2.5 screen MAIN O&M

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M.A.IND. srl Sede Legale - Head Office: Via Calcinaro, 2131 - 47521 CESENA (FC) - Italy

Tel: +39 0547 385043 Fax: +39 0547 638182 E-mail: [email protected]

Unit Produttiva - Factory: Via Pitagora, 30 - 41010 LIMIDI DI SOLIERA (MO) - Italy

Tel: +39 059 525720 Fax: +39 059 525443 Web: www.maindsrl.it

C.F. & P.IVA: 03147280402 - R.I. Forl-Cesena n. 03147280402 - R.E.A. Forl-Cesena n.288130

MI15E

SELFCLEANING SCREEN FOR SMALL

TREATMENT PLANTS

Operation and Maintenance Manual

Rev.

01dated

21/1/08


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MI15E

Operation and Maintenance Manual Page 2 of 27

INDEX

1 GENERAL INFORMATION ............................................................................. 41.1 INTRODUCTION ................................................................................................... 41.2 HOW TO READ THE MANUAL ............................................................................. 41.3 IDENTIFY THE UNIT ............................................................................................. 41.4 WARRANTY .......................................................................................................... 51.5 MANUFACTURER DECLARATION (TYPE B) MACHINE ..................................... 61.6 MANUFACTURER DECLARATION (TYPE B) ELECTRIC MOTOR ..................... 61.7 TECHNICAL SERVICE .......................................................................................... 6

2 TRANSPORT AND INSTALLATION ............................................................... 72.1 CHECKING AFTER RECEPTION ......................................................................... 72.2 PACKING ............................................................................................................... 72.3 LIFTING AND POSITIONING ................................................................................ 72.4 INSTALLATION AREA ........................................................................................... 82.5 INSTALLATION ..................................................................................................... 9

2.5.1 ELECTRICAL CONNECTION ........................................................................ 92.5.2 EFFLUENT INLET CONNECTION SCREENINGS OUTLET CONNCETION

..................................................................................................................... 113 SAFETY RULES ............................................................................................ 12

3.1 NOT PERMISSIBLE USE .................................................................................... 123.2 SAFE USE ........................................................................................................... 133.3 SAFETY DEVICES OF THE PLANT.................................................................... 14

4 DESCRIPTION AND SPECIFICATIONS ....................................................... 154.1 SAFE AND CORRECT USE ................................................................................ 154.2 COMMANDS ....................................................................................................... 154.3 WORKING PRINCIPLE, NOT PERMISSIBLE USE ............................................. 154.4 TECHNICAL CHARACTERISTICS ...................................................................... 16

4.4.1 BUILDING FEATURES STANDARD DIMENSIONS ................................. 164.4.2 Flow rates (m3/h) .......................................................................................... 174.4.3 Weight .......................................................................................................... 17

5 USE FO THE MACHINE ................................................................................ 186 MAINTENANCE ............................................................................................. 19

6.1 PRELIMINARY OPERATION FOR SAFETY ....................................................... 196.2 PERIODICAL CHECKS ....................................................................................... 19


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6.3 EXTRAORDINARY MAINTENANCE ................................................................... 206.3.1 CLEANING BRUSHES REPLACEMENT ..................................................... 206.3.2 GEARMOTOR REPLACEMENT .................................................................. 21

7

ACCESSORIES AND SPARE PARTS .......................................................... 22

7.1 SPARE PARTS .................................................................................................... 227.2 HOW TO ORDER SPARE PARTS ...................................................................... 22

8 OTHER INFORMATION ................................................................................ 258.1 LONG TERM STORAGE ..................................................................................... 258.2 DISMANTLING OF THE MACHINE ..................................................................... 25

9 FAULT RESEARCH ...................................................................................... 2610

ATTACCHEMENTS ....................................................................................... 27

10.1 DECLARATION OF THE MANUFACTURER ....................................... 2710.2 OPERATION AND MANINTENANCE MANUAL MANUFACTURER

DECLARATION OF ELECTRIC MOTOR ............................................................ 27


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1 GENERAL INFORMATION

1.1 INTRODUCTION

Before starting with every operation, it is necessary to read very carefully the manual toavoid every problem and/or dangerous use of the machine.

Operation and instruction manual is part of the technical leaflets supplied with the machineand the scope is to give all the information necessary for a safe and correct use of themachine.

Manual is addressed to the persons in charged for the installation of the machine and tothe persons in charged for the use and for the maintenance who have to read this manualvery carefully.

1.2 HOWTOREADTHEMANUAL

During the consultation of this manual it is possible to see some symbols and the meaningof these symbols is explained in the following table:

GENERAL WARNING This type of notice advises the personnelabout the dangers during the operation of themachine. In case this notice will not befollowed, the machine could cause damageswith danger for the personnel.

NOTICE OF DANGERBECAUSE PRESENCEOF ELECTRICTENSION ON THEMACHINE

This type of notice advises about thepresence of electric tension. Before startingwith every maintenance on the machine it isnecessary to stop the electric tensionswitching off the general switch. After that itis necessary to be sure that the electrictension is not more present on the machine.

WARNING This type of notice advise about thenecessity to give particular attention.

1.3 IDENTIFYTHEUNIT

The machine can by identified by the descriptions punched on the metallic Plate herefollowing represented and explained. The Plate is easily recognizable on the metallic frameof the unit.

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On the Name plate it is possible to find the following details:

1) Name and address of the manufacturer

2) Machine type

3) Serial number

4) Years of manufacturing

5) Power

6) Weight

Name plate data cannot be modified.

In case of necessity to contact our after sales service, please advise us about the serialnumber of the machine.

1.4 WARRANTY

MA.IND. give the warranty that the machine supplied was tested concerning the safety andthe functionality.

Warranty period of time is always present wi th our order confirmation.

Warranty is referred to the mechanical components and in case of defect, themanufacturer will replace the components without any extra cost for the customer.Warranty doesnt include the electric motor, electric components and every problemcaused from external reasons, wrong maintenance or not permissible use. Everyalteration of the machine, in particular on the safety devices, will cause the

termination of the warranty and the manufacturer will be free from everyresponsibility.


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1.5 MANUFACTURERDECLARATION(TYPEB)MACHINE

The machine is manufactured according to the directive 2006/42/CE and its followingmodifications. The machine is destined to be part of a plant that will be executed from theinstaller.

In attached to the present manual is reported the Manufacturer Declaration provided forthe directive2006/42/CE.

1.6 MANUFACTURERDECLARATION(TYPEB)ELECTRICMOTOR

Here attached the manufacturer declaration of the electric motor and the gearbox.

1.7 TECHNICALSERVICE

To obtain the best performance from the machine and to avoid every possible problem that

could cause the termination of the warranty it is necessary to follow all the indications ofthe present operation and maintenance manual.

This operation and maintenance manual is part of the machine and it must be easilyreachable by all the personnel in charge.

In case of need to contact , even after reading the instruction, it is necessary tohave this manual close at hand, to have a better understanding of all the explanations.

Please always remember to inform our Service about the serial number of the machine.The serial number is always reported on the Plate of the machine.

Warnin !


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2 TRANSPORT AND INSTALLATION

2.1 CHECKINGAFTERRECEPTION

Before proceeding with the unloading of the unit, please check that the machine was notdamaged during the transport. In case of damages, it is necessary to make a shortdescription on the transport document.

2.2 PACKING

The machine can be delivered on request in a wood cage packing of the weight of about30 Kg.

2.3 LIFTINGANDPOSITIONINGLifting and positioning of the machine can be done by means of lifting system suitable forthe weight and dimension (for the weight of the machine, please check the weight on theName plate and on the weight table, paragraph 4.4). In case the unit is provided with thewood cage packing take also that weight into consideration (ref. paragraph 2.2)

The lifting of the machine must always be done by means of the suitable eyebolt fixed onthe unit. Only hooks provided of a safety fastener device can be connected to the eyebolt.In case of wood cage packing move the structure connecting the hooks to two suitablelifting belts positioned in correspondence of the bars.

Always lift and move the machine using exclusively the eyebolt positioned on the machine.

Picture 1: Lifting eyebolt of the unit


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It is forbidden to use clamps, rings, open hooks or other system that do not guarantee thesafety in lifting operation.

Lifting and position ing operation must be executed only by competent persons. It isforbidden to displace in the action range of the means of lifting.

WARNING:

Personnel in charge for the lifting and positioning of the machine must operate withmaximum attention to avoid any damage to the goods or to the people. Nobody canremain under the area where the machine is hanging.

Check the efficiency of the lifting system to avoid damage to the operator or other.It is forbidden to use lifting chain that can damage the surface of the machine. If chain willdamage the surface of the steel, it is necessary to make again the surface treatment ofpassivation.

Transport packing must be removed only when the machine is positioned close to theinstallation area (machine is supplied without packing in the standard version).

2.4 INSTALLATIONAREA

The area designated for the positioning of the machine must be provided by the user withall the connections (electric power, air, etc..) for the operation of the machine, in conformitywith the information of the present manual, and in conformity with the characteristic of theelectric and electronic components. It is responsibility of the user that the positioning areawill be conform with the local laws and safety rules : aeration, ground lead, appropriateillumination, etc...

It is responsibil ity of the user to preview the positioning area with the safety devicesas per the present manual.

Warning !


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2.5 INSTALLATION

It is recommended to foresee, in phase of installation, adequate spaces all aroundthe machine to let the movements and facilitate the operations of maintenance in full

safety.The machine is fixed to the inlet pipes through the scheduled flanges. The unit must becollocated inside a container which grant a level of the effluent lower than the screeningzone.

An unsuitable fixing may cause damages to people or th ings; it is so recommendedto follow the present instructions and verify the tightening of all bolts and screwsand the whole stability of the structure.

2.5.1 ELECTRICALCONNECTION

Machine is supplied with standard electric components for the normal operation of themachine: the electric motor.

It is responsibility of the user to provide the electric panel, installation and connection to themachine following international laws and local rules.

Electric work must be executed only by specialized worker.

Project and execution of the electric panel is under the responsibility of the installer. We

recommend to provide appropriate protection against excessive adsorption of the electricmotor.

Fixing of the unitthrough the connectionof the flange to the inlet

pipe and direct layingon the base of thecontainer


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Besides, it is necessary to foresee the impossibility of the automatic startup of the machinein case of stop and restart of the electric power.WARNING:

Electric work must be executed only by specialized worker.

Check that voltage is the same as per the Name plate present on the electric motor.

Electric cables must have the correct dimensions and safety as requested from theelectric motor.

It is forbidden to work on the electric motor when it is in tension.

During electrical connection, the principal electric power line must be disconnectedand the work must be executed only from specialized workers following

international and local laws and ru les.

Electric cables must be protected considering the installation area and places toavoid to obstruct the working of the machine, following specific applicable rules.

It is forbidden to introduce the hands inside the screw in operation.

Concerning the technical characteristics of the motor make reference to the fabricantsdocumentation attached to the present manual. Particularly, what required by the fabricant

about environmental characteristics and electric connections must be respected.

2.5.1.1 Working principle

Electric panel must be designed and supplied by the end-user in conformity with the rulesand the laws regulating the safety of the workers.

For a correct work it is necessary to follow this working principle:

1) Electric motor startup in case of:

- Manual startup- Automatic startup (through timer or level indicator)

2) Electric motor stop in case of:

- Manual stop

- Automatic stop (through timer or level indicator)

- Emergency manual stop (red button)


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2.5.2 EFFLUENTINLETCONNECTIONSCREENINGSOUTLETCONNCETION

Picture 2: inlet and outlet connections

POS. DESCRIPTION

1 Effluent inlet

2 Screenings outlet

3 Screen

1

2

3


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3 SAFETY RULES

3.1 NOTPERMISSIBLEUSE

The machine is provided of all necessary protections, however due to its conformation andfunctionality there is a part of the unit which can be protected only on the installation place(see picture here under).

This indispensible protection is responsibility of the installer.

Picture 3: Dangerous zones depending from installation unit MI15E

INLET ZONE OUTLET ZONE


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WARNING:

Never put hands, objects etc inside the solids outlet. A not ice must be fixed near

the outlet to inform the personnel.Screen zone inside the channel must be closet with a cover. If this operation is notpossible, it is necessary to round the area with a proper enclosure and with noticesto prohibit the access. Where it is possible, to provide with automatic device toswitch off the machine in case of access.

3.2 SAFEUSE

To avoid every accident, it i s necessary to read carefully the fol lowing information:

The machine can be used only by qualif ied and expert personnel.

Al l the connect ions must be executed from quali fied and expert personnel .

Execute a correct fixing among the different components and a correct fixing to thefloor.

When the machine is running, all the personnel must remain at the safety distance.

Before starting the machine it is necessary that all the safety devices are connectedand working and that the machine is in perfect condit ions.

In case of defects, in particular on the safety devices, the operator must informimmediately h is superiors, the safety manager and the operator of the next shif t.

If the defect prevents the machine from a safe use, the machine must beimmediately stopped.

If during the working more people are in charged, before to make any operation it isnecessary to inform also the other people.

The machine can be used only for the correct use (see . 4.1)

Every modification regarding the use or the safety conditions can be executed only

f rom personnel , and fol lowing this, refuse every responsibi li ty for not authorized modifications or damages caused from these modifications.

It is forbidden to remove safety devices present in the machine.

Al l checks, maintenance etc, can be executed only by quali fied and expertpersonnel.

Personnel in charged must use a proper workwear. It is necessary to ask for thisworkwear (gloves, shoes, ) at the safety manager.

Disconnect electric power before making every operation and/or maintenance at themachine.

To avoid every accidental startup of the machine during inspection, cleaning andmaintenance, it is necessary to turn the general switch on the position OFF andpush the emergency button to block the machine.

Warning !


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Before starting the machine it is necessary to be sure that all the safety devices areactive.

refuses every responsibility for damages to people and objects causedform the absence and/or tampering of the safety devices (notices and protections).

It is necessary to make inspection of the plant minimum once per day, or once eachworking shift to check possible damages or defects that can be seen from outside.

In case of any anomaly, stop immediately the plant, in particular if there are risks foryour safety or for the safety of the plant.

Be sure that safety devices, safety notices and the identifying plate of the plant arealways clearly readable.

It is compulsory the connection to the floor of the external metallic part of themachine.

It is forb idden to remove safety and warning notices.It is forbidden to start the work with safety devices opened or to open them duringthe working.

Touching the rotating part of the machine could cause serious injuries.

Never introduce hands inside the outlet of the machine.

3.3 SAFETYDEVICESOFTHEPLANT

Every plant must be provided, by the installer, with an emergency button (red colour) tostop the plant. Pushing this button in particular dangerous conditions the plant must stopimmediately.

Emergency button must be present near the machine and it must be easily approachable.

Safety devices include:

Protection covers of electric motor fan

Enclosure, covers or automatic protection of the screen zone

Warning notices

It is responsibility of the fitter to ensure the presence of all protections necessary to grant asafe use of the plant both in using and maintenance phases.


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4 DESCRIPTION AND SPECIFICATIONS

4.1 SAFEANDCORRECTUSE

The unit MI15E has three principal functions: Screening

Lifting

Compacting

The machine is connected directly to the inlet pipe of the incoming effluent, inside thespecific collecting container. The effluent is immediately screened in the inlet zone where asuitable screen is placed. The solid retrained by the screen is removed through brushespositioned on the screw and it is transported to the compacting zone before the outletzone.

For a correct functioning of the unit it is necessary to ensure that the level of the effluentinside the container does not exceed the screening zone of the machine.

Every other use of the machine will cause the finish of the warranty and will avoid to

every responsibil ity.

4.2 COMMANDS

The running of the plant is automatically done by means of a timer or a level indicator.

4.3 WORKINGPRINCIPLE,NOTPERMISSIBLEUSE

Functioning of the plant or functioning of each machine can be prejudiced if the

transported solids:

Solids cannot be mechanically separated from the liquid flow

Solids form an agglomerate (between each other or on the machine)

Solids cause incrustations (between each other or on the machine)

Solids contain an excessive quantity of grease

Solids react between each other mechanically (polymerize, coagulate..etc)

In case of a screening which tends to agglomerate or encrust, the solid accumulatedmust be capable to be taken off from the machine with a vacuum water machinewithout mechanical tools!

The percentage of solid in the inlet waste water must not overcome the value on which thecapability of the machine was dimensioned. If into the water to screen exists a high

quantity of fibrous solid and solid which tends to tangle and/or a particularly highpercentage of paper some working problems can happen; so it is not advised the use ofthe machine under this conditions.

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4.4 TECHNICALCHARACTERISTICS

4.4.1 BUILDINGFEATURESSTANDARDDIMENSIONS

Picture 4: Standard dimensions of the machine

The above dimensions are indicative of the principal machine types fabricated; differentdimensions can be accorded on request by the client at the moment of the order.


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4.4.2 FLOW RATES (M3/H)

Type Filtration/screening meshes Maximum capability

MI 15 E 2 mm 8 mc/h

MI 15 E 3 mm 13 mc/h

MI 15 E 5 mm 20 mc/h

The flow rates must be considered for urban waste water constituted by 250 mg/l ofsuspended solid.

4.4.3 WEIGHT

The machine weights about 35 kg.


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5 USE FO THE MACHINE

Warning:

Before proceeding with start/stop of the machine, please check that all the blockingconditions are removed.

Before proceeding with start/stop of the machine, please check that all safetydevices are present and perfectly efficient.

CHECKS AND STARTUP.

Before starting the machine, please provide as per the following:

Read carefully all the OPERATION and MAINTENANCE MANUAL

Check the positioning and the fixing of the machine.Check the hydraulic connections.

Check the power supply connections and the cable box: it must be perfectly sealed.

Check that the direction of rotation of the screw is as per the arrow installed on themachine (see picture here under).

Check that all the safety protection at the inlet and at the outlet are present.

Check that all the warning notices are present on the machine.

Warning:

During first startup, it is necessary to check very carefully regarding every singlething that could appear like a working defect, for example: vibrations, high noiselevel, wrong rotation direction, etc.

Startup procedure must be executed every time that the machine remained stoppedfor a long period of t ime (more than one week).

To grant personnel safety and machine safety, it is necessary to read very carefullysection SAFETY RULES.

Picture 5: Correct sense of rotation of the gearmotor


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6 MAINTENANCE

6.1 PRELIMINARYOPERATIONFORSAFETY

CAUTIONS:

Before making any maintenance, please stop the machine and switch off the electr ic

power.

SAFETY CONDITIONS IN CASE OF MAINTENANCE

In case of particular dangerous condition, a second person must be presenttogether with the technician in charge for maintenance.

Maintenance of the unit must be executed only from expert, trained and qualifiedpersonnel.

Before proceeding with the maintenance, it is necessary to inform all the otherpersonnel in charged in the work.

Any maintenance, when the machine is operat ing.

Every time, before restarting the machine, be sure that all the protections and safetyguards are efficient; be sure that all the tools are removed; be sure that otherpersonnel is not working on the machine.

Warning:

To grant the full efficiency of the machine only original spare parts must be used.

6.2 PERIODICALCHECKS

It is possible to divide all the checks in two parts :

CHECKS TO DO AFTER 10 WORKING HOURS

PERIODICAL CHECKS

DESCRIPTION

Check bolts and screws fixing wearing bars

Electric motor and gearbox: check noise level and temperature

DESCRIPTION TIMING

Cleaning brushes (screen basket) 100 hours

Screen basket efficiency 100 hours

No clogging in the Screening outlet Daily

Gearbox Monthly

Electric motor Monthly


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For gearbox lubrication please refer to the gearbox manufacturer use and maintenancemanual here attached.

6.3 EXTRAORDINARYMAINTENANCE

Here-under you can find information about how to replace some components mostlysubject to wearing. To make all the replacements it is necessary to remove the machinefrom the working area, wash it and put it in safe conditions. (ref. chapter 6.1)

6.3.1 CLEANINGBRUSHESREPLACEMENT

1. Dismount the screen basket unscrewing the fixing boltsA.

Remove the screen basket from the pipe.

2. Unscrew the bolts B fixing the brushes to the spiral.

3. Fix new brushes to the spiral with new bolts.

4. Reassembly the screen.

A

B


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6.3.2 GEARMOTOR REPLACEMENT

1. Dismount the protection.

2. Unscrew boltA fixing the motor shaft.

3. Unscrew bolts B fixing the gearmotor to the screen screw

frame.

4. Put the new gearmotor following the previous operation on

the opposite.A

B

B

INTERNAL SIDE

EXTERNAL SIDE


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7 ACCESSORIES AND SPARE PARTS

7.1 SPAREPARTS

Please find hereunder a list with the principal parts. is in the condition to replaceevery single component of the machine.

Description Picture

Kit of brushes with fixing bolts

Gearmotor

7.2 HOWTOORDERSPAREPARTS

To order spare parts it is necessary to check the label present on the unit:

Machine model and serial number

Manufacturing year

Part code (if specified on the part)


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8 OTHER INFORMATION

8.1 LONGTERMSTORAGEIn case of long term storage:

Clean the machine in the screen zone, transport and compaction.

Fix the machine in a wood cage and to stock it inside a covered area.

Gearmotor: follow the instruction present in the manufacturer manual.

Before restartin the machine proceed as per first startup.

8.2 DISMANTLINGOFTHEMACHINE

In case of dismantling of the machine, it is necessary to separate different materials

composing the machine:

Plastic, brushes and seal, must be separated and stocked in a proper area.

Metallic part must be recycled as steel material.

Gearmotor oil must be stocked in a proper area.

For the dismantling of the machine it i s advised to contact a specialized company

for the recycle of the materials.

PRECAUTIONS:

Dismantling of the machine must be executed following general and localenvironmental rules.


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9 FAULT RESEARCH

Problem

MACHINE DOESNT START AND ELECTRIC MOTOR DOESNT WORK.

VIBRATIONS WITH MACHINE EMPTY.

HIGH ADSORBED POWER WITH MACHINE EMPTY.

VIBRATIONS AT THE INLET DURANG THE WORK.

MACHINE IS RUNNING, BUT AFTER A FEW SECOND, ELECTRIC MOTOR LIMIT SWITCH STOP THE

MACHINE.

MACHINE DOES NOT SCREEN, TRANSPORT AND DISCHARGE.

Cause Solution

z There is not electric power. Switch on electric power.

z z z z Wrong electric connections. Make the electric connections.

z z Bad regulation of electric motor limit switch. Regulate it.

z Very low tension, very high frequency. Check wire conditions.

z z Overload for screw conveyor blocked.Check the reason of the block and to start thescrew again.

z z z A foreign solid or cloth can block the screw.Remove the foreign solid, inverting the screw

rotation direction.

z Gearmotor can be damaged.Check that electric motor is well connected.Voltage and phases must be as per electric motor

manufacturer label.

z zScrew conveyor rotation direction can be in

the wrong sense.Invert electric motor poles.

z z A coarse or voluminous solid can clog thescrew.

Remove the foreign solid, inverting the screw

rotation direction.

z Brushes not efficient. Replace it.

z Screen clogged. Clean it.

z Very high % of solids in the effluent. Check the situation at the inlet of the plant.

z Very high flow rate. Reduce the flow rate.

z High level after the screen.Check the reason because the level of the effluent

after the screen remain high.

zFiltration meshes of the drum are not correct

to treat the effluent typology.Replace the drum if necessary.

z Outlet clogged. Invert the screw rotation direction to remove theclogging solid.


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10 ATTACCHEMENTS

10.1 DECLARATIONOFTHEMANUFACTURER

10.2 OPERATION AND MANINTENANCE MANUAL MANUFACTURERDECLARATIONOFELECTRICMOTOR

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