVI A BRUGOLA - SOCKET HEAD TOOLS SERIE 5 - 6 - 10

4 TUBO INTRODUTTORE GUARNIZIONI CH - TUBE FOR CH GASKET 001.03591

5 PROLUNGA ESTRAZIONE PISTONE - EXTENSIONS FOR PISTONS EXTRACTION 001.03551/1, /2, /3

6 ESTRATTORE SEDI VALVOLE - VALVE SEAT EXTRACTOR 001.02211

7 LEVA (PER FLANGE, ECC...) - LEVER 072.0007

8 TONDO PVC (PER GUARNIZIONI, ECC..) - PVC GASKET INTRODUCER 001.03146

9 MOLLA - SPRING 001.00043

10 VALVOLA A SFERA - SPHERA VALVE 007.0015

11 SEDE VALVOLA DI SICUREZZA - SAFETY VALVE SEAT 001.04076

45

See fig. 4.3.1; every pumping group is composed by:

- pumping piston A

- guiding band B

- guiding bushing C

- gasket CH D (formed by 4 rings: D1 - D2 - D3 - D2)

- gasket block spacer E

- gasket F

- frontal flange G

- nuts H

4.5 ORDINARY MAINTENANCE: PUMPING GROUP

- 4.5.1 PUMPING GROUP COMPOSITION -

A

B

C

D1 D2 D3

E

F

GH

A C

D

E F G H

I

D2

Fig. 4.3.1 - Esploso del gruppo pistoni pompanti -Exploded view of the pumping pistons group

46

- 4.5.2 COMPONENTS OF PUMPING GROUP THAT GET WORN OUT -

Pumping piston AThis component should be replaced when the surface is visibly so worn out that the gasketCH D needs to be replaced too often.

Guiding band BThis component should be replaced when coupling the guiding bushing C (that contains theband) and the pumping piston A you feel there si too much light (more that a tenth of mm).It should be remembered that the guiding band does not has a fundamental function in themachine operations but makes the movement of the pumping piston to become axial soallowing the piston and the gaskets CH D to last longer.

Gasket CH DThis component should be replaced when product comes out on the back rear of the com-pression head or as a preventive maintenance.As for this last case, the preventive maintenance should be decided by the user once control-led the average operative time of the actual production (type of product, homogenizing pres-sure, temperature, cooling water hardness, etc...).

Gasket FThis component should be replaced when product comes out on the frontal part of the com-pression head or as a preventive maintenance (as for gaskets CH).

47

ATTENTION!

!

- 4.5.3 MAINTENANCE OF PUMPING PISTONS, GASKETS CH AND GUIDINGBANDS -

Remember that before carrying out any maintenance operation it will becompulsory TO STOP THE MACHINE by cutting off power supply.

Prepare, in addition to the usual tools, the dynamometric wrench, the pistons extractor kit, thepipe for introducing the gaskets CH and a tube of lubricant suitable to be used for food stuff.

- Disassembling operations -- See fig. 4.3.1 e 4.3.2, remove the nuts H screwing them counter clockwise using the

supplied key.

- Remove the flange G and the spacer E.

- Remove the transparent protection over the compartment where the pumping pistons rodsare placed by unscrewing counter clockwise the fastening nuts.

- See fig. 4.3.2, loosen the screws R of the unionclamps P between pistons A the pumpingpistons rods ; in case the clamp can not be re-moved screw in a Allen screw TCEI M8 in pointT to open the clamp and help removing it.

To avoid the risk of abrasion weargloves while carrying out the fol-lowing operations:

- See fig. 4.3.3, turn manually the transmission pul-leys until a piston will reach the superior deadpoint.

- Turn farther the pulleys until the shaft reaches thelower dead point (while the piston will keep onthe upper dead point) and remove the clamp.

- Repeat this operation until every clamp will be re-moved.

- Now take the pistons extractor kit for pistons 3of fig.4.2.1 in page 42. The kit is composed byextensions with progressive length.

Fig. 4.3.3

Fig. 4.3.2

R P

A

T S

D A N G E R !

!

48

i

- See fig. 4.3.4, these extractors have a niche, atone extremity, suitable to be introduce in the rodsof the guiding pistons S.

- Mount the short extension on a rod and, turningmanually the pulleys, carry out a complete cycleof the rod (ahead and back). It will cause a firstphase of piston expulsion.

- Repeat the operation on the same rod using theother extension in length progression, and if nec-essary, combine them in series to each other, untilyou are able to hold the piston with your the handsand pull so it comes out easily.

- Take the CH D gaskets pack and the guide bushC away from the piston.

.- Assembling operations -- See fig. 4.3.1, apply a very thin film of lubricant

suitable to be used for food stuff on:pumping piston A, guide band B, gaskets CHD, gasket F and in the gasket seat of flangeG.

- See 4.3.5, couple the rod S with pumping pistonA by means of the clamp P, without tighteningthe screws R.

- See fig. 4.3.1, insert the guiding bushing Cpaying attention that the bushing holes are fac-ing the gaskets CH D.

It is most important that the bushing is placed correctly since the holes allow thepassage of water that cool down the pumping piston.If the guiding bushing is not placed correctly the water will not flow and the pump-ing pistons, the gaskets CH and the guiding bands could get worn out abnor-mally.

To avoid the various mechanical parts getting faulty, carry out thefollowing operations carefully:

- See fig. 4.3.5, make sure the plane surface of the pumping piston A touches the planesurface of the rod S and fasten the screws R of clamp P using a pair of as indicatedin table of chap. 5.4.

ATTENTION!

!

Fig. 4.3.4

3S

Fig. 4.3.5

SP

A

R

49

Fig. 4.3.6

i

i

5

A

DC

Fig. 4.3.7

A

C D E F G

H

- See fig. 4.3.6, using the supplied special intro-ducer ref. 5 fig. 4.2.1, introduce the various ringsthat compose the gasket CH D for 3-4 cm in-side the head.

The gasket CH is composed by 4 ringsthat must be introduce in the followingorder:

- V ring with plane bottom D1; the rings planesurface must face the guiding bushing C.

- V rubber-cloth ring D2.



- See fig. 4.3.6, once all rings have being placed, lay the special introducer on the last Vring that has being inserted and press on the introducer (eventually and if necessary use ahammer), place the gaskets CH on the guiding bushing already installed.

- See fig. 4.3.7, insert the pack spacer E paying attention that the V side faces thegaskets CH

Insert gasket F in the frontal flange Gand control it does not get kinked. If thegasket F kinks it will get worn outeasily.

- Mount the flange G with the gasket F insertedin the compression head.

- Screw the nuts H clockwise and tighten themusing the force indicated in table chapter 5.4.

Before starting again the machine:turn manually the bigger pulley 6/7 turns to control that all pistons execute their strokes without problems.

Assemble all protection panels.Assemble the transparent protections on top of the pumping pistonsrod compartment and fasten it in position by screwing the two relativenuts clockwise.

ATTENTION!

!

D A N G E R !

!

50

4.6 VALVE GROUPS

- 4.6.1 COMPOSITION OF THE VALVE GROUP -

Every pumping group is composed by two valve groups:

- suction valve group (located inside the compression head, under the relative pumpinggroup)

- supply valve group (located inside the compression head, over the relative pumpinggroup)

The upper and lower valve groups are perfectly interchangeable.See fig. 4.4.1, every valve group is composed by:

- valve guide A

- spring B

- ball valve C

- valve seat D

- gasket E

A

B

C

D

E

Fig. 4.4.1 -Esploso gruppo valvola - Valve group exploded view

51

- 4.6.2 COMPONENTS OF THE VALVE GROUP THAT CAN GET WORN OUT-

Spring BThis component should be replaced when broken or when the surface that contacts the ballvalve C is clearly worn out.

Ball valve CThis component should be replaced when its surface is not perfectly spherical (and thereforeis not capable of adhering perfectly against the sealing surface of the valve seat D) or wheneven regularly worn out, the diameter of the valve is smaller than 17 mm (the diameter of anew valve is 19 mm).

We advise to use only original spare parts to replace the parts of the ball valvesince the market offers also not original spares with very low sphere accuracy.Be aware that the use of unsuitable ball valves will result in the valves and seatsgetting worn out to soon.

Valve seat DThe sealing surfaces (the conical one that bears the ball valve) that present incisions, cuts orthat are not perfectly circular should be changed.

A practical and extremely efficient method to value the correct sealing of thevalve seat/ball valve is composed by the following phases:

1 Wash accurately the valve seat and the ball valve.

2 Put the lower side of the valve seat (the one where the gasket E is in-stalled) against your lips and lay the ball valve on the sealing surface of thevalve seat.

3 Suck with your mouth and make sure that no air passes through the couplingbetween the valve and the valve seat. Control the operating state of the wholesurface of the ball valve by turning it with two fingers while carrying out thedescribed operations.

Gasket EWhen the gasket of the lower valve group is too worn out, product comes out of the compres-sion head O and of the suction collector P ref. fig.4.4.3Gasket E of the supply valve group gets worn out less easily than the one located on thelower valve group and must be replaced as a prevention every four-five changes of the lowervalve group.

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- 4.6.3 MAINTENANCE OF THE SUPPLY VALVE GROUP -

The supply valve group is composed bythe same components as for the valvegroups and so the components that getworn out are the same. Therefore apartfrom the components indicated in theprevious chapter there are a few othercomponents, in this valve group that getworn out and need to be replaced:Pressure indicator TThis component has to be replacedwhen does not indicate the pressurecorrectly or when the membrane lo-cated in the lower part of the compo-nent (near gasket M in fig. 4.4.2) isbroken.Gasket F e MThis component is to be replaced whenproduct comes out in between the up-per flange and the head.Gasket PThe function of this component is thatof cleaning and therefore will need tobe replaced only when broken.

Disassembling the supply valve group- See fig. 4.4.2, unscrew counter clockwise the nuts

H.

- Lift the upper flange G and the flange that stopsthe pressure indicator N and remove them.

- Remove the guide of valve A, the spring B, andthe ball valve C.

- See fig. 4.4.3, insert the point of the special ex-tractor, rif.6 fig. 4.2.1, a little under the valve Dseat, widen the points of the extractor (hold thelower point of the extractor and turn the handleclockwise) until it adheres to the valve seat, thenremove the valve seat.

- Remove the gasket E only in case it needs tobe replaced.

Fig. 4.4.3

6

D

Fig. 4.4.2 - Esploso gruppo valvola di mandata -Supply valve group exploded view

AB

DC

E

F

I

L

M

N

H

G

T

IF

P

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- Assembling the supply valve group -- See fig. 4.4.1 e 4.4.2, assemble the supply valve group and insert it in the special seats of

the upper part of the compression head O.

- Insert gasket F in the special seat of the compression head.

- Insert the upper flange G and block it by means of nuts H (to be screwed up clockwiseand using a pair as indicated in table of chapter 5.4).

- Insert the tablet of the pressure indicator I on the gasket F (already mounted in thecompression head).

- See fig. 4.4.2, insert the relative pressure indicator T in the relative fastening flange N.

- Place the fastening washer of the pressure indicator L (half moon shaped) inside thefastening flange of the pressure indicator.

- Insert gasket F in the pressure indicator.

- Insert the whole assemble in the compression head (the pressure indicator will get cen-tred on the relative tablet I already mounted in the compression head).

- Screw nuts H clockwise and tighten them using a pair as indicated in table of chapter5.4.

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Fig. 4.4.5

8

A

D

E

B

C

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Disassembling the suction valve group- See fig. 4.4.6 for maintenance of suction valve

group disassembling the product inlet pipe Pby unscrewing nuts G counter clockwise.

- In case just the suction valve group needs to bemaintained carry out the following operations:inset the extremity of the special extractor, fig.4.4.4, a little under the valve D seat; widen theextractor extremities (hold the lower point of theextractor and turn the handle clockwise) until itadheres to the valve seat, then remove the valveseat located in the compression head.

Since this operation could easily damage the suction valve seat, we advise tocarry out the following operations:

- See fig. 4.4.5, the suction valve group can be re-moved from the supply valve seat but you needto remove the pumping piston and the supplyvalve group first. Then insert the special percus-sion bar (made of red plastic rif.8 fig.4.2.1) in theupper part of the head, pass through the pistonchamber and lay it on the suction valve guide.Use a hammer given light mallet blows on thepercussion bar and carefully remove the suctionvalve group (place a container under the valvegroup to avoid that the component might fall dur-ing the extracting operations).

Fig. 4.4.4

6

D

E

- 4.6.4 MAINTENANCE OF THE SUCTION VALVE GROUP -

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Fig. 4.4.6 - Suction valve group exploded view

A

BC

E

D

P

O

Q

- Assembling the suction valve group -

- See fig. 4.4.6, assemble back thegaskets E and the complete suc-tion valve group and mount it backin the head.

- Press the gasket E so that it holdsthe valve group inside the head.

- Mount the suction collector andtighten the nuts turning them clock-wise using a pair as indicated intable of chap. 5.4.

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4.7 SAFETY VALVE

- 4.7.1 Composition of safety valve -

See fig. 4.8.a, the safety valve is composed by:

- safety valve seat A

- ball valve B

- gasket C

- shutter guide D

- shutter gasket E

- shutter group F

- blocking flange G

- valve support I

- screws W

- 4.7.2 Components of the safety valve that can get worn out -

Safety valve seat A / ball valve BBoth the valve and its seat can get worn out due to vibrations/strong impacts the valve

undergoes when being operated during long periods of time. If these components are wornout product will come out of the product pipe even if the machine is working at a regularpressure.

Gasket CThe reasons why this gasket gets worn out are the same as for the previous paragraph,

but in this case if the gasket is worn out the product comes out of the fastening flange.

Shutter gasket EThe function of this component is that of protecting the valve boy (avoiding that the product

enters in the valve) and will need to be replaced when showing worn out signals duringmaintenance operations of other components.

Fig. 4.8.a Exploded view of the safety valve

AB CDEFGW I

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- 4.7.3 Maintenance of the safety valve -When the safety valve is operating, the product comes out of the relative drain pipe. Find

out what is causing the anomaly as described in chap. 3.2.2.

If product has come out for a short time or a very small quantity has been drained, it ispossible to end production before carrying out the washing cycle.

Maintenance of the safety valve is very simple:

- Remove pipe X and the safety valve by unscrewing screws W counter clockwise.

- Remove the components listed before and wash them carefully using suitable cleaningproducts.

- If product has been drained for a short time you can mount back the components ofthe safety valve without further operations.

- If product has been drained for a long time, no matter the homogenizing pressure iswithin regular operating values, it will be necessary to replace the worn o

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