ISTRUZIONI D’USO E MANUTENZIONE INSTRUCTIONS FOR USE … · omogeneizzatore/pompa ad alta...

OMOGENEIZZATORE/POMPA AD ALTA PRESSIONEHOMOGENIZER/HIGH PRESSURE PUMP

ISTRUZIONI D’USO E MANUTENZIONE

INSTRUCTIONS FOR USE AND MAINTENANCE

BETRIEBSANLEITUNG

INSTRUCTIONS D’EMPLOI ET ENTRETIEN

INSTRUCCIONES PARA EL USO Y EL MANTENIMIENTO

HANDLEIDING

Via M. da Erba Edoari, 29/A43100 Parma, Italy

Tel: +39 0521/965411Fax: +39 0521/242819

Internet: htttp://www.niro-soavi.itE-mail: [email protected]

Niro Soavi S.p.A

FOREWORD

Dear Customer, we wish to thank you for selecting our product and ensure you our best assistance in order to enable you to make the most of your machine. Also, we remind you that a good understanding of the contents of this manual - through careful reading of all sections - is essential for the correct, safe use and operation of the machine you have purchased. No one should operate or perform maintenance on this machine without first having read and understood the following Instructions for Use & Maintenance. For any further support or information, you may contact us at the below listed address. Yours faithfully,

Niro Soavi S.p.A. Via Mario da Erba Edoari 29/A - Parma, Italia tel. +39 0521 965411 fax +39 0521 242819 e-mail: [email protected] Internet: http://www.niro-soavi.it

0C00SE0C.DOC 0.0.1

Niro Soavi S.p.A

CONTENTS - SECTIONS

1. Technical Specifications 2. General Information 3. Machine Operation and Use 4. Maintenance 5. List of Spare Parts 6. Wiring Diagrams 7. Documentation about Suppliers and Components

HOW TO USE THE MANUAL

This manual is made of separate sections as indicated in the list of CONTENTS. Each section is divided into chapters and paragraphs, and pages are numbered separately in each section. A specific list of contents is given at the beginning of each section. The pictures and tables referred to in the text are numbered inside each section. Before installing the machine you must be thoroughly familiar with the information given in Section 2, Chapter 2.8 and, in particular, paragraph 2.8.5.

0C00SE0C.DOC 0.0.2

Niro Soavi S.p.A

SECTION 1

TECHNICAL SPECIFICATIONS 1.1. TECHNICAL DATA 1.2. FLOW-SHEET 1.3. FLOW-SHEET LEGEND (SPEC 102) 1.4. MACHINE INSTALLATION DRAWING 1.5. UTILITIES SPECIFICATIONS (SPEC 103) 1.6. RUNNING SEQUENCE (ONLY IF MACHINE IS SUPPLIED

WITHOUT ELECTRICAL POWER BOARD BY NIRO SOAVI) 1.7. ELECTRICAL SPECIFICATIONS 1.8. DECLARATION OF CONFORMITY “CE”

1c00se0c.doc 1.0.1

Niro Soavi S.p.A

1.1 TECHNICAL DATA SHEET

1 GENERAL 1.1 Serial Number 4537 1.2 Kind of Machine HOMOGENIZER 1.3 Model ARIETE 1.4 Type NS3006H 1.5 Execution Sanitary 1.6 Special Features 3A+ELECTROPOLISHED 1.7 MAX Operating Pressure 1000 bar 1.8 Flow Rate Type F 1.9 MIN Flow Rate / l/h @ / Hz 1.10 MAX Flow Rate 120 l/h @ / Hz 1.11 MIN Feed Pressure 5-6 bar 1.12 MAX Backpressure 10 bar 2 OPERATING CONDITIONS 2.1 Product CELL RUPTURE 2.2 MAX Viscosity <500 cP 2.3 MAX Relative Humidity 90 % 2.4 Ambient Temperature 40 °C 2.5 MAX Altitude 1000 m 2.6 MAX operating temperature <90 °C 2.7 MAX temperature CIP / SIP <140 °C 3 TECHNICAL FEATURES 3.1 COMPRESSION BLOCK 3.1.1 Type MONOBLOCK VHP 3.1.2 Number of plungers 3 3.1.3 Material of plungers CERAMIC 3.1.4 Plunger diameter 12,7 mm 3.1.5 Stroke 40 mm 3.1.6 Pumping valve type PVB 1/2" 3.1.7 Overpressure valve SPRING LOADED setpoint 1100 bar3.1.8 Connection, Inlet 3/4" TRICLAMP 3.1.9 Connection, Outlet 3/4" TRICLAMP

Scheda_c.doc 1.1.2

Niro Soavi S.p.A 3.2 HOMOGENIZING VALVE 3.2.1 Number of Stages 2 3.2.2 Type of actuator PNEUMATIC 3.2.3 Type of control PNEUMATICD.11,9-30 3.2.4 Homogenizing Valve Type D.11,9-30 3.3 DRIVE END 3.3.1 Main Motor (frame size; type) 132MB/6P AC 3.3.2 Main Motor Power 5,5 kW 3.3.3 RPM Crankshaft / MIN 3.3.4 RPM Crankshaft 171 MAX 3.3.5 Drive Type STD 3.3.6 Gearbox speed reduction ratio / 3.4 LUBRICATION 3.4.1 Type SPLASH 3.4.2 Lubricating system SPLASH SYSTEM 3.4.3 Oil Cooling system SPLASH SYSTEM 3.5 MAIN ELECTRICAL CIRCUIT 3.5.1 Number of phases 3 3.5.2 Voltage 460 V 3.5.3 Frequency 60 Hz 3.6 AUX ELECTRICAL CIRCUIT 3.6.1 Number of phases / 3.6.2 Voltage 24DC V 3.6.3 Frequency / Hz 4 OPTIONS 4.1 Suction side pulsation damper / 4.2 Delivery side pulsation damper / 4.3 Feeding pump / 4.4 Inlet pressure gauge / 4.5 Electric Power Board / 4.6 Overpressure Valve in Line / setpoint / Bar /

Scheda_c.doc 1.1.2

26.02.02 0DATE REV.

1/220013 4537 DDNIRO SOAVI JOB MACHINE SERIAL NO. SIG.

MAIN MANUFACTURER ABB PHASE NO. 3MOTOR RATED OUTPUT 5,5 kW FRAME SIZE 132M

VOLTAGE 460 V MOUNTING DESIGN. N.F.FREQUENCY 60 Hz THERMAL PROTECTION N.F.

EFFICENCY 86 % ROLLER BEARING NO

RATED CURRENT 11,9 A STANDARDS IEC-CENELECSTARTING CURRENT 82,1 APOLES 6POWER FACTOR 0,78

CODE: CONNECTION STARMB6111Y2

CABINET RATED OUTPUT kW POLESCOOLING FAN VOLTAGE V PHASE NO.MOTOR FREQUENCY Hz MOUNTING DESIGN.

RATED CURRENT A STANDARDSCODE: CONNECTION

OIL PUMP RATED OUTPUT kW POLESMOTOR VOLTAGE V PHASE NO.

FREQUENCY Hz MOUNTING DESIGN.RATED CURRENT A STANDARDS

CODE: CONNECTION

FAN MOTOR RATED OUTPUT kW POLESON THE VOLTAGE V PHASE NO.MAIN MOTOR FREQUENCY Hz MOUNTING DESIGN.

RATED CURRENT A STANDARDSCODE: CONNECTION

RATED OUTPUT kW POLESVOLTAGE V PHASE NO.FREQUENCY Hz MOUNTING DESIGN.RATED CURRENT A STANDARDS

CODE: CONNECTION


CODE: CONNECTION


CODE: CONNECTION

SPEC-E1C

MACHINE MODELNS 3006H

ASYNCHRONOUS MOTORS SPECIFICATION SHEET

PHONE : +39.0521.965411 - FAX : +39.0521.242819

Niro-Soavi S.p.A.via M. da Erba Edoari, 29/A43100 PARMA (ITALY)

Specialty ProductsDivision

26.02.02 0DATE REV.

1/220013 4537JOB NIRO SOAVI MACHINE SERIAL NO.

Required Min MaxPressure (Bar) 2 3

Temperature (°C) 10 25Consumption (l/h) 180Pressure (Bar)

Temperature (°C)Consumption (l/h)

Pressure (Bar)Temperature (°C)Consumption (l/h)

Pressure (Bar)Temperature (°C)Consumption (l/h)

Required Min MaxPressure (Bar) 7,5 10

Consumption(Nm3/h) 0Pressure (Bar)

Temperature (°C)Consumption(Nm3/h)

Required Min MaxPressure (Bar) (1)


Pressure (Bar) (2)


V = 3x 460 Hz = 60kW = 4,9A = 9,9

Note :

STERILE CONDENSATE EXCHANGER NO

COMPRESSED AIR

Note : max. hardness < 15°fH ; max. particle size = 60 microns .

(1) THE CLIENT MUST INSTALL A PRESSURE REDUCER AT THE STEAM INLET CONNECTION TO ADAPT THE PRESSURE TO THE MACHINE'S REQUIREMENTS

NO

NOSTERILE CONDENSATE PRODUCTION

PULSATION DUMPER

ELECTRICITYElectrical supply (V/Hz)Power absorbed (kW)Current absorbed (A)

YESCOMPRESSED AIR

STEAM

SPEC-103CUTILITY SPECIFICATION

SIG.

DDMACHINE MODEL

NS 3006H

OIL EXCHANGER

GEAR REDUCER

PISTONS

LUBRICATING & COOLING FLUID

WATER

NO

NO

YES

PHONE : +39.0521.965411 - FAX : +39.0521.242819



LEGENDTO CONCEPT FLOW SHEET

SPEC - 102 C

____________________ REV. DATE

Page 1 of 2 ____________________ SIG.

0

1. INSTRUMENT SYMBOLS

LOCAL

IN MAIN PANEL

LIMIT VALUEH: HIGH OR OPENL: LOW OR CLOSED

POINT OF MEASUREMENTWITHOUT INSTRUMENTATION

2. PROCESS LINES

PRIMARY FLOW LINE, GENERAL

SECONDARY FLOW LINE, GENERAL

MECHANICAL CONNECTION

SUPPLY LIMIT MARKER

3. INSTRUMENT SIGNAL LINES

GENERAL

ELECTRICAL

PNEUMATIC

HYDRAULIC

CAPILLARY

4. FLOW LINE ABBREVIATIONS

AS AIR SUPPLYCIP CLEANING IN PLACECS CONDENSATE SUPPLYCWS CHILLED WATER SUPPLYES ELECTRIC SUPPLYGS GAS SUPPLYNS NITROGEN SUPPLYOS OIL SUPPLYSS STEAM SUPPLYWS WATER SUPPLY

. R RETURN

5. MACHINERY AND EQUIPMENT

AUTOMATIC ACTUATOR FOR REMOTE CONTROL, GENERAL

MANUAL ACTUATOR NOT FOR REMOTECONTROL

AUTOMATIC ACTUATOR WITH INTEGRATEDMANUAL CONTROL FACILITY

DIAPHRAGM ACTUATOR

SOLENOID ACTUATOR

PISTON ACTUATOR

ELECTRIC AC MOTOR

ADJUSTABLE SPEED CONTROL

COMPRESSOR OR VACUUM PUMP,GENERAL

FAN

PUMP FOR LIQUIDS GENERAL

CENTRIFUGAL PUMP

HIGH PRESSURE PUMP

1-STEP HOMOGENIZER

2-STEP HOMOGENIZER

FILTER, GENERAL

HEAT EXCHANGER WITHOUT CROSSFLOW e.g. ELECTRIC HEATER

LIGHT SOURCE

VALVE CLOSES (FC)

VALVE OPENS (FO)

VALVE RETAINS POSITION

FAIL-OPEN INDICATION FOR A 3-WAY VALVE

T

H

PHONE : +39.0521.965411 - FAX : +39.0521.242819



LEGENDTO CONCEPT FLOW SHEETS

SPEC - 102 C

____________________ REV. DATE

Page 2 of 2 ____________________ SIG.

6. LETTER CODE FOR IDENTIFICATION OF INSTRUMENT FUNCTIONS

FIRST LETTER SUCCEEDING LETTER (1) MEASURED OR INITIATING VARIABLE MODIFIER DISPLAY OR OUTPUT FUNCTION

A ALARMB DISPLAY OF STATE (2)C CONTROLLING (4)D DENSITY DIFFERENCEE ALL ELECTRICAL VARIABLES (5) SENSING ELEMENTF FLOW RATE RATIOG GAUGING, POSITION OR LENGTHH HAND (MANUALLY INITIATED) OPERATEDI INDICATING (3)J SCANK TIME OR PROGRAMMED TIMEL LEVELM MOISTURE OR HUMIDITYN USER'S CHOICE USER'S CHOICEO USER'S CHOICEP PRESSURE OR VACUUM TEST-POINT CONNECTIONQ QUALITY (5) INTEGRATE OR TOTALIZE INTEGRATING OR SUMMATINGR NUCLEAR RADIATION RECORDINGS SPEED OR FREQUENCY SWITCHING (2)T TEMPERATURE TRANSMITTINGU MULTIVARIABLE MULTIFUNCTION UNITV VISCOSITY VALVE, DAMPER, ACTU, ELEMENTW WEIGHT OR FORCEX UNSPECIFIED (5) UNCLASSIFIED FUNCTIONSY VIBRATION COMPUTING RELAY, RELAYZ EMERG. / SAFETY ACTING (2)

EXAMPLE : PDIRC DIFFERENTIAL PRESSURE INDICATION, RECORDING AND CONTROLFIRST LETTER P, MODIFIER D, SUCCEEDING LETTERS I,R,C

1) NORMAL SEQUENCE OF SUCCEEDING LETTERS : B.I.R.C.T.Q.S.Z.A.2) SIGNAL TYPE : ON/OFF3) SIGNAL TYPE : CONTINUOUS4) SIGNAL TYPE : NORMALLY CONTINUOUS. IF ON-OFF, S IS ADDED

5) A NOTE SPECIFIES THE MEASURED PROPERTY. E.g. FOR LETTER E, I, U, P OR F

PHONE : +39.0521.965411 - FAX : +39.0521.242819



0

4537 SERIAL NO.

1

A

2

A

B

C

2A

A

3

A

B

C

D

4

A

5

A

6

A

7

A

8

A

9

A

REPEAT THE RESULT OF THE SEQUENCE DESCRIBED AT POINT 3, AFTER 15 SECONDS DELAY

INTERVENTION OF THE AIR INLET PRESSURE SWITCH

26.02.02

SIG.

DD

HOMOGENIZERS WORKS ON PRESSURE

RESULT

INSERT THE MAIN MOTOR

SWITCHBOARD ENERGIZED

0

RUNNING SEQUENCE REGARDING THE SWITCHBOARD SUPPLIED BY THE CUSTOMER

REV.

1/220013 JOB NIRO SOAVI

RUNNING SEQUENCESPEC-E4C

DATE

ACTION

INSERT THE MAIN SWITCH

MACHINE MODEL

NS 3006H

PUSH THE STOP BUTTON

PUSH THE START BUTTON

INSERT THE SOLENOID VALVE FOR WATER SUPPLY

INSERT THE SOLENOID VALVE FOR AIR SUPPLY AFTER 15 SECONDS

SETTING 4÷20 mA SIGNAL OF MODULATING VALVE 1st STAGE

DISCONNECT THE SOLENOID VALVE FOR AIR SUPPLY

RESET 1st HOMO. STAGE MODULATING VALVE SETTING THE SIGNAL TO 4 mA

INTERVENTION OF THE MAIN MOTOR PROTECTION

DISCONNECT THE MAIN MOTOR

DISCONNECT THE SOLENOID VALVE FOR WATER SUPPLY

INTERVENTION OF THE LUBRICATING OIL PRESSURE SWITCH

REPEAT THE RESULT OF THE SEQUENCE DESCRIBED AT POINT 3

INTERVENTION OF THE INLET PRESSURE SWITCH

INTERVENTION ON THE EMERGENCY STOP PUSHBUTTON

REPEAT THE RESULT OF THE SEQUENCE DESCRIBED AT POINT 3

REPEAT THE RESULT OF THE SEQUENCE DESCRIBED AT POINT 3, AFTER 1 MINUTE DELAY

REPEAT THE RESULT OF THE SEQUENCE DESCRIBED AT POINT 3, AFTER 15 SECONDS DELAY

LIGHTING OF THE ‘’LOW INLET AIR PRESSURE’’ WARNING LIGHT

INTERVENTION OF THE WATER FLOW SWITCH

PHONE : +39.0521.965411 - FAX : +39.0521.242819



44__4537-E4C.xls

Niro Soavi S.p.A

NIRO SOAVI S.p.A. Via Mario da Erba Edoari 29/A - 43100 PARMA - ITALY Tel +39 0521 965411 - Fax +39 0521 242819

DECLARATION OF CONFORMITY

MACHINE: HOMOGENIZER ARIETE Model: NS3006H Serial number: 4537 Max Press. (MPa): 100 Rated Flow (dm3/h): 120 Year: 2002 The undersigned

DECLARES under his own responsability that the above mentioned Machine, object of this declaration,

IS IN CONFORMITY

with the precepts of the following EEC directives: • 98/37/EEC • 73/23/EEC and following updated 93/68 EWG • 89/336/EEC

The above identified Machine has successfully passed all the trials and tests to which it has been submitted. PARMA 04/04/2002

D_ce_r1c.doc 0.0.1

Niro Soavi S.p.A

SECTION 2 GENERAL INFORMATION - INDEX

2.1. SAFETY 2.1.1 SAFETY INFORMATION 2.1.2 PERSONNEL SAFETY 2.1.3 USE OF THE MACHINE IN DANGEROUS ZONES

2.2. CE MARK AND ISO 9000 CERTIFICATION 2.3. IDENTIFICATION OF THE MACHINE 2.4. GUARANTEE

2.4.1 SCOPE OF THE GUARANTEE 2.4.2 DURATION OF THE GUARANTEE 2.4.3 APPLICATION OF THE GUARANTEE 2.4.4 EXCLUSIONS AND LIMITATIONS 2.4.5 HOW TO RETURN THE DEFECTIVE MATERIAL

2.5. HANDLING 2.6. RECEIVING AND CHECKING THE MACHINE 2.7. STORAGE

2.7.1 STORAGE BEFORE INSTALLATION 2.7.2 STORAGE FOR PERIODS LONGER THAN 3 MONTHS

2.8. INSTALLATION 2.8.1 POSITIONING 2.8.2 ACCESS TO THE INSIDE OF THE MACHINE 2.8.3 MACHINE LEVELING 2.8.4 CONNECTION TO UTILITIES AND PRODUCT LINE 2.8.5 INSTALLATION 2.8.6 POSITIONING THE ELECTRIC EQUIPMENT 2.8.7 ELECTRICAL CONNECTIONS 2.8.8 DIRECTION OF ROTATION OF ELECTRIC MOTORS

2.9. SPECIAL NOTES 2.9.1 CONTROL BOARD TO BE PROVIDED BY THE CUSTOMER 2.9.2 ELECTRIC MOTOR SUPPLIED BY THE CUSTOMER

2.10. NOTES ON MACHINE TEST 2.11. CLEANING THE MACHINE 2.12. DEMOLITION AND DISPOSAL 2.13. OPTIONS

2.13.1 SECOND STAGE HOMOGENIZING VALVE 2.13.2 ASEPTIC EXECUTION

2.13.2.1 STERILIZING THE MACHINE 2.13.2.2 REGULATING THE FLOW OF COOLING WATER 2.13.2.3 DESCALING AND WASHING

2.13.3 PARTIAL HOMOGENIZING SYSTEM 2.13.3.1 HOW THE BYPASS SYSTEM WORKS

2C001E0C.DOC 2.1.0

Niro Soavi S.p.A

2.1. SAFETY

These INSTRUCTIONS FOR USE & MAINTENANCE are part of the machine and should accompany it throughout its service life until disposed of. Before starting ANY operation, consult the relevant Section of these INSTRUCTIONS. Make sure that nobody has access to the machine before getting thoroughly acquainted with these Instructions.

The only operations allowed are those described in these INSTRUCTIONS; for any operation other than these, contact NIRO SOAVI Customer Service. CAUTION: Do not attempt tampering the calibration of any component or part of the machine or to modify any parameter of programmable devices unless expressly authorized in writing by NIRO-SOAVI.

Any calibration carried out by NIRO-SOAVI at the time of testing has the purpose of ensuring the machine’s safety and troublefree operation: any unauthorized modification will void the machine’s guarantee immediately. Because the tampering of any safety device may undermine the safety of the equipment, NIRO-SOAVI shall not be held liable for damages in case of accidents resulting from such unauthorized modification.

Keep these INSTRUCTIONS FOR USE AND MAINTENANCE within the operator's reach and make sure that their place of storage is suitable to protect them from accidental damage.All operators must be thoroughly familiar with the instructions given in this manual, comply with safety regulations, use personal protection devices and avoid wearing clothes or accessories which could get drawn into moving machine parts.

Operators must be familiar with the instructions given in this manual before they can do any work on and with the machine. WARNING: For safety during transport, the machine is supplied WITHOUT LUBRICATION OIL. Before starting the machine fill with oil as described in Section 4 -MAINTENANCE.

2C001E0C.DOC 2.1.1

Niro Soavi S.p.A 2.1.1 SAFETY INFORMATION

Although this machine has been designed to prevent all risks for operators the possibility of risk for both personnel and materials or equipment is not excluded; the general safety instructions and norms for operators and objects must be observed scrupulously, taking every precaution to prevent accidents. The machine must be used only if its state of preservation, operation and repair is perfect and in compliance with what is required and specified in this manual. Use of this machine is permitted only for the purposes for which it was constructed and tested; use of the machine for purposes other that the ones mentioned or beyond specified use limits shall relieve the manufacturer of all responsibility in case of damage to persons or things and invalidate the warranty. Failure to service the machine according to the instructions provided in this manual, or use of non-original spare parts, may lead to risks for the personnel operating the machine. 2.1.2 PERSONNEL SAFETY

The machine must be used only by personnel members who are familiar with the INSTRUCTIONS FOR USE AND MAINTENANCE and with the specific technical information required to carry out their tasks, using suitable tools and equipment; only authorized personnel are allowed to access, operate or service the machine. All members of personnel must wear clothes that are suitable to prevent accidents due to clothing getting caught in moving machine parts or to contact with sharp or pointed parts or with high temperatures. Protection clothes, safety goggles and safety boots must be worn at all times. We also recommend the use of personal protection devices to protect operators from the noise that may be produced by the machine. Operators must be familiar with the use of the equipment required to carry out routine and extraordinary maintenance work. In particular, these instructions must be read by all members of personnel who may be operating or interacting with the machine, such as: - Personnel in charge of transportation and handling the machine - Personnel in charge of connecting the machine to supply mains - The operator who is to use the machine - Personnel in charge of servicing the machine - Personnel who are to carry out machine tests and to check the

characteristics of the product treated.

2C001E0C.DOC 2.1.2

Niro Soavi S.p.A 2.1.3 USE OF THE MACHINE IN DANGEROUS ZONES

Use of the machine in dangerous zones is allowed only if the machine has been designed specifically for use in such conditions using suitably certified components. Identification and classification of danger zones is the responsibility of the customer who is required to specify them. The factory electric system as well as ground and unipotential connections must be designed so as to prevent any danger of explosion. Where equipment for the detection of dangerous gas, liquids or vapors is used it must installed by the user; the same applies to systems for ventilation and exhaust of smoke and vapor from the danger zone. All personnel must be aware of the potential hazards present in the danger zone and connected with the use of dangerous products for the safety of persons and of the environment. Any tools and equipment used inside danger zones must be suitable for use in these conditions; the user of the machine is responsible for selecting them and making them available as well as for the way they are used. It is extremely important to regularly check belt tension in order to prevent dangerous overload or overheating as this could create a risk of fire or explosion.

2C001E0C.DOC 2.1.3

Niro Soavi S.p.A

2.2. CE MARK AND ISO 9000 CERTIFICATION

The machine has been designed and built in accordance with EEC standards on the safety of equipment (CEE/98/37). NIRO-SOAVI guarantees that this machine complies with the above-mentioned standard by marking the front of the machine with "CE" as shown in figure 2.2.1 here below, on the front part of the machine. In Section 1 – TECHNICAL SPECIFICATIONS we have attached the Declaration of Conformity CE of the machine.

TYPE S.N.

RATED FLOW (dm3/h)

MAX PRESS.

YEAR

via M. da Erba Edoari, 29/A 43100 PARMA (ITALY)

Niro Soavi S.p.A.

FIGURE 2.2.1 In addition to this, NIRO SOAVI is certified according to UNI EN ISO 9001 for design, manufacturing and servicing of homogenisers and high pressure pumps, therefore your machine has been enginnereed and produced according to approved quality procedures. See figure 2.2.2 for the UNI EN ISO 9001 Quality System Certificate.

2C001E0C.DOC 2.2.1

Niro Soavi S.p.A

FIGURE 2.2.2

2C001E0C.DOC 2.2.2

Niro Soavi S.p.A

2.3. IDENTIFICATION OF THE MACHINE

The machine is identified by the name plate (fig.2.2.1) located on the front panel (or on the pulley protection panel, for the Hercules versions without casing), which includes - the manufacturer's name - model and type - serial number. The serial number is also punched on the compression head. This number should always be quoted in any correspondence addressed to NIRO-SOAVI's Customer Service in order to identify the machine properly.

2C001E0C.DOC 2.3.1

Niro Soavi S.p.A

2.4. GUARANTEE

If not specified otherwise in the order confirmation, the terms and conditions of guarantee are as follows: 2.4.1 SCOPE OF THE GUARANTEE

NIRO-SOAVI guarantees the good quality and workmanship of its products and shall - during the specified guarantee period - repair or replace free of charge any part whose failure or premature wear and tear are the result of poor quality of materials, defective workmanship or assembling. The guarantee shall not apply to those parts whose failure or wear and tear are due to: - operator's negligence in checking the levels of the fluids, cleaning the filters,

providing the correct utility lines or improper feeding; - insufficient infeed pressure in the machine; - use of the machine with operating values exceeding the ones specified in

the contract, especially with respect to maximum pressure, flow, product treated, operating and washing temperatures, feed pressure, specifications of required utilities.

- use of inappropriate tools for the ordinary or extraordinary maintenance; - failure to perform or incorrect maintenance; - alterations or modifications carried out - whether directly or indirectly -

without the specific authorization in writing by NIRO-SOAVI; - failure to comply with the INSTRUCTIONS FOR USE & MAINTENANCE. - incorrect machine use, incorrect operating procedures and conditions - incorrect machine installation or incorrect layout of feed line - use of unsuitable components upstream or downstream the machine, and in

particular use of inadequate feed pump. For this reason, we strongly recommend that the instructions contained in this Manual are understood and followed, as a pre-condition for the correct and safe use of the machine. Using the machine and reading the INSTRUCTIONS FOR USE AND MAINTENANCE imply integral acceptance of Warranty conditions. For further information about application of the Warranty, see General Terms of Sale.

2C001E0C.DOC 2.4.1

Niro Soavi S.p.A 2.4.2 DURATION OF THE GUARANTEE

The guarantee shall last for 12 MONTHS from the date of delivery of the machine, unless otherwise specified in the Order Confirmation. Such period shall remain unchanged even in the event that spare parts replacements or repairs are carried out during the 12-month period. 2.4.3 APPLICATION OF THE GUARANTEE

As a condition of the applied warranty, any parts claimed to be defective by the customer shall be provided to NIRO SOAVI to establish the cause. The cost of shipping of materials shall always be charged to the customer. Any work required for replacement/repair under guarantee shall be executed - at NIRO-SOAVI's option, on the manufacturer's premises, on thirds' party or directly on the spot. The cost of shipping materials to the customer’s presmises shall always be charged to the customer, especially in the case of urgent and specials shipments of material or spare parts. For any work carried out locally, the customer shall provide and pay for the necessary utilities, extraordinary equipment, auxiliary personnel that may be required and the costs of travel, board and accomodation of NIRO-SOAVI's technicians.

2.4.4 EXCLUSIONS AND LIMITATIONS

The guarantee shall not cover the materials and parts subject to normal wear and tear such as, but not limited to, all the gaskets used in the machine, V-belts, plunger seals and relevant packing and support washers, safety valve seat, filters, etc., as well as those parts whose life can not be estimated beforehand - such as lamps, fuses, plungers - together with any coating, delivery valve and their seats, homogenizing valve, pressure gauges. For the components and accessories bought from independent Vendors, the guarantee shall be the one granted to NIRO-SOAVI by such Vendors. 2.4.5 HOW TO RETURN THE DEFECTIVE MATERIAL

Before returning to NIRO-SOAVI any part for which a replacement/repair under guarantee is claimed, the necessary approval shall be ontained from NIRO-SOAVI's Customer Service. All parts shall be properly packed to avoid any damage in transit, and accompanied by: - reference to the purchase order number; - machine serial number; - code number of the part; - accurate description of the defect and the circumstances which caused it. All parts approved to be under guarantee are delivered ex works; replaced parts are the property of NIRO-SOAVI and shall be returned ex works.

2C001E0C.DOC 2.4.2

Niro Soavi S.p.A

2.5. HANDLING

CAUTION: These instructions shall be made available to the personnel involved in the handling and installation of the machine.

The machine is sent to the Customer usually packed in a properly sized wooden crate and wrapped in plastic film for additional protection, unless otherwise specified in the Order Confirmation. The wooden crate allows the machine to be handled with a fork lift or crane, and appropriate marks are provided on the crate at the points for running steel cables or belts for lifting (figure 2.5.1).

FIGURE 2.5.1

2C001E0C.DOC 2.5.1

Niro Soavi S.p.A Concerning the dimensions and weight of the machine, see the “Installation Drawing” shown in Section 1 – TECHNICAL SPECIFICATIONS, in order to use the proper lifting equipment. The weight given is merely indicative and should be used only to select the correct handling and transport means. Please note that the center of gravity of the machine lies towards the compression head (front part). When handling unpacked machines use fork lifts (unless otherwise specified in the handling instructions) and make sure that the compression head lies on the operator's side. Forks should be adequately spaced and sized so as to accomodate the entire base of the frame (figure 2.5.2) to prevent damage to the machine frame or panels. Side panels can be removed during transport to prevent damage; the front part of the bodywork, under the compression head, has not been constructed to support the weight of the machine. Do not use this part as a lifting point as this could result in damage.

G G

FIGURE 2.5.2

CAUTION: In order to ensure a balanced handling of the machine and avoid damage to the machine itself or hazards for the personnel, all movements should be carried out VERY SLOWLY by authorized operators, who must wear suitable protection devices and comply with safety regulations.

2C001E0C.DOC 2.5.2

Niro Soavi S.p.A WARNING: Before handling the machine, make sure that the route to be followed and the intended place of installation are clear of any obstacle. WARNING: Operators are required to read these instructions before handling the machine; all personnel involved in handling of the machine must be acquainted with transport and handling regulations, as well as with regular safety standards.

WARNING: Use only tested hoisting devices approved to support the machine’s weight, as indicated in the dimension drawing in Section 1 – TECHNICAL SPECIFICATIONS.

Do not under any circumstances leave suspended loads and never stand below suspended loads. WARNING: The floor on which the machine is to be placed must withstand to at least 150% of the machine’s weight indicated in the “Installation Drawing” in Section 1 – TECHNICAL SPECIFICATIONS.

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Niro Soavi S.p.A

2.6. RECEIVING AND CHECKING THE MACHINE

Unless specified otherwise in the Order Confirmation, once the machine has left the Manufacturer's premises, any damage shall be under the responsibility of the carrier - whether an independent one or a Customer's employee. Therefore, when receiving the machine, the following should be checked: - contents of the packing against the Packing List; - integrity of the packing, so that any evident damage can be immediately

reported to the carrier; - any damage suffered by the machine as a result of improper transport by the

carrier. In order to minimize the amount of inconvenience for the Customer, NIRO-SOAVI Shipping Department is always available to assist with clarifications, evaluation of any damages, and any other action required to restore the machine to its proper and safe conditions.

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Niro Soavi S.p.A

2.7. STORAGE

2.7.1 STORAGE BEFORE INSTALLATION

During the time preceding installation, the machine and its apparatus should be conveniently stored in closed, clean premises to avoid deterioration and preserve its efficiency. If no storage place can be provided other than outdoor, a waterproof cover should be provided to prevent contact with dust, humidity, rain, etc. Special attention should be given to electric control boards and electronic equipment, which are easily affected by humidity and low temperature. If separate from the machine, they should be stored indoors and provided with special humidity absorbers. WARNING: Storage temperature should not be less than -5°C and more than +55°C; humidity should be less than 95%, with no-condensate. Vibrations should be avoided as much as possible.

2.7.2 STORAGE FOR PERIODS LONGER THAN 3 MONTHS

If the machine is expected to remain stored for over three months before installation, provide a closed storage place protected from bad weather, dust or corrosive releases, as described before. Observe the above precautions for electric components. In addition YOU MUST: - loosen the tension of V-Belts using the appropriate tighteners (sees Section 3

- MAINTENANCE); - disassemble the plungers and seal packings (see Section 3 -

MAINTENANCE) WARNING: Pistons and seal packings should be reassembled, and belts tensioned at the time of machine installation. WARNING: In case the machine plungers are chrome coated, or are using a tungsten carbide detonated coating (see Section 1 – TECHNICAL SPECIFICATIONS), they must be disassembled together with the packings if the machine is in storage more than ONE month.

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Niro Soavi S.p.A

2.8. INSTALLATION

2.8.1 POSITIONING

The correct positioning of the machine within the production line is a pre-condition for ideal performance and easy access for ordinary maintenance. For this reason, according to the machine dimensions (see Section 1 – TECHNICAL SPECIFICATIONS), allow enough space around the machine for the service personnel to carry out the necessary maintenance. Specifically, allow clearance for the eventual replacement of the main motor using suitable lifting gear (crane or fork lift). The front part and head require routine servicing; allow sufficient space to permit complete removal of the head if required. In addition, make sure the machine is not placed near sources of heat which may undermine the necessary cooling, or near obstacles which may obstruct a free air flow. Plan suitable drainage points to be available in the area where the machine is installed, in order to avoid its flooding, and avoid water hosing of the machine through ventilation openings. CAUTION: the floor on which the machine stands must have a bearing capacity of at least 150% of the machine's weight indicated in the “Installation Drawing” in Section 1 – TECHNICAL SPECIFICATIONS.

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Niro Soavi S.p.A

2.8.2 ACCESS TO THE INSIDE OF THE MACHINE

The machine is provided with a satin-finish stainless steel fairing for: - protection of the internal components from dirt, water or fouling with product; - easy cleaning of the external parts; - operator's protection from moving, under voltage or hot parts which may be

hazardous for the personnel, in compliance with EC standards and CE mark requirements, and safety regulations in force in the country where the machine is installed.

CAUTION: to avoid any danger of injuries to the operators, the machine should be operated ONLY with the panneling in place or protections completely closed.

Panels may be removed to allow maintenance and/or installation work to be carried out. Side panels are fitted with handles and special key locks to access the inside of the machine. WARNING: To prevent accidents, ensure that ALL retainers are tightened?? before starting the machine; to remove or replace panels always use the handles provided. Depending on the size of the panels, two persons might be needed to remove or instal the panels.

CAUTION: Before removing the protection panels, the installation/ maintenance personnel should cut off the power input to the machine by locking the appropriate power switch with a padlock.

2C001E0C.DOC 2.8.2

Niro Soavi S.p.A

2.8.3 MACHINE LEVELING

To ensure a smooth, vibration free operation, the machine should be properly leveled and its legs should rest evenly on the floor. To this effect, the machine is supplied with adjustable legs and rubber pad (figure 2.8.1, item 1); in some cases, with fixed legs which do not require to be adjusted or with pivoting wheels which have to be locked before operating the machine. For the leveling, proceed as follows: - lift the machine and place the pads under the legs; - lower the machine until the legs sit firmly on the blocks; - adjust height from floor by tightening or loosening the adjustable legs, then

check the levelling with respect to the machined surface of the head; - make sure that the machine's weight is divided among all legs; - lock the legs using the appropriate lock ring (figure 2.8.1, item 2). In some cases, due to vibrations, the machine may move and consequently cause stress to the piping; if you wish to avoid this, the leg pads can be secured by steel rings fixed to the floor.

2

1

FIGURE 2.8.1

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Niro Soavi S.p.A

2.8.4 CONNECTION TO UTILITIES AND PRODUCT LINE

The type, dimension and position of the connectors normally used to connect the machine to the production line are specified in the dimension drawing in Section 1 – TECHNICAL SPECIFICATIONS. The machine also includes (section 1 – TECHNICAL SPECIFICATIONS): - water connection for lubrication of packs and cooling (max. hardness 8 °dH /

15 °fH; recommended chloride value < 25 mg/liter, max 200 mg/liter - water drain pipe; - (possible) connection for compressed air (for homogenizers provided with air-

operated control system); - (possible) connection for steam (for aseptic versions) - condensate drain from lubrication system; - discharge grid for cooling air. For the specific requirements of each machine, type of connections and fluid specifications, please refer to Section 1 – TECHNICAL SPECIFICATIONS. As far as the utility connections, we recommend providing on/off solenoid valves designed to open at the machine start (if not already included in the machine) to be placed at the machine’s utilities inlet ports. In particular, the manual valves of the lubrication water circuit should remain always open, in a position which allows controlling an adequate flow of water for lubrication or production of enough condensate (for the aseptic version). Keep in mind that excessive lubrication water can lead to flooding of the sump where water is collected, with the risk of water going into the drive section and polluting the lubrication oil; for this reason it is important to regularly drain any condensate or water that may be found in the lubrication circuit, as described in Section 4 - MAINTENANCE. WARNING: For the machines provided with aseptic system, the Customer shall be responsible to install a steam pressure reducer to protect the aseptic system and ensure operators’ safety. Fluid specifications are shown in Section 1 – TECHNICAL SPECIFICATIONS.

In case a pipe is used for the water drainage, when calculating the required diameter and slopes, remember that water is discharged by gravity and not by pressure. Provide an adequate degree of slope in the system to avoid water to accumulate in the sump. WARNING: For the disposal of waste water or cooling water, refer to the specific regulations in force locally. No traces of lubrication oil or product residues are allowed in the effluents disposed.

2C001E0C.DOC 2.8.4

Niro Soavi S.p.A Cooling air is discharged through grids, situated on the top of the machine, controlled by a fan of suitable size for free discharge (not for all models). In case the discharged air needs to be conveyed via ducts, please contact NIRO-SOAVI's Technical Office for details. WARNING: No device designed to throttle, whether totally or in part, the delivery pipe, is allowed to be installed downstream the machine, as this may cause risk of excessive pressure in the pipes and compression head.

In fact, the machine has been designed to withstand output counterpressures not bigger than those indicated in the Technical Specifications, Section 10 but, as this is a positive-displacement pump it can create dangerous overpressure which can burst the pipes downstream the machine when the outlet is closed for the liquid flow. WARNING: For safety reasons we recommend you ALWAYS install a safety valve downstream the machine to protect the line and users. You should also ensure that all the valves used downstream the machine are NORMALLY OPEN valves, so that they will not close in case of accidental stops or emergency power down, or power failures. The machine has been designed to have a certain level of inertia, so it will go on pumping even after the main motor has been disconnected..

FIGURE 2.8.2

2C001E0C.DOC 2.8.5

Niro Soavi S.p.A 2.8.5 INSTALLATION

These guidelines are provided to ensure correct machine installation and operation and guarantee long life to the machine and its components while preventing situations of danger for operators. • For high-pressure positive displacement pumps and homogenizers, infeed

pressure must ALWAYS be kept over a minimum level for correct operation without cavitation conditions which could damage the machine. The minimum values indicated in Section 1 – TECHNICAL SPECIFICATIONS must be observed strictly; in any case, depending on the process temperature and viscosity characteristics, it is necessary to ensure that infeed pressure is constant and sufficient to prevent cavitation and underfeeding of the machine. For further information or special requirements ALWAYS contact NIRO SOAVI

• to feed the machine use an infeed pump with delivery 1.2 times greater than

the rated flow in case of machines with 3 or more pistons, and 1.5 times in case of machines with 1 or 2 pistons. Pump delivery must be calculated at least over the minimum pressure required for feeding.

• If a positive displacement pump (lobe, single screw, etc.) or diaphragm pump

is used , a suitable by-pass pipe regulated by a modulating valve on the infeed pump, and/or an adequate speed regulating system for the infeed pump, to ensure correct machine feeding

• if the products treated vary greatly in terms of viscosity, or if a positive-

displacement pump must be used for viscous products and washing water, you must use a pump speed adjustment system regulated by infeed pressure to ensure that machine feeding is correct under all conditions, including during transitory production stages.

• installation of the two homogenizers or piston pumps in series can only be

carried out provided a few changes are made, such as providing speed variation of both machines controlled by an an infeed pressure adjustment loop and installation of a by-pass system; for information in this respect please contact NIRO SOAVI

• it is necessary to use a feeding pump for each single machine; do not install

two or more machines in parallel with one single feeding pump to prevent dangerour pulsation interferences

• the feeding line between the feed pump and the homogenizer or piston pump

must be direct, possibly without bends, and with a size equal to or greater than the size of the homogenizer/piston pump, without section variations, to

2C001E0C.DOC 2.8.6

Niro Soavi S.p.A

prevent loss of load; the radius of curves must be as large as possible to prevent loss of load especially in the infeed stage and to avoid noise problems at delivery.

• we recommend you install a pressure gauge near the area where product is

fed into the homogenizer / piston pump in order to check infeed pressure; this pressure gauge can be supplied as an optional by NIRO SOAVI and can be standard, with minimum contact or with continuous analog signal for remote control.

• if filters need to be installed on the feeding line, you must allow a clear area

at least 3 times the size of the pipe used; you also need to install a pressure gauge downstream the filter to check actual infeed pressure and prevent filter clogging and danger of cavitation of the machine. For cleaning purposes we recommend installing parallel filters to be used alternatingly.

• every homogenizer or piston pump is characterized by pulsating operation:

for this reason, depending on the kind of system and machine flow, we recommend you install a pulsation damper both for suction and delivery (providing up to 20 bar maximum counterpressure on the line)

• the pulsation damper is always recommended for flow rates exceeding

5000÷6000 l/h; on the suction end, it must be installed as close as possible to the machine inlet, while on the delivery end it must be installed on a horizontal pipe at a distance of minimum 1 meter from adjacent bends. For technical details about size and installation please contact NIRO SOAVI

• the pulsation damper must be installed in a vertical position; do not install the

damper so that the flow enters the damper directly, otherwise the damper will fill up too quickly and become less effective as no air will be left at the top

• if the feed pump is connected to a tank, ensure that no air is sucked in by the

suction inlet through the creation of vortices by fitting suitable internal barriers to divert the flow; the suction inlet must be sotto battente? at all times

• we recommend you install a suitable safety valve downstream the

homogenizer or piston pump in order to protect the system from possible overpressure caused by inexperience or incorrect operation procedures downstream the machine; the safety valve fitted in the machine, even where a piston pump is used, will protect the machine, but not the system to which it is connected, in case of dangerous overpressure.

2C001E0C.DOC 2.8.7

Niro Soavi S.p.A • Never use the machine to fully drain the feeding tank, to avoid product

suddenly running out during operation under pressure, but provide at least one level sensor to remove pressure (in the case of a homogenizer) and stop the machine before the product being fed runs out

• the product treated must contain no air or gas, to prevent cavitation problems

in the machine. If the product contains air because it is very viscous or due to previous processing phases, you need to remove the air using appropriate deaeration equipment

• if processing temperature exceeds 90 °C, it is absolutely necessary to

increase feeding pressure due to increased steam pressure which can lead to cavitation. Feeding pressure should therefore be increased by 1 bar for each 5 °C of temperature increase above 90 °C added to the minimum feeding pressure specified in Section 1 - TECHNICAL SPECIFICATIONS. This value must be doubled in case of products with a viscosity value greater than 500 cP. For special products and special process temperatures contact NIRO SOAVI

• the machine is fitted with automatic pumping spring valves; the load is defined according to the type of valve and the characteristics of the product. This means that if the machine has been stopped or is inactive, and the feeding line is open and under pressure, you are able to check the flow of product through the machine. To make sure there is no product flowing through the machine when the machine is inactive, the user must provide a cutoff valve for the feeding line upstream the machine.

2C001E0C.DOC 2.8.8

Niro Soavi S.p.A

2.8.6 POSITIONING THE ELECTRIC EQUIPMENT

Our machines are supplied in the standard version without electric power board; this will be designed and constructed according to the specifications of the machine as an optional; in any case the machine is fitted with a terminal box which houses all the connections of the electric devices installed in the machine, excluding the motors. Where the electric board is supplied, and as a general recommendation, the cabinet containing the electric control and power equipment - if not built in the machine - should be placed as far as possible in clean, dry, ventilated premises which should be free from vapour, suspended dust or corrosive release. Before ordering the machine, the Customer should make sure that the intended place of installation is suitable to protect the equipment from any aggression. Besides, it should be ascertained that no heat sources are present in the vicinity to avoid local overheating and ensure that all electric equipment can be cooled down efficiently. When forced ventilation is provided, any air vent should remain unobstructed. If it has been established that the ambient air is not suitable for proper ventilation, an air duct should be provided, in addition to selecting a control board suitable for the particular operating conditions existing locally. For the type, overall size, weight and installation requirements of the control board, see Section 1 TECHNICAL SPECIFICATIONS (if the board has been supplied by NIRO-SOAVI).

2C001E0C.DOC 2.8.9

Niro Soavi S.p.A 2.8.7 ELECTRICAL CONNECTIONS

The power line to the control board should be of appropriate type according to the length, type of routing, ambient temperature, nature of the load, and always in accordance with the provisions of the local regulations on this matter. If no specific agreements have been made in writing with NIRO-SOAVI, the user shall be responsible for establishing the features of the power line and earthing conductor up to the terminal board of the machine, as well as selecting appropriate protection devices against short-circuits and contact voltage. Where the electric board is supplied by NIRO SOAVI we will provide a list of cables with size calculated assuming a length of 50 meters, closed conduit with three-pole cables and 40 °C ambient temperature. As far as the power details of the machine and wiring diagrams, reference should be made to the electric specifications and diagrams shown in Section 1 - TECHNICAL SPECIFICATIONS and in Section 6 – WIRING DIAGRAM. CAUTION: The indications given concerning the wiring refer to standard laying and environmental conditions; the values shown are purely indicative, therefore they should ALWAYS be cross-checked by the user depending on the actual operating conditions.

The electric connections between machine and electric power board and between electric power board and power mains must be made by the Customer who is also responsible for checking that they have been properly executed and that they comply with the wiring diagram, before the machine is started up. NIRO SOAVI shall not be liable for injury to people or damage to objects caused by incorrect connection of electric equipment; all electric connection must be checked by authorized personnel. If in doubt please contact NIRO SOAVI.

2C001E0C.DOC 2.8.10

Niro Soavi S.p.A 2.8.8 DIRECTION OF ROTATION OF ELECTRIC MOTORS

At the time of wiring, make sure that all motors rotate in the correct direction: CAUTION: To check the direction of rotation, the motors should be operated ONLY by impulses. When performing these operations, follow strictly the safety rules and stay away from any moving part inside the machine. Remove only the panels on the LEFT HAND SIDE of the machine. Before starting the machine, make sure that the protection panels on the RIGHT HAND SIDE (drive) of the machine are in place. • main motor: the correct direction of rotation is shown by the arrow on the

flywheel; it is COUNTERCLOCKWISE for machines with FORCED LUBRICATION and gear reducer); COUNTERCLOCKWISE for machines with splash lubrication (see Section 1 - TECHNICAL SPECIFICATIONS), unless otherwise specified by the direction of the arrows on the machine (flywheel and/or motor)

• oil pump motor (only for machines with motor-driven lubrication pump): follow the direction of the arrow printed on the pump body. In case of mistake, the low pressure in the circuit triggers the pressure switch, which prevents the machine operation;

• electric fan of main motor (only for machines designed for variable speed): follow the direction indicated by the arrow;

• electric fan of machine body: follow the direction indicated by the arrow; Auxiliary motors may be installed depending on the type of machine: verify the actual installation with reference to the technical sheet and the wiring diagrams, Section 1 -TECHNICAL SPECIFICATIONS. If the direction of rotation is not correct, reverse any of the two phases of the supply cord. CAUTION: Before starting the motors ensure that ONLY installation personnel are present in the vicinity, and that NOBODY is in contact with the machine.

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Niro Soavi S.p.A

2.9. SPECIAL NOTES

2.9.1 CONTROL BOARD TO BE PROVIDED BY THE CUSTOMER

If the electric power and control board (optional) is not supplied with the machine, NIRO-SOAVI will include a Technical Sheet (Section 1 - TECHNICAL SPECIFICATIONS) showing the electrical requirements of the machine, together with an operation sequence to enable the Customer to establish the elements of the control board and the operating features of the required protection devices for a correct execution and the selection of appropriate control and protection devices. CAUTION: NIRO-SOAVI shall not be held liable for damages caused to either persons or the machine due to mistakes made in the design and/or execution of the control board.

CAUTION: The control board should be built in accordance with the local operational and safety regulations in force. 2.9.2 ELECTRIC MOTOR SUPPLIED BY THE CUSTOMER

The electric motor shall be made in accordance with the general specifications laid down by NIRO-SOAVI as to POWER, NUMBER OF POLES, SIZE, SERVICE (Section 1 - TECHNICAL SPECIFICATIONS). The motor shall be placed either on the supporting plate and secured by bolts in the holes provided (or made at the time of installation) taking care that the motive pulley is in line with the flywheel. For information on installation and tensioning of V-belts see Section 3 - MAINTENANCE.

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Niro Soavi S.p.A

2.10. NOTES ON MACHINE TEST

Before shipment all of our machines are accurately tested by qualified personnel through operational tests which simulate the normal working conditions. Through the operational tests - run with cold water - it is possible to verify the actual performance of the machine against the design data, the calibration of safety, control and check devices, the conditions of any seals, as well as the noise and vibration-free operation of the machine and the parameters introduced in any programmable instruments or equipment that might be used. To test the conditions of operation of the machine (flow rate with the maximum operating pressure allowed, noise level, electric absorption) the machine is run with water at a temperature of approximately 20 °C, so it is possible to verify the deviation of the machine’s actual flow rate compared to the rated value ± 5% with product. However, at the time of start-up, after the machine has been installed in the production line, a final test of the conditions of operation is required. Upon request of the Customer, NIRO SOAVI can dispatch an engineer for the first machine start-up in order to check that the wiring has been executed correctly and that the machine has been properly installed, besides providing any additional information or instruction to the operators and service personnel with reference to this Manual. CAUTION: Should the Customer decide not to ask for the attendance of our engineer at the time of the start-up, NIRO-SOAVI shall not be liable for damages to persons or property caused by failure to observe the instructions provided in this Manual (INSTRUCTIONS FOR USE AND MAINTENANCE).

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2.11. CLEANING THE MACHINE

The machine is supplied with external paneling in glazed stainless steel plate (ARIETE version) which is easy to clean with water. Washing prevents the deposit of product residuals on the machine: wash the bodywork with running water from time to time, paying particular attention to the compression head and the sump. If required you may use a cloth and any standard mild detergent. To prevent water from entering the machine, place a suitable covering over the ventilation hole; do not wet the electric panel or the control panel. The HERCULES industrial version is supplied without external paneling, but only with protection panels to cover moving parts: in this case make sure you do not wet unnecessarily the electrical components of the machine. WARNING: Before washing with running water, make sure that power has been cut off by means of the sectioning switch of the supply line that should be locked with appropriate padlock.

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2.12. DEMOLITION AND DISPOSAL

The demolition and disposal of the machine must be carried out in compliance with various procedures according to the type of material to be disposed of. First of all, it is necessary to: - discharge lubricating and hydraulic oils for separate disposal; - disassemble the electric system (components, cables and protection

sheaths) and all the plastic parts for separate disposal. The machine is manufactured with the following materials, in various quantities: - stainless steel; - steel alloys and steel for construction purposes; - cast iron. The following are also present in very limited amounts: - aluminium; - copper; - bronze; - ceramic; - PTFE; - nitrile; - viton; - PVC. - PEEK - Elastomers and plastic materials. All these materials must be disposed of in compliance with the regulations currently in force in the country at the time of disposal.

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2.13. OPTIONS

2.13.1 SECOND STAGE HOMOGENIZING VALVE

As an option, a second homogenizing stage can be installed on NIRO-SOAVI Homogenizers in series with the first stage valve. In this way it is possible to reduce the increase of viscosity produced by the treatment of the product, in case it contains colloidal or thickening substances. Although the micronization effects obtained with the 1 stage are unaffected, the 2nd homogenizing stage reduces the product viscosity and allows the distributing of the pressure drop. Moreover, it is possible to avoid the clustering of micronized particles, due to the homogenizing effect. The application of the 2nd stage should be decided on the basis of specific considerations concerning the type of product. As a general rule, the second stage pressure is usually applied as 1/10 to 1/5 of the maximum homogenizing pressure, according to the processed product requirements. The formula which relates the homogenizing pressures in a two stage system (see figure 2.13.1) is the following:

Ptot = P1 = P2 + dP

where: Ptot = P1 is the total pressure measured on the compression head,

equivalent to the 1st stage pressure P2 is the pressure applied to the 2nd stage dP = P1 - P2 is the pressure difference between the 1st and the 2nd stage,

applied in the passage through the 1st stage valve. Do not hesitate to contact NIRO-SOAVI for advice and clarifications.

2C001E0C.DOC 2.13.1

Niro Soavi S.p.A

Ptot = P1

P2

dP

FIGURE 2.13.1

2.13.2 ASEPTIC EXECUTION

Whenever a sterile plant and product needs to be ensured, an aseptic version of the NIRO-SOAVI machine is available. This can be achieved by running sterile condensate through the plungers in the seal section and through the seal of the homogenizing valve shaft using appropriate sterile chambers to avoid contamination from outside sources. Condensate is produced by steam condensation at a temperature of approximately 140 to 150C through water run in a heat exchanger. The cooling water should be clean and preferably softened to avoid scaling deposits in the exchanger. Water hardness must be under 8 °dH / 15 °fH, with recommended chloride value < 25 mg/liter and in no case greater than 200 mg/liter. The required flow rate and water temperature values are indicated in the consumption tables, Section 1 – TECHNICAL SPECIFICATIONS.

2C001E0C.DOC 2.13.2

Niro Soavi S.p.A 2.13.2.1 STERILIZING THE MACHINE

Before starting up the machine following an extended period of standstill - or at first start-up - we recommend sterilizing the areas to be maintained aseptic with live steam (max temperature 150 °C at 3.8 bar) and with the machine stopped: to do so, open the steam on/off tap without sending any water to the exchanger. After sterilizing cool down the system by flowing the sterile condensate obtained from steam condensation through the aseptic circuit. This operation should be performed with the machine stopped to avoid damaging irreparably the seal packings of the plungers. The machine’s product circuit can be sterilized using live steam or pressurized water, with a maximum temperature of 150 °C and for maximum 30 minutes. To avoid damaging the seal packings of the plungers and thus reduce their life, we recommend that you stop the machine before sterilizing it or that you alternate 1 minute operation phases with 10 minute stops (in case of fixed flow rate/speed machines), or with the lowest speed possible in case of operation with frequency converter. During the sterilizing phase the alarm for " HIGH CONDENSATE TEMPERATURE" may go on: you may either exclude it or just switch it off.

2.13.2.2 REGULATING THE FLOW OF COOLING WATER

During operation, the cooling water on/off valve (whether manual or solenoid) should remain open. An additional manual valve on the outlet of the exchanger has been provided to control the water flow and obtain sterile condensate at a temperature of 40 to 50°C. This has the extra advantage of helping reduce any waste of softened water. 2.13.2.3 DESCALING AND WASHING

The use of water – even when softened - for steam condensation inevitably produces some deposits of lime in the exchanger. Whenever a reduced exchange power is noticed - evidenced by an insufficiently cooled condensation - a descaling of the aseptic system is required. It is impossible to predict the frequency of this operation, since the formation of lime deposits depends largely on the hardness of the water available. For more details on maintenance operations, see Section 4 - MAINTENANCE.

2C001E0C.DOC 2.13.3

Niro Soavi S.p.A 2.13.3 PARTIAL HOMOGENIZING SYSTEM

NIRO SOAVI homogenizers can have installed, as an option, a partial homogenizing system, to homogenize only a part of the total flow which is then mixed with the remaining non homogenized part in a special mixing chamber (see figure 2.13.2). The homogenized part is normally around 30% of the total capacity of the system. A typical application is the homogenization of fresh milk where only the fat part (milk cream) coming directly from the centrifuge is homogenized then mixed downstream of the homogenizing valve to get fresh milk with standardized fat content. The system includes, in addition to the homogenizing valve, a special mixing chamber featuring the recombination of the two portions using the high speed turbulence of the flow, plus a by-pass system with pneumatic valve and check valve (see figure 2.13.3) to feed the machine properly during the centrifuge desludging phase and avoid underfeeding at the homogenizer inlet. A typical scheme of partial homogenizing system is shown in figure 2.13.4.

FIGURE 2.13.2

2C001E0C.DOC 2.13.4

Niro Soavi S.p.A 2.13.3.1 HOW THE BYPASS SYSTEM WORKS

To make the by-pass circuit work properly, it is necessary to open and close the pneumatic butterfly valve (position A, figure 2.13.3) with a signal coming from the centrifuge. This valve must be closed during normal operation, opened during desludging phase and cleaning of the equipment.

A

FIGURE 2.13.3 Follow the instructions below for the correct operation of the system: • Open the pneumatic butterfly valve few seconds before the desludging phase

of the centrifuge; the single-acting check valve installed prevents the product to be homogenized from flowing through the by-pass even when the butterfly valve is open

2C001E0C.DOC 2.13.5

Niro Soavi S.p.A • Close the pneumatic butterfly valve few seconds after the desludging phase

of the centrifuge has been completed; • Keep downstream the homogenizer a minimum backpressure of 1÷2 bar, to

allow the backflow of the homogenized product into the suction manifold through the by-pass, when opened. Thus it is necessary to avoid a free discharge into an open vessel or tank without pressure; if the backpressure generated by the downstream plant is not enough to make the system work properly, it will be necessary to install a suitable adjustable backpressure valve.

WARNING: To ensure the complete and proper cleaning of the by-pass circuit, it is necessary to keep the pneumatic butterfly valve (pos. A, figure 2.13.3) during the cleaning phase. Moreover, the backpressure downstream the homogenizer must always be higher than the suction side pressure.

100%5÷15%

CREAM 15÷25%

SKIMMED 70%

FIGURE 2.13.4

2C001E0C.DOC 2.13.6

Niro Soavi S.p.A

SECTION 3

OPERATION & USE OF THE MACHINE - INDEX

3.1. GENERALS

3.2. CHECKS BEFORE START-UP

3.3. START-UP PROCEDURE 3.3.1 OPERATOR’S POSITION 3.3.2 CONTROL PANEL 3.3.3 START-UP

3.4. OPERATION AND ADJUSTMENT 3.4.1 HOMOGENIZING PRESSURE ADJUSTMENT – 1 STAGE 3.4.2 HOMOGENIZING PRESSURE ADJUSTMENT - 2 STAGES 3.4.3 REMOTE PNEUMATIC CONTROL (OPTIONAL)

3.5. MACHINE STOP 3.5.1 EMERGENCY STOP

3.6. CLEANING

3.7. SAFETY DEVICES 3.7.1 OVERPRESSURE VALVE

3.7.1.1 OPERATION 3.7.1.2 CLEANING

3.7.2 PROTECTIONS ON MAIN MOTOR 3.7.3 EMERGENCY PUSH-BUTTON 3.7.4 COMPRESSION HEAD GUARD

3.8. TROUBLESHOOTING

3.9. SPECIAL FEATURES OF NON STANDARD MACHINES

3C001E0C.DOC 3.1.0

Niro Soavi S.p.A

3.1. GENERALS

The NIRO-SOAVI Homogenizer consists of a positive-displacement piston pump provided with automatic valves with suction and delivery spring , connected to a homogenizing section where the product undergoes the process of high-pressure micronization to reduce the size of the solid particles suspended in the fluids and achieve homogenous dimensional distribution. This process can be applied to a wide range of products with variable viscosity, and it allows to obtain more stable suspensions through micronization and dissipation of solid particles, depending on the level of pressure applied. To find out about the specific configuretion of the machine, model, technical data, accessories and optionals, see Section 1 - TECHNICAL SPECIFICATIONS.

WARNING: For safety during transport, the machine is supplied WITHOUT LUBRICATION OIL inside the drive section.

Before carrying out any operation fill with oil as described in Section 4 –MAINTENANCE, paragraph 4.9 LUBRICATION.

3C001E0C.DOC 3.1.1

Niro Soavi S.p.A

3.2. CHECKS BEFORE START-UP

WARNING: The operating temperature of the machine must be between +5°C and +40°C; maximum humidity 90%; maximume altitude 1000 m. For operating conditions outside these value limits a special version must be used. WARNING: Any operation involving the removal of the machine panelling should be performed with the MACHINE STOPPED AND ISOLATED from the power line by locking the isolator switch with a padlock, so that nobody can accidentally give power to the machine. Since the NIRO-SOAVI homogenizer has been designed to reach high pressures, good practice is to take certain precautions to avoid injuries/damage to persons, the plant or the machine itself. These instructions refer to the first startup or after period during which the machine is not in constant use. For correct and safe use of the machine we recommend that you carry out the periodical check required depending on the type of machine use, to ensure the machine is in perfect condition and prevent possible problems, if any; it is also a good practice to check from time to time that the machine is being operated in accordance with the prescription of the manual. Specific indications concerning normal start are given in chapter 3.3. • Check the connections with utilities and product line. Refer to Section 1 –

TECHNICAL SPECIFICATIONS for their specifications and location. • Check that the pipes upstream and downstream the machine are clean and

free from scaling or welding residues which may damage the machine seriously.

CAUTION: Do not use the machine to dispose of any impurities found in the piping up- and downstream the machine • Check the V-belt drive assembly. For the correct tensioning and alignment of

belts refer to Section 4 - MAINTENANCE.

3C001E0C.DOC 3.2.1

Niro Soavi S.p.A • Verify the level of lubrication oil through the sightglass: this should be

covered with oil by 3/4 or reach the level shown on the special visual indicator. When checking the oil level, the machine should be stopped, because normally the start-up causes the level to lower as it fills the circuits. If topping-up is needed, use only the oil types indicated in Section 4 - MAINTENANCE.

• For machines equipped with gear reducer, check the level of lubrication oil through the inspection hole provided on the reducer. If topping-up is needed, use only the oil type indicated in Section 4 -- MAINTENANCE.

• Make sure that the high pressure flanges, unions and nuts in the compression head are properly tightened to the values shown in the "Tightening torque" table, Section 4 - MAINTENANCE, .

• Verify that plungers are tight and that seal packings are in place, if they have been removed during storage or after standstill of over 3 months.

• Check the direction of rotation of motors as described in Section 2 - GENERALS, chapter 2.8.7.

• Make sure that all protection panels are in place and securely fixed. CAUTION: Failure to observe the last recommendation here above may - in case of machine starting - result in a severe risk of injury for anyone standing near moving parts.

• Make sure that the homogenizing pressure controls (figure 3.2.1) (air-

operated switch A and reducer B) are either completely loosened or on the OFF position, and that any manual controls are fully loosened (fig.3.2.2)

• Verify that all safety and protection devices are in perfect operating condition. • Make sure that any valves and parts of the system downstream the

homogenizer are open to prevent overpressure in pipes when the homogenizer is started.

3C001E0C.DOC 3.2.2

Niro Soavi S.p.A

FIGURE 3.2.1

2

1

D

A

B

C

-

+

FIGURE 3.2.2

3C001E0C.DOC 3.2.3

Niro Soavi S.p.A

3.3. START-UP PROCEDURE

3.3.1 OPERATOR’S POSITION

To ensure the safe use of the machine during start-up and adjustment operations, we recommend that the operator should stand as indicated in figure 3.3.1. The control panel - configurated according to the Customer's requirements - is on the left hand side of the machine front; an EMERGENCY STOP PUSH-BUTTON is always fitted on each machine. ATTENTION: Adequate free space must be provided in front of the machine under any circumstances in order to allow immediate access to the emergency push-button and any start/stop or setting devices.

.

FIGURE 3.3.1

3C001E0C.DOC 3.3.1

Niro Soavi S.p.A 3.3.2 CONTROL PANEL

The control panel is located on the front left side of the machine (in the Ariete version with paneling). There is a single panel for all the different languages which shows the symbols and instruments used to control the machine (see fig. 3.3.2): • Emergency Stop push-button to halt the machine instantly in case of

emergency • On/Off push-button (indicated by the symbols I/O); general alarm light (with !

symbol). These controls are available only if the electric board has been supplied by NIRO SOAVI

• Pneumatic controls for adjustment of the homogenizing pressure (1st and 2nd stage) consisting in an air-operated control to switch pressure ON and OFF and a pneumatic regulator to increase or reduce pressure (shown on a measuring scale)

• Pressure gauges for controlling pressure of air sent to the pneumatic head in order to reach homogenizing pressure.

• Pressure gauge for controlling pressure of drive lubrication oil, identified by a relevant symbol

2

1

NIRO SOAVI

FIGURE 3.3.2

3C001E0C.DOC 3.3.2

Niro Soavi S.p.A 3.3.3 START-UP

WARNING: The lubrication oil indicated in the specifications is suitable for operating temperatures between +5°C ed i +40°C: DO NOT START the machine if ambient temperature is lower than +5°C to avoid damage to the lubrication system.

Check with NIRO-SOAVI Customer Service for the type of lubricant suitable for the specific local conditions.

ATTENTION: If ambient temperature is lower than +5°C, do not start the machine before checking the conditions of the plunger water lubrication system and any water heat exchanger. Once all preliminary checks have been completed, the machine can be started following the procedure below. • Open all on/off valves on utility lines (water, air, steam) and regulate the flow

rates if necessary. ATTENTION: The machine must NEVER be started without water for plunger lubrication, otherwise serious damage could be caused to the seal packings and plungers; with ceramic plungers, this incorrect procedure may cause plungers failure because of thermal shock. For further details on thermal shock problems with ceramic plungers see Section 4 - MAINTENANCE.

WARNING: An excess of cooling water can lead to flooding of the sump or excessive water splashing on guiding pistons, with the risk of water going into the drive section. It is therefore important to check the water flow and adjust it to approximately 60÷100 l/h per piston. The lubrication circuit should be regularly drained to drain out any water that might have gone inside the oil.

• Feed the machine with product at the required flow rate and pressures as

indicated in Section 1 – TECHNICAL SPECIFICATIONS. WARNING: Feeding pressures lower than the limits given will cause CAVITATION in the machine, recognized by the typical noise produced by the head, which will seriously damage the whole machine. NIRO SOAVI shall not be libale for breakages, malfunctions or damage to the machine caused by CAVITATION even if this occurs during the 12 month guarantee period.

3C001E0C.DOC 3.3.3

Niro Soavi S.p.A • Give power using the main switch on the electric power board • Press the start push-button. In case the control board has been supplied by

NIRO-SOAVI, this operation allows to start the machine according to the correct sequence, depending on the type of machine and optionals provided:

- opening of any utility solenoid valve (optional) - start of the oil motor-driven pump (if this type has been provided) - start of electric fans (if provided) - start of main motor. In case the control board is supplied by the Customer, the correct operating sequence is provided (see Section 1 – TECHNICAL SPECIFICATIONS), and should be observed strictly. To identify the machine configuration refer to Section 1 – TECHNICAL SPECIFICATIONS.

3C001E0C.DOC 3.3.4

Niro Soavi S.p.A

3.4. OPERATION AND ADJUSTMENT

Once the machine has been started, before increasing the homogenizing pressure, check that the machine itself is operating normally, with a particular attention paid to the feed pressure, establishing it is stable and within limits as prescribed in Section 1 – TECHNICAL SPECIFICATIONS. Then it is possible to operate the control devices in order to increase the homogenizing pressure up to the desired process value. If your machine is equipped with a second stage homogenizing valve, refer to paragraph 3.4.2.

3.4.1 HOMOGENIZING PRESSURE ADJUSTMENT – 1 STAGE

This type of adjustment, through an air-operated cylinder, controls the position of the homogenizing valve to establish the homogenizing pressure. On the machine front panel (see figure 3.4.1) it is located a pneumatic switch (A) and a pressure regulator (B). Adjustment operations consist of: • make sure that pressure reducer (B) is fully backed off, counterclockwise • set the pneumatic switch to ON position; • rotate the reducer knob clockwise until the desired homogenizing pressure is

obtained, by reading the reached value on the pressure gauge.

CAUTION: To allow a slow, gradual pressure increase, the pneumatic adjustment system has been designed to ensure a certain inertia. Operate the pressure regulator slowly while checking the actual homogenizing pressure increase until the operating value has been reached.

WARNING: check the increase of air pressure on the pneumatic head using the pressure gauge installed on the panel control; this makes it possible to have a slow increase of homogenizing pressure. It is also possible to use the air pressure gauge to refer to if the head pressure gauge is not working correctly. Once the homogenizing pressure has been set to the desired value, lock the reducer knob (B) by pressing it. If the set pressure is the one used normally during production, the homogenizing pressure can be applied or released by operating ONLY the pneumatic selector (A), with the reducer left on the adjustment position.

3C001E0C.DOC 3.4.1

Niro Soavi S.p.A

CAUTION: this procedure is allowed ONLY for machines with operating pressure up to 250 bar, to prevent overstressing the machine and avoid too rapid an increase of pressure as this could cause the safety valve to open.

2

1

D

A

B

C

FIGURE 3.4.1

3C001E0C.DOC 3.4.2

Niro Soavi S.p.A

3.4.2 HOMOGENIZING PRESSURE ADJUSTMENT - 2 STAGES

To adjust the pressure, follow the same steps as for the single-stage machine. In order to adjust the pressure, please read carefully what is written in paragraph 3.4.1, and in specific all warnings. The pressure to be applied by the second stage varies from about 1/10 to 1/5 of the maximum homogenizing pressure, according to the product handled. WARNING: The intended homogenizing pressure value must be set FIRST on the second stage, THEN on the first stage to reach the total desired pressure.

A different operating sequence may result in SERIOUS RISK because the machine may inadvertently and suddenly reach higher pressure values than those for which the machine is designed.. Adjustment operations consist of (see figure 3.4.1): • make sure the pneumatic regulator is completely backed off counterclockwise • set the 2nd stage pneumatic switch (A) to ON position; • rotate the 2nd stage reducer knob (B) until the desired homogenizing

pressure is obtained, by reading the reached value on the pressure gauge. • set the 1st stage pneumatic switch (C) to ON position; • rotate the 1st stage reducer knob (D) until the desired homogenizing

pressure is obtained, by reading the reached value on the pressure gauge. WARNING: To allow a slow, gradual pressure increase, the pneumatic adjustment system has been designed to ensure a certain inertia. Operate the pressure regulator slowly while checking the actual homogenizing pressure increase until the operating value has been reached.

ATTENTION: check the air pressure increase on the pneumatic adjuster using the air pressure gauge located on the control panel; this allows a slow rise of the pressure. It is also possible to use this air gauge as a reference for the homogenizing pressure in case the main gauge on the compression block is not working properly as a temporary solution to be able to work with the machine. Once the homogenizing pressure has been set to the desired value, block the reducer knob (B and D) by pressing it. If the set pressure is the one used normally during production, the homogenizing pressure can be applied or released by operating ONLY the pneumatic selector (A and C), with the reducer left on the adjustment position.

3C001E0C.DOC 3.4.3

Niro Soavi S.p.A CAUTION: this procedure is allowed ONLY for machines with operating pressure up to 250 bar, to prevent overstressing the machine and avoid too rapid an increase of pressure.

CAUTION: To release homogenizing pressure in a two-stage system you need to reverse the procedure used to give pressure. Therefore first release pressure from the 1st stage and then from the 2nd stage.

3C001E0C.DOC 3.4.4

Niro Soavi S.p.A

3.4.3 REMOTE PNEUMATIC CONTROL (OPTIONAL)

The pneumatic control for adjustment of homogenizing pressure can be designed as a remote system using a proportional solenoid valve (requiring minimum 7.5 bar air pressure supply) actuated by a 4÷20 mA signal; the type of system used depends on the configuration selected by the Customer. The method for adjusting homogenizing pressure is the same as the one described for standard pneumatic systems in paragraphs 3.4.1 and 3.4.2. The supervision and control system (installed by the Customer) must send an electric regulation signal to the proportional valves, with suitable ramp time and graduality. CAUTION: Even with remote control, if the system has two stage the intended pressure value should be set FIRST on the second stage, THEN on the first stage to reach the total desired pressure.

A different operative sequence may result in SERIOUS RISK because the machine may inadvertently reach higher pressure values than those designed for the machine. It is important to send the signal gradually over approximately 30 seconds/1 minute to avoid a sudden increase of homogenizing pressure which could cause the overpressure valve located on the compression head to open. The remote control system via proportional solenoid valve uses also an ON/OFF solenoid valve for switching pressure on and off; this can be installed as an optional even with the manual control system instead of the pneumatic switch (see paragraphs 3.4.1 e 3.4.2). Another optional available is the automatic pressure control system, actuated by a regulation loop which can also mount, as an optional, a pressure gauge with 4÷20 mA analog outpu. Using this system it is possible to set an operating pressure value which will be kept constant even if the operating conditions of the machine or of the product change (e.g. variations in flow rate. Fpr further information about operating and control features please contact NIRO SOAVI. Machines fitted with remote system for control of the homogenizing pressure can also be equipped, upon request by the Customer, with local repetition of remote controls for operation during servicing. The use of the local system is described in paragraphs 3.4.1 and 3.4.2.

3C001E0C.DOC 3.4.5

Niro Soavi S.p.A

3.5. MACHINE STOP

To stop the machine, follow these steps: • release the homogenizing pressure by operating either the pneumatic switch

to the OFF position, or the remote control electric valve (or proportional valve) via an appropriate electric signal

• press the stop push-button (if available on the machine’s control panel) or give a stop signal via the control system. For machines with electric board supplied by NIRO-SOAVI this operation makes it possible to stop any auxiliary electric motors and the main motor by following the correct sequence given in Section 1 - TECHNICAL SPECIFICATIONS for Customers who wish to make their own board if it has not been supplied by NIRO SOAVI;

• cut off power using the main switch. 3.5.1 EMERGENCY STOP

In case of dangerous situations or serious machine failure, the operation can be immediately halted by pressing the emergency push-button located on the front panel (figure 3.5.1) After you have done that, release pressure following the procedure described before. WARNING: Before resuming the machine operation, elimitate the condition which led to the emergency stop. WARNING: By resetting the emergency push-button to its normal status, the machine is not started automatically, but it is enabled to start operating through the normal startup procedure.

S GREME

ENCY

O PTS

FIGURE 3.5.1

3C001E0C.DOC 3.5.1

Niro Soavi S.p.A

3.6. CLEANING

A thouroug of the machine will maintain the sanitary or aseptic conditions as necessary to avoid harmful deterioration or contamination of the product handled. When designing the machine, special care has been given to the parts in contact with the product to make them easily cleanable (C.I.P.) and to avoid recesses where the product may stagnate. However, the following recommendations should be followed to ensure hygiene: • to avoid the formation of a product film on the inner surfaces and product

deposit, the machine should be cleaned IMMEDIATELY after production. Do not allow the product to rest inside the machine, and do not let the empty machine stand still without rinsing it;

• make sure that any residue of chemical solution used for cleaning is completely removed by rinsing the machine thoroughly;

• if the cleaning solutions involve the use of concentrated products or powders, first prepare the solutions separately in order to avoid any undissolved clods or solid particles.

Cleaning should be performed in a closed cycle (C.I.P.) while the machine is running at homogenizing pressure equal to zero (for homogenizers). This allows avoiding energy waste and damage to the homogenizing valve. WARNING: For the machines with variable or double capacity, the cleaning should be performed at the maximum speed admitted, however not exceeding the maximum operating capacity by more than 20% (see Section 1 – TECHNICAL SPECIFICATIONS).

WARNING: The products used for cleaning and rinsing of the equipment should contain only the substances specified in Table 3.6.A. The presence of CHLORINE and IODINE ions - including simple traces - is very harmful to the materials used in the construction of the machine, as it may lead to stress corrosion phenomena which may cause the compression block failure in a short time and unpredictably.

3C001E0C.DOC 3.6.1

Niro Soavi S.p.A

TABLE 3.6.A

P R O D UCT max concentr.

(%)

max temp. (°C)

Caustic Soda (NaOH) 3 90

Nitric Acid (HNO3) 1 70

Phosphoric Acid (H3PO4) 3 85

Hot Water - 95

Hot Pressurized Water / Steam - 130 CAUTION: Dispose of the cleaning solution and washing fluids as prescribed by the laws in force locally.

3C001E0C.DOC 3.6.2

Niro Soavi S.p.A

3.7. SAFETY DEVICES

NIRO-SOAVI machines are provided with safety devices to prevent reaching critical conditions which may cause sudden breakage of the machine and hazards for the personnel. In addition the machines are designed with ample safety margins, in consideration of high pressures which may be reached as a result of improper operations by the user or failures of the line in which the machine has been included. The following safety devices have been incorporated: overpressure valve on the compression head, electric protections on the main motor (if the machine includes a control board), an emergency push-button and a guard to protect the head, as described here below. 3.7.1 OVERPRESSURE VALVE

The pressure relief valve has been designed by NIRO-SOAVI to protect the machine from the possibility of overpressure which might be producted inside the compression head as a consequence of the pumping action of the machine. CAUTION: The safety valve is used to protect the machine; piping downstream the machine can be protected only if a valve is fitted on the line.

ATTENTION: the valve protects only the pressurized chamber on which it is installed. It features the following advantages: • reduced maintenance • designed to "3-A" Standards, suitable for C.I.P. • it closes automatically in case the overpressure is released to allow the

immediate resuming of production • accurate calibration and repeatable actuation.

3C001E0C.DOC 3.7.1

Niro Soavi S.p.A 3.7.1.1 OPERATION

The valve consists of a ball maintained in place in its seat by a spring, which allows it to open when the calibration set point is exceeded. The spring loading should not be changed as this would modify the valve opening value and cause the immediate forfeiture of the safety conditions established by NIRO-SOAVI and the guarantee. Therefore a seal has been applied to the spring load adjustment nut. In the event the calibration setting is exceeded, the valve opens automatically and lets the product flow out of the discharge pipe; it closes again when pressure reduces below the opening value. This can be achieved by adjusting the pressure regulating device until the valve is closing, or reducing the pump speed in case of high pressure pumps. Once the valve has closed again, normal operating pressure can be re-established, provided the machine has not been damaged and the cause of overpressure has been addressed.

ATTENTION: The discharge pipe must ALWAYS be directed downwards to avoid harming the operator; the Customer shall be responsible to install a funnel to collect the outcoming product and carry it to the drainage system ATTENTION: Dispose of any waste fluids as prescribed by the laws in force locally. ATTENTION: the valve seat of the overpressure relief valve is damaged to some extent each time the valve blows. This will lower the pressure setpoint of the safety valve. Therefore it is necessary to replace seat and ball to recover the original setpoint conditions.

3C001E0C.DOC 3.7.2

Niro Soavi S.p.A 3.7.1.2 CLEANING

The part in contact with the product is normally cleaned during the machine washing (C.I.P.).

CAUTION: it is ALWAYS necessary to disassemble the valve from the compression head and clean it manually, especially the valve seat and the discharge pipe, after any overpressure relief valve discharge. For disassembling and maintenance, please refer to Section 4 - MAINTENANCE. CAUTION: Do not disassemble the valve body and do not remove the plastic cap. Changes to the safety valve setting are not allowed and shall invalidate the guarantee and affect protection of the machine, of its components and of the operators, unless a written authorization has been obtained from Niro Soavi.

3.7.2 PROTECTIONS ON MAIN MOTOR

If the machine is supplied by NIRO-SOAVI complete with electric power board, this includes the electric protections suitable for the main motor power and amps, type of starting device and conditions of operation. These protections consist of magnetic and thermal cutout switches, quick fuses or automatic switches for short-circuits, automatic switches or the frequency converter itself for protection against overheating. For the specific case see Section 1 – TECHNICAL SPECIFICATIONS.

3.7.3 EMERGENCY PUSH-BUTTON

On the front panel of the machine there is installed an emergency stop push-button (figure 3.5.1) of the colour prescribed by the safety standards in force. This device allows the operator to stop the machine immediately in case of hazardous situations for the personnel or the machine itself (abnormal operation, unusual noise, risk of failures). For the stop procedure and relevant notes see paragraph 3.5. In the event that the machine is supplied complete with the electric power board, the main switch can be used for emergency stops as well. WARNING: When positioning the machine and making the connections with the production line, allow enough space to reach the emergency stop push-button of the machine quickly and without obstacles.

3C001E0C.DOC 3.7.3

Niro Soavi S.p.A 3.7.4 COMPRESSION HEAD GUARD

The compression head is provided with an additional guard to protect the operator from any projection of machine parts, from high temperatures possibly reached by the head and from any injury caused by protruding, sharp parts. WARNING: The machine should not be used if the guard is not correctly secured in place.

3C001E0C.DOC 3.7.4

Niro Soavi S.p.A

3.8. TROUBLESHOOTING

This chapter lists the most frequent problems which are likely to be encountered during the machine operation, their possible causes and remedies in order to restore normal working conditions. If the failure persists, or does not appear among those listed below, our Service Department will be pleased to give you the advice and means required to achieve the best possible results.

TROUBLE

POSSIBLE CAUSE

REMEDY

1. The machine does not run

• main motor does not start

• check the electrical wiring, fuses, automatic switches

• the drive belts are

broken or loose • replace or tighten the

belts 2. There is no product flow

• no feed flow or pressure to the machine inlet

• feed properly the machine (see Section 1 – TECHNICAL SPECIFICATIONS)

• feeding piping clogged or closed

• clean properly the pipeline and filters

• bypass valve (if any) opened

• close the bypass valve

3. Reduced flow rate • not enough feeding • feed properly the machine

• not correct operation (wear) of suction / delivery valves

• clean or remove particles between valve and seat (see Section 4 - MAINTENANCE)

• verify the wear conditions of the seating surface of the valves and if needed replace

3C001E0C.DOC 3.8.1

Niro Soavi S.p.A

TROUBLE

POSSIBLE CAUSE

REMEDY

3. Reduced flow rate • slipping belts • provide correct belts tension (Section 4 - MAINTENANCE)

• low main motor speed • verify the correct motor speed (Section 1 – TECHNICAL SPECIFICATIONS)

• leakage on plunger packings

• replace (Section 4 - MAINTENANCE)

• air into the product • eliminate air • broken valve springs • replace (Section 4 -

MAINTENANCE) 4. Noisy compression head

• broken springs • replace (Section 4 - MAINTENANCE)

• not enough or too high feeding pressure

• feed properly the machine

• worn out pumping valves


• pumping valves not working properly

• verify the valve cleaning and wear

• air into the product • eliminate air 5. Noisy drive end • wear of bearings • check,

lubricate/grease and eventually replace the bearings

• loose plungers • tighten (Section 4 - MAINTENANCE)

• not enough feeding pressure


6. Noisy belt drive • slipping belts • provide correct belts tension (Section 4 - MAINTENANCE)

3C001E0C.DOC 3.8.2

Niro Soavi S.p.A

TROUBLE

POSSIBLE CAUSE

REMEDY

7.Vibrations of the machine

• the machine is not properly supported by all feet

• check the machine level adjusting the feet height


• feed properly the machine (see Section 1 – TECHNICAL SPECIFICATIONS)

• pulsations at suction and / or delivery

• install suitable pulsation damper (contact Niro Soavi)

8.No cooling water on plungers

• valve on water plant closed

• open

• water filter clogged • disassemble and clean

• no pressure in the water circuit

• check the required water supply conditions at Section 1 – TECHNICAL SPECIFICATIONS

9. Pulsating delivery pressure



• damaged or worn out pumping valves


• pump valves not suitable for the product

• Contact NIRO SOAVI

• valves springs not suitable for the product


• Unsteady backpressure

• Adjust the backpressure

3C001E0C.DOC 3.8.3

Niro Soavi S.p.A

TROUBLE

POSSIBLE CAUSE

REMEDY

10.Total lack of homogenizing pressure

• Not enough flow • See trouble point 3

• Damaged homogenizing valve

• Check, clean or replace (Section 4 - MAINTENANCE)

• No air pressure in pneumatic circuit

• Check the pneumatic circuit and the air supply (Section 4 - MAINTENANCE)

• Defective pneumatic actuator

• Replace

11.Homogenizing pressure not reached

• Not enough feeding pressure

• Feed properly the machine

• Blocked homogenizing valve

• Disassemble and clean (Section 4 – MAINTENANCE)

• Worn out homogenizing valve

• Replace (Section 4 – MAINTENANCE)

• Faulty pressure gauge • Replace (Section 4 – MAINTENANCE)

• Damaged homogenizing valve shaft

• Replace (Section 4 – MAINTENANCE)

3C001E0C.DOC 3.8.4

Niro Soavi S.p.A

TROUBLE

POSSIBLE CAUSE

REMEDY

12.Fluctuating homogenizing pressure

• Air or bubbles in the product

• Remove air or bubbles

• Air into the compression head

• Release pressure, then apply pressure again

• Not enough or unsteady feeding pressure

• Feed properly the machine

• Not correct operation of the pumping valves

• Check, clean or replace (Section 4 – MAINTENANCE)

• Not correct operation of the homogenizing valve dampening device

• Check the pneumatic plant and dampening device (Section 4 – MAINTENANCE)

• Pumping valves not suitable for the product


• Unsteady backpressure

• Adjust the backpressure

13.Noisy homogenizing valve

• Worn out homogenizing valve

• Replace (Section 4 - MAINTENANCE)

• No oil or air pressure

into the dampening device

• Check and restore correct operating conditions (Section 4 – MAINTENANCE)

• Resonance in the

plant • Modify the

backpressure; install pulsation damper dowstream; move away the existing damper; contact NIRO-SOAVI

3C001E0C.DOC 3.8.5

Niro Soavi S.p.A

TROUBLE

POSSIBLE CAUSE

REMEDY

14.Oil level drops quickly

• Leakage in the lubricating circuit

• Check the plant and look for leakage, replace gaskets, tighten joints, replace the oil cooler

15.White foam in the lubricating oil

• Water into the oil • Stop the machine for at least 1 hour and drain water from lowest point (Section 4 – MAINTENANCE)

• Water in the oil because of broken oil cooler

• Pressure check the oil cooler and replace

• Excess of water on the plungers

• Adjust the water flow to reduce splashing and sump flooding

16. Oil overheats and darkens

• Machine overload • Eliminate overload

• Faulty oil cooler or lack of cooling water

• Check the oil cooler and the water flow

• Worn out bearings • Contact NIRO SOAVI 17.No oil flow and pressure

• Wrong oil pump rotation

• Change the direction of rotation of the oil pump (Section 2 – GENARAL INFORMATION)

• Failure of the oil pump • Contact NIRO SOAVI

3C001E0C.DOC 3.8.6

Niro Soavi S.p.A

TROUBLE

POSSIBLE CAUSE

REMEDY

18.Not enough oil pressure and intervention of pressure switch

• Leakage on the lubricating circuit

• Check the oil circuit, replace gaskets and tighten joints

• Low oil level • Restore correct oil level

• Worn out sliding bearings or crankshaft


• Faulty pressure switch • Check the pressure switch and in case replace; contact NIRO SOAVI

• Leaking oil cooler • Check and replace; contact NIRO SOAVI

19. Main motor overload

• Too high homogenizing pressure

• Reduce to nominal value

• Wear on drive end • Check wear and contact NIRO SOAVI

• Too high belts tension • Check belts tension • Faulty main motor • Check main motor; in

case replace 20.Oil leakage in the water sump

• Leakage from crossheads seals

• Replace gaskets (Section 4 – MAINTENANCE)

• Scratched crosshead extensions

• Replace (contact NIRO SOAVI)

3C001E0C.DOC 3.8.7

Niro Soavi S.p.A

3.9. SPECIAL FEATURES OF NON STANDARD MACHINES

BLANK PAGE

Ricerca Guasti - 21.2

Niro Soavi S.p.A

SECTION 4

MAINTENANCE - INDEX 4.1. GENERAL INFORMATION 4.2. ORDINARY MAINTENANCE 4.3. TIGHENING BOLTS AND STUDS 4.4. COMPRESSION HEAD 4.5. HOMOGENIZING GROUP 4.6. OVERPRESSURE VALVE AND PRESSURE GAUGE 4.7. TRANSMISSION 4.8. POWER END - CRANKCASE 4.9. LUBRICATION 4.10. PNEUMATIC PLANT 4.11. ASEPTIC PLANT

4c00se0c.doc 4.0.1

Niro Soavi S.p.A

4.1. GENERALS

This Section contains the necessary information to maintain your machine in perfect operating conditions. The steps described are easy to follow and normally do not require the back-up of a qualified technician. However, NIRO-SOAVI Customer Service will be glad to provide the necessary supplements of information and means to reach the target quickly and effectively and to dispatch its technicians for on-the-spot assistance or as part of a Planned Maintenance Service; please contact us for further information. A careful reading and consulting of the Sections of this Manual are essential to execute a correct maintenance and ensure a good, lasting performance of the machine as well as compliance with safety regulations currently in force. CAUTION: For the personnel safety, any check and maintenance operation should be carried out with the MACHINE STOPPED and with the isolator switch LOCKED (with the appropriate padlock) in the OPEN POSITION.

CAUTION: The use, access to internal parts and maintenance of the machine should not be allowed to any personnel not acquainted with the indications of this Manual, which should be made available to as many operators as possible.

CAUTION: The only operations allowed are the ones described in this INSTRUCTION MANUAL; for extraordinary work on the machine please contact our Service Department.

4c010e0c.doc 4.1.1

Niro Soavi S.p.A

4.2. ORDINARY MAINTENANCE OPERATIONS

Here below are the tables showing the periodical maintenance required by the machine to operate efficiently and safely. Values shown refer to a normal use of the machine; heavy-duty conditions or particularly abrasive/aggressive products may reduce sensibly the life of some parts, which should therefore be checked more frequently. In case of machine malfunction or abnormal noise, we suggest you try to identify the components which seem to produce the noise and check whether they have been correctly assembled and tightened or whether they might be worn and in need of replacement. In particular, machines operatine on very high pressure (over 600 bar) require frequent servicing to replace gaskets, plunger seals, delivery valves, valve seats and springs, homogenizing valves, depending on the type of product used – see the Table of Periodical Maintenance for high pressure machines – in addition to regular checks. All the operations listed here below are described with detailed procedures in the following paragraphs. Execute carefully all the checks prescribed in these tables and note scrupulously the DATE, MACHINE HOURS, OPERATOR in the Tables for the checks to be performed every 1500 HOURS - 6 MONTHS and every 3000 HOURS - 12 NONTHS. In this way the machine will be maintained in the best conditions of running and safety, and a track will be kept of the maintenance operations actually completed. CAUTION: The Periodical Maintenance tables shown below refer to normal operating conditions and in any case provide merely an indication as to the average life of a component and not a guarantee of minimum component life.

Special conditions such as high operating pressure, high temperature, steam sterilization and frequent washing, incorrect operating procedures, can substantially affect the life of the machine and of its components and therefore the intervals suggested for maintenance of compression head components may vary significantly. As additional tool for ordinary maintenance of the machine, please refer to the form “CHECKLIST FOR MACHINE INSPECTION” at Section 5 – SPARE PARTS LIST.

4c010e0c.doc 4.2.1

Niro Soavi S.p.A PERIODICAL MAINTENANCE TABLE – GENERIC FOR ALL MACHINES When Action required Machine hrs After first start-up

• Check belt tensioning • replace lubrication oil • replace lubrication filter

200 500 500

Every day • check oil level and top up and if needed • visual check for leaks in seals and gaskets

Once a week - 40 hrs

• visual check of plunger gaskets • drain condensate from lubrication system • check tightening of nuts and plungers • check drive • check belt tensioning • check tightening of drive elements and

reducer support

When (hrs)

Action required Mach. hrs

Operator Date

1500 and every 1500 hrs

• change lubrication oil • clean/replace filters (lubrication

system, pneumatic system, water system)

• check drive belt wear, tensioning and if required replace

• check wear of plungers and if required replace

• check pressurization of pneumatic system and oil level

• check oil level in gear reducer

3000 and every 3000 hrs

• check / replace springs and pumping valves

• check / replace homogenizing valve

every 5000 hrs

• replace lubrication oil in gear reducer (mineral oil)

4c010e0c.doc 4.2.2

Niro Soavi S.p.A When (hrs)


Operator Date

4500 • change lubrication oil • clean/replace filters (lubrication





6000 • check / replace springs and pumping valves
















4c010e0c.doc 4.2.3

Niro Soavi S.p.A When (hrs)


Operator Date








PERIODICAL MAINTENANCE TABLE FOR HIGH-PRESSURE MACHINES (OVER 600 bar) When Action required Machine hrs Every 50 hrs • visual check for leaks in packings and

head gaskets • check tightening of nuts in all high-

pressure head elements

Every 100 hrs • check packings and head gaskets and if required replace

• check pumping valve seats and if required replace

• check ball valves and if required replace • check springs and if required replace • check homogenizing and if required

replace

Every 200 hrs • check oil-air operated system for vibration damping in homogenizing valve

• check cooling water piping, check water flow

• tighten nuts in high-pressure head using dynamometric wrench

4c010e0c.doc 4.2.4

Niro Soavi S.p.A ORDINARY MAINTENANCE LOG When (hrs)


Operator Date

4c010e0c.doc 4.2.5

Niro Soavi S.p.A

4.3. TIGHTENING NUTS AND STUDS

All the studs used in the compression head are subject to vibrating stress so, in addition to being made of special, highly resistant material with an accurate processing cycle, they require specific tightening in accordance with the values shown in Table 4.3.1. It is also necessary to frequently check screwn and nuts to make sure that they do not become loose. NIRO SOAVI supplies a Maintenance box with the wrenches needed for the nuts fitted on their machines; we suggest you use a dynamometric wrench (not included) to check tightening torques as specified in the table below.

STUD SIZE TIGHTENING TORQUE (N*m)

TIGHTENING TORQUE (lb.*ft.)

M 8 8 ÷10 6 ÷8

M 10 15 ÷ 20 11 ÷ 15

M 12 25 ÷ 30 19 ÷22

M 16 60 ÷ 70 44 ÷52

M 20 120 ÷ 140 89 ÷104

M 24 210 ÷ 230 155 ÷ 170

M24x2 235 ÷ 260 174 ÷ 192

M 27 310 ÷ 340 229 ÷251

M27x2 350 ÷ 390 258 ÷ 288

M 30 410 ÷ 450 304 ÷ 332

M 33 560 ÷ 600 413 ÷ 445 M33x2 635 ÷ 680 469 ÷ 502 M39 880 ÷ 960 650 ÷709

TABLE 4.3.1

4c010e0c.doc 4.3.1

Niro Soavi S.p.A ATTENTION: The head maintenance operations require disassembling the parts which are secured by studs and nuts. When tightening them, refer to the torque values shown in Table 4.3.1 to avoid imposing abnormal stress and undermining their strentgh. CAUTION: For safety reasons it is strictly forbidden to replace studs in the high-pressure head with non-original spare parts, which might not be able to stand the stress applied resulting in severe risk of injury!

4c010e0c.doc 4.3.2

Niro Soavi S.p.A

4.4. COMPRESSION HEAD (MULTI-BLOCK VHP)

ATTENTION: The compression head maintenance operations require to remove the head guard, unscrewing the side screws. The machine should not be used if the guard is not correctly secured in place. ATTENTION: The head maintenance operations require disassembling the parts which are secured by stud bolts and nuts. When tightening them, refer to the torque values shown in Table 4.3.1 to avoid imposing abnormal or excessive stress and undermining their strentgh. Before giving a description of maintenance operations, it is important to remember that couplings in high pressure seal areas are made with O-rings, made of plastic or elastomers, sometimes fitted with anti-extrusion rings, made with materials suitable for contact with the products handled and capable to withstand the temperatures reached by the machine. It is good practice to replace the gaskets not only when clearly leaking or when damaged, but also every time you are reassembling parts which are in contact with the gaskets. Gaskets should be greased with a food-grade lubricant and assembled with non-sharp tools which might damage them; in any case keep in mind that forced or incorrect assembling can affect the life and seal of gaskets. To identify and position gaskets correctly, refer to the drawings provided herein for the disassembling of compression head and its components and to the general drawings in Section 5 – SPARE PART CATALOGUE. These maintenance instructions refer in particular to very high pressure heads Multi-Block VHP, especially designed and constructed with highly resistant materials for safe and reliable performance under high-pressure operating conditions.. ATTENTION: the compression head type Multi-Block VHP is built using several parts connected together by studs and nuts. It is extremely important to follow the correct assembling procedure to avoid possibile misalignment of the parts with consequent not correct tightening of all the gaskets. During assembly proceed carefully with progressive tightening of ALL the nuts of the head one after the other and in cross, till the final tightening with torque wrench (not supplied).

4C042E0C.DOC 4.4.1

Niro Soavi S.p.A 4.4.1 PUMPING PLUNGERS

The plungers normally supplied for very high pressure heads (VHP) are made of solid ceramic. This gives them high surface hardness and excellent resistance to wear, for longer life of plunger gaskets. The ceramic material used is compatible with most of the washing methods normally used; if in doubt about the use of washing products contact Niro Soavi for information and suggestions. Ceramic plungers are sensitive to sudden temperature changes (thermal shock) which can result in breakage. You should therefore avoid sudden temperature changes above 70 °C, and check that lubrication water is always present to avoid local overheating of plungers which can both damage gaskets and break plungers. For this reason machines fitted with ceramic plungers are equipped with flow switch which triggers an alarm to halt the machine. CAUTION: if the machine is fitted with ceramic plungers, specific instructions must be followed to prevent breakage of the plungers due to thermal shock. More specifically you should bear in mind the following information:

• Thermal shock is due to rapid temperature change in the fluid which is in contact with the plunger, exceeding approximately 70 °C

• Make absolutely sure that the plungers are not operated without liquid even for a short period of time; the temperature generated on the surface of the plunger due to friction can result in the plunger breaking once the cooling water is opened

• Avoid changing quickly from a hot liquid to a cold liquid even inside the compression head, where the plunger moves alternatingly.

• The temperature of water must remain within the specified range (10÷+25 °C or +40÷+60 °C for aseptic machines). See Section 1 - TECHNICAL SPECIFICATIONS

• Temperature variation over time must be 70 °C in 15 minutes (about 5 °C per minute).

CAUTION: avoid to by-pass the alarm and machine stop if there is no water for plunger lubrication. If the electric board is not supplied by Niro Soavi, follow the steps given in the instructions to make the electric board with the required protection devices.

The flow switch does not exclude the possibility of plungers breaking. It is also absolutely necessary to assemble the plungers precisely as specified to avoid misalignment problems with consequent breakage of the plunger.

4C042E0C.DOC 4.4.2

Niro Soavi S.p.A

4C042E0C.DOC 4.4.3

CAUTION: it is important to periodically and regularly check tightness of both plunger and plunger extension, whether with threaded connector or clamp, to make sure that they will not loosen or disconnect during machine operation, with consequent breakage of the plungers or of other machine parts.

4.4.1.1 DISASSEMBLING

ATTENTION: Removing the plungers can result in damage to the gaskets (packings) : check their condition and if necessary replace them before assembling back the plungers and head (see paragraph 4.4.2). Before you begin with disassembly make sure all the necessary spare parts are available.

Ceramic pistons (figure 4.4.1) are fixed by a clamp (B): to remove them first unscrew the clamp’s retaining screws (A) and move the plunger away from the extension (C). To open the clamp it may help to insert one of the screws in the middle bore of the clamp to expand it. To pull the plunger away from the extension of the guide plunger you need to rotate the crankshaft; to do this open the right side panel and rotate the flywheel: follow the instructions and safety rules described in chapter 4.1 and 4.7.

FIGURE 4.4.1

Niro Soavi S.p.A In the VHP high-pressure head the plunger gaskets are housed inside removable flanges which can be accessed from the read of the head, inside the water sump. For complete disassembly instructions see paragraph 4.4.2. 4.4.1.2 ASSEMBLING

CAUTION: The ceramic plungers fixed by clamps do not have a specific direction for assembly, and can be mounted from either end. To assemble the plungers refer also to the specific instructions given in paragraph 4.4.2 describing packing assembly. Below we describe the procedure for fixing the plungers which complements the operations described above. Once the flange which contains the packing and the plunger has been fixed on the studs and on the special centering dowels, it is possible to fix each plunger to its guide plunger, using a clamp (item. B, figure 4.4.1) and correctly tightening the retaining screws. (tightening torque 7÷8 N*m). Take care not to bend the ceramic plungers as you risk breaking them. CAUTION: We recommend you move the plungers to the outer dead center (completely forward) by rotating the flywheel, while the guide plungers must be taken back to the inner dead center (completely back), in order to have more space for tightening the packing flanges.

CAUTION: Plungers must be mounted one by one, starting with the outer and leaving the middle one(s) last for easier access. Once all the nuts of the packing flanges have been tightened (see details in paragraph 4.4.2) proceed as follows (figure 4.4.1): • Insert the clamp (B) onto the end of the guide plunge extension (C) or on the

part of the plunger which protrudes from the packing flange • Move the guide plunger extension completely forward, by rotating the

flywheel manually, until the plunger is right against the extension (C) • Move the clamp into position, against the diameter enlargement of the

extension, then tighten the clamp with the screws (A), by applying a 7÷8 N*m tightening torque.

• Repeat this procedure for every plunger, starting with the outer ones.

4C042E0C.DOC 4.4.4

Niro Soavi S.p.A CAUTION: During assembly make sure that the plunger and clamp are fixed in the correct position, and that the various clamps do not interfere with one another during alternating plunger movements. We therefore suggest that you rotate the drive pulley by hand to verify that plunger movement is correct.

CAUTION: tighten the nuts DIAGONALLY, as shown in figure 4.4.2; apply the torque values given in table 4.3.1.

FIGURE 4.4.2

4C042E0C.DOC 4.4.5

Niro Soavi S.p.A

4.4.2 PLUNGER SEALS

The lifetime of these parts is dependent on the following factors: - Working pressure - conditions of plungers surface; - process temperature; - type of product; - machine underfeeding (not enough feeding pressure, see Section 1 –

TECHNICAL SPECIFICATIONS for reference); - worn out parts (washers, spacers) in contact with the seals. The life of gaskets, and in particular of plunger packings, is not covered by guarantee and cannot be estimated beforehand; we therefore suggest you calculate the average life of the packings in order to schedule preventive maintenance. To avoid situations where production has to be stopped due to missing plunger gaskets, we suggest you schedule preventive replacement on the basis of their expected mean life. In high-pressure machines, check and preventive replacement of packings should be carried out every 100÷200 hours. Replacement is necessary when you notice leaks from the sump; the production cycle can be allowed to go on if the leak is not too big. Plunger gaskets in high-pressure machines must be considered as one single seal system, in which all the components contribute to the life and efficiency of the gasket; we therefore recommend that you replace all the support and anti-extrusion rings during maintenance work, in order to increase the life of the sealing system. For the maintenace procedure and seals replacement it is necessari to disassemble the pumping plungers, therfore follow the specific directions of paragraph 4.4.1. CAUTION: Before you begin with maintenance and gasket replacement make sure all the necessary spare parts and tools are available.

4C042E0C.DOC 4.4.6

Niro Soavi S.p.A 4.4.2.1 DISASSEMBLING

Plunger gaskets are housed inside the flanges located in the rear part of the head, so disassembly must be carried out through the part of the sump behind the head. CAUTION: To carry out maintenance FIRST remove the packing of the middle plunger (for machines with 3 plungers; of the central plungers for machines with more than 3 plungers), THEN of the side plungers.

With reference to figure 4.4.3: • move the plunger all the way forward (outer dead center); • remove the plunger clamp (figure 4.4.1 item B) by loosening the screws

(figure 4.4.1 item A); if necessary insert one of the two screws in the middle bore of the clamp to loosen it;

• move the guide plunger all the way back (inner dead center); • disconnect water or sterile condensate pipe; • loosen the retaining nuts (N) of the packing flange (E) and remove it; • pull out the packing flange (F) together with the plunger, if necessary use a

lever on the flange (F); • remove the packing (H + R + M + L) and piston (G) from the flange (F).

4C042E0C.DOC 4.4.7

Niro Soavi S.p.A

FIGURE 4.4.3

FIGURE 4.4.3

4C042E0C.DOC 4.4.8

Niro Soavi S.p.A 4.4.2.2 ASSEMBLING

For assembly refer to figure 4.4.4, which shows how to assemble the elements which make up the plunger packing: • prepare the rings (H) which are supplied ready cut and preformed • insert the rings in the flange which contains the packing (F) as specified

below • insert the plastic ring (R) to the bottom of the flange • insert, one at a time, the rings (H) which make up the seal packing, taking

care to stagger the joints regularly (for exambple by 120°). If the packing is a standard type with multiple V rings or a single plastic piece, insert it all in one go.

• Insert the plunger to give the rings the required shape • Insert the double conic washer (M) as shown in the picture, making sure that

the direction of assembly is the one shown in the cross section • Insert the packing washer (L); in some cases this washer can be made up

by two separate washers (L1, L2) made with both plastic and metal material. • Lay the retaining flange (E) against the rear part of the flange which contains

the packing (F)

FIGURE 4.4.4

4C042E0C.DOC 4.4.9

Niro Soavi S.p.A • Install the o-ring (P – figure 4.4.3) or, where used, the antiextrusion (R) ring

on the front of the flange (F) • Insert the pre-assembled packing on the studs, check position against

centering dowels • Tightent the nuts diagonally (N) • Mount the plunger as described in paragraph 4.4.1

4.4.3 SUCTION AND DELIVERY VALVES

The good conditions of suction and delivery valves are essential for a trouble-free operation of the machine; an impaired seal of the valves would cause leakage and product backflow, resulting in pressure and flow instability. The valve assembly (figure 4.4.5) consists in a ball, a seat, a spring, a guide for the spring which acts as stop for the balls and a ball guiding element. In some versions the valve seat and guiding element can be made into a single element (figure 4.4.6). Seat and ball are made of special hard alloys, very resistant to wear; these however need to be replaced if they show signs of wear on the surface or if pressure becomes unstable or the machine’s flow is reduced. The spring tends to lose gradually the original elasticity and, for this reason, it should be replaced approximately every 1000 hours of operation, unless broken earlier generally because of the machine is not fed correctly. For the replacement procedure of the valve assembly see here below; follow the specific assembly drawings in Section 5 – SPARE PARTS CATALOGUE. 4.4.3.1 DISASSEMBLING

To remove the valve assemblies requires: • On suction: disconnection and disassembly of suction manifold, disassembly

of retaining flanges of valve assembly (if separate from manifold, item U on figure 4.4.3)

• On delivery: disassembly of delivery manifold (A, figure 4.4.3). Before you proceed with disassembly the homogenizing assembly must be removed together with any other head accessories (pressure gauge, safety valve)

4C042E0C.DOC 4.4.10

Niro Soavi S.p.A CAUTION: The components to be removed (suction manifold, flanges, delivery manifold) are heavy. You need to wear personal protection devices such as safety boots and gloves, and use suitable lifting gears. The weight of the components can be calculated by assuming a specific weight of approximately 8 kg/dm3. These operations require 2 people.

FIGURE 4.4.5

Once the manifolds have been removed, the valve assemblies for suction and delivery are the same, with the configuration shown in figure 4.4.5 or 4.4.6. Bear in mind that the seat (E) made of special wear-resistant material is forced into the seat housing (A) so in case of replacement it must be removed with the help of a press.

4C042E0C.DOC 4.4.11

Niro Soavi S.p.A

LH

A

PN

B

C

D

E

FIGURE 4.4.6 4.4.3.2 ASSEMBLING

To mount the valve assemblies refer to figures 4.4.5 and 4.4.6 (as an alternative). • Carefully place the o-rings (H + N + F) and the relative anti-extrusion rings (L

+ P + G) in the slots provided, if necessary use food-grade vaseline to hold them in position

• For delivery valve assemblies, position the seat housing (A), and the guide (M) where present, using the existing studs as guides

• For suction valve assemblies, the seat housing (A), and the guide (M) where present, must be placed on the bottom support flanges or on the suction manifold itself, if made as one single element (depending on machine model)

• Insert the inner components: ball (D), spring (C) and valve cap (B), making sure that the position of the spring is correct

• If necessary check that the ball (D) can be lifted, by pushing it from underneath

4C042E0C.DOC 4.4.12

Niro Soavi S.p.A • Position the delivery manifold, and tighten the nuts using the torque values

specified in table 4.3.1. When tightening proceed gradually through ALL the nuts and tighten them in circle with all the other parts of the head in place.

• Position the retaining flanges of the suction valve assemblies, or the complete suction manifold if made as one single elements (depending on machine model), and tighten all the nuts using the torque values specified in table 4.3.1

• Mount the suction manifold WARNING: when tightening the head nuts observe the tightening torques shown in chapter 4.3, Table 4.3.1; use a torque wrench (not provided). 4.4.4 VALVE SEATS

Valve seats (figure 4.4.5 e 4.4.6, item E) are of removable type; they are made from a particularly hard material to ensure wear resistance and longer lifetime. Possible light marking by pricks on seat surface does not affect the valve sealing and functionality. The lifetime of the seats is normally longer than the one of the valves, and depends on the characteristics of the product and on the working conditions of the machine. In case of particularly abrasive products, seats can be refurbished or replaced when necessary. To do this you need to remove the seats from their housing (figure 4.4.5 e 4.4.6, item A); a press may be needed both for disassembly and then for re-assembly. Once the seats have been installed, the operating pressure of the machine will block them into position, so it is important to increase pressure very gradually when the machine is first started-up after replacements. To aseemble and disassemble the valve groups follow the directions at paragraph 4.4.3. CAUTION: The tools used for removing the valve seats are NOT included in the maintenance box. Tightening of the head nuts must be made using the torque values indicated in chapter 4.3, Table 4.3.1.; use a torque wrench (not supplied).

4C042E0C.DOC 4.4.13

Niro Soavi S.p.A

4.5. HOMOGENIZING GROUP

4.5.1 HOMOGENIZING VALVE

The homogenizing valve consists of 3 parts (figure 4.5.1): - lower head or passage head (A) - impact head (B) - impact ring (C). The homogenizing effect occurs - at very high speed - during the passage between the exposed surfaces of the two heads, and is completed by the impact with the external ring. The high pressure fluid dynamic effects which take place inside the homogenizing valve are extremely complex; generally speaking it is possible to describe the micronization of the particles dispersed in the liquid phase as a resulting of combined turbulence, shear, local cavitation and high speed impact effects. These three parts, manufactured from very hard material, are normally subject to more or less wear, depending on the type of product handled; therefore, various effects resulting from wear or damage can be noticed on their surface: - radial grooves developing from the internal diameter (fig. 22.14-S1); - small craters next to the external diameter (fig. 22.14-S2); - large craters and wear next to the internal diameter (fig. 22.15-S3).

S2

C

A

S1

S3

B

B

C

A

S4

FIGURE 4.5.1

4c053e0c.doc 4.5.1

Niro Soavi S.p.A When the grooves reach the external diameter, the homogenizing efficiency collapses, therefore the component should be replaced either when the grooves cover nearly 3/4 of the useful surface or whenever a reduced homogenizing efficiency is noticed. In some cases, because of extreme wear of the parts, the homogenizing pressure cannot be achieved anymore, therefore the complete homogenizing valve must be replaced. Some local cavitation effects may sometimes create some craters or strong wear path on the valve surface, therefore it is necessary to proceed with replacement of the parts. As far as the impact ring (figure 4.5.1 pos. C), it has the dual function of completing the homogeneization by impact and protecting the body of the homogenizing assembly from erosion. Due to wear, a groove (S4) is produced on its internal surface, and good performance is undermined. We recommend replacing the ring when the groove is approximately 1 mm deep. CAUTION: the impact head and the passage head are manufactured from a material whose hardness is suitable to withstand the abrasive action of the product handled for a long time. Whenever wear signs appear that may jeopardize the homogenizing efficiency, working surfaces can be rectified to remove max 1 mm of material: this can be done either at NIRO-SOAVI or at properly equipped workshops.

ATTENTION: The above mentioned indications are related to normal conditions and are general guidelines for ordinary and preventive maintenance. It in necessari to mention that the wear of the components of the homogenizing valve is something absolutely NORMAL, and depends on the various phenomenons which take place inside the homogenizing valve. In case the wear of the valve is considered too fast, please contact NIRO SOAVI for advice and possible alternative solutions.

4c053e0c.doc 4.5.2

Niro Soavi S.p.A

4.5.2 HOMOGENIZING GROUP

Follow the below listed instructions for the ordinary maintenance of the pneumatic actuated homogenizing group. DISASSEMBLING Taking figure 4.5.2 as reference: − disconnect the line of the pneumatic-hydraulic control of the piston on the

front panel of the machine CAUTION: oil dripping may occur when disconnecting the pipes of the pneumatic-hydraulic system: provide a container to collect such oil and dispose as prescribed by the local regulations.

CAUTION: the homogenizing assembly block is quite heavy! For all handling operations use both hands to avoid any accident to the personnel, and use suitable personal safety protections.

− Loose the nuts (M) of the studs of the homogenizing group − Remove the pneumatic actuator group (L) and the supporting flange (N)

which are coupled through the screws (K) − pull out the guide (H) together with the shaft (S) on the impact head (G); if

needed you can lever on the slot provided − in case of excessive vibrations or noise produced by the valve, you need to

check the surface of the impact head shaft (S) and, if required, replace the guide bushings (J) made of self-lubricating plastic material

− Remove the homogenizing valve block (B) and put it on a suitable workbench

4c053e0c.doc 4.5.3

Niro Soavi S.p.A

FIGURA 4.5.2 − Disassemble from the bottom the valve group parts (see details in picture

4.5.3): passage head spacer (Y), passage head (V) and impact ring (U) − The above mentioned items are assembled into an housing (D) − Remove also all the Oring gaskets (Z, W, E, F) and the antiextrusion rings

(A, C) if installed − Remove the guide (T) of the impact head (G) and check its inner surface; if

wear marks are present or there is excessive play between the guide (T) and the impact head (G) it is necessary to replace it

4c053e0c.doc 4.5.4

Niro Soavi S.p.A ASSEMBLING CAUTION: the homogenizing assembly is normally subject to high pressure and temperature conditions which impose a considerable stress on the seal gaskets. To ensure a correct operation and avoid product leakage or product contamination, it is recommended to replace all gaskets every time that the homogenizing group is disassembled. CAUTION: to facilitate the gasket assembling, grease them with food-grade Vaseline or similar.

FIGURA 4.5.3 − Put the homogenizing valve chamber (B) on its side and insert the impact

head guide (T) − Put inside the impact head (G) and make sure this is not coming out of its

guide (T) − Assemble the impact ring (U) − Put the homogenizing valve chamber on the studs and push it towards the

compression head − Assemble the impact ring (U) and the passage head (V) inside the housing

(D), including the Orings (E, F), then put all the parts inside the valve chamber (B)

4c053e0c.doc 4.5.5

Niro Soavi S.p.A − Insert the spacer (Y) complete with Oring gaskets (Z, W) and antiextrusion

rings (C, A), if present − Slide the homogenizing chamber on the studs towards the compression

head, taking care of the Oring (Z) and of the antiextrusion ring (A) to avoid they can come out of position

Prepare for assembling the impact head shaft (S) and its guide (H) (figure

4.5.2): − Insert from the top the plastic bushings (J) inside the guide (H); this is usually

not required if the bushings are not removed from their location or are not damaged

− Place the gaskets (P) and (R) into their grooves − Put from the top the impact head shaft (S) into the guide (H) being careful not

to damage the gasket (P) − Check the smooth sliding of the impact head shaft (S) into the guide (H) Proceed with assembling of the homogenizing group: − Insert the assembly guide and impact head into the homogenizing chamber

(B), from the top − Assemble the flange (N) together with the pneumatic actuator (L) on the

homogenizing chamber (B) − Tighten completely the nuts (M) in cross − Connect the piping of the pneumatic control system The above indications are valid for both homogenizing valves, on machines supplied with second stage homogenizing valve (available as option).

4c053e0c.doc 4.5.6

Niro Soavi S.p.A 4.5.3 POSSIBLE CONFIGURATIONS FOR THE HOMOGENIZING VALVE

A characteristic of the homogenizing assembly is that homogenizing valves of different sizes can be installed in the same valve housing. In particular, with reference to figure 4.5.4, the impact head (G) is made as one single element with relative shaft. In this case the spacer (T) is no longer used as guide for the impact head. Maintenance procedures for disassembly and assembly of parts are the same: the only difference is that the impact head is mounted together with the guide (H) by inserting the shaft (G) from the bottom. It is important to always refer to the specific detail drawings in Section 5 – SPARE PARTS CATALOGUE.

FIGURE 4.5.4

4.5.4 PNEUMATIC ACTUATOR

The pneumatic control assembly - comprising a pneumatic actuator (L) - does not require any particular maintenance (fig. 4.5.2). In case of oil leak or difficulty to keep the homogenizing pressure not related to any other cause (see Section 3 – Chapter 3.8) it is possible to replace the gaskets of the pneumatic actuator. In order to replace the gaskets, it is necessary to ask for the necessary spare set to the Niro Soavi Spare Parts Dept. To remove the pneumatic actuator (L) it is necessary to remove the four screws used to fix the actuator itself on its supporting flange.

4c053e0c.doc 4.5.7

Niro Soavi S.p.A The pneumatic actuator cylinder, used to close the homogenizing valve and achieve homogenizing pressure, is connected in the bottom part to an hydraulic/pneumatic system for dampening pulsations. The presence of air in the bottom part of the pneumatic cylinder may cause incorrect operation of the dampening system resulting in abnormal noise level and vibrations of the homogenizing valve, particularly if the machine operates with two homogenizing stages. In this case you need to eliminate the air by pressing the pneumatic switch 3 or 4 times to apply and release pressure. Please follow the specific instructions listed at SECTION 4 – Charter 4.10 “Pneumatic Plant”.

4.5.5 ASEPTIC VERSION

The homogenizing assembly used in the aseptic version is the same as the one used in the sanitary version in terms of functional features; the only difference is that the impact head shaft is flushed with sterile condensate used as barrier fluid. The homogenizing chamber body has all the connections with the system for distributing sterile condensate, and the guide of the impact head shaft has outlets for the condensate with relative gaskets, as shown in figure 4.5.7. It is important to always refer to the specific detail drawings in SECTION 5 – Spare Parts Catalogue.

FIGURE 4.5.7

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Niro Soavi S.p.A

4.6. OVERPRESSURE VALVE AND PRESSURE GAUGE

4.6.1 OVERPRESSURE VALVE

The pressure relief valve (see SECTION 3 - Paragraph 3.7.1) is usually installed on the compression head or on the high-pressure delivery line to protect the machine and operators from accidental overpressure which can create risk of danger. Maintenance (figure 4.6.1) requires only checking and, if necessari, replacing the sealing gaskets (B) between head and seat (D) of the valve, of the anti-extrusion rings (A, C), of the ball (N) and of the valve seat (D). To disassemble the valve from its operating position slowly loosen the nuts (G) and pull out the complete valve (J) and the flange (F). Loosening of the nuts (G) involves gradually releasing the spring load until the ball pressing shaft reaches the elastic ring stop (L). Once the whole valve body has been removed, you can remove the ball (N) and then the seat (D); if necessary use an extractor for the extraction slot provided in the seat (D). After that remove the O-ring (B) and the anti-extrusion rings (A)and (C). Make sure you do not lose the ball (E), as the valve cannot work without it; we recommend you always keep a spare seat and ball in case you need to replace them. Valve maintenance does NOT require replacing the spring; to avoid sudden release of the spring’s preloading DO NOT remove the elastic ring (L).. Carefully clean the seat (B) from any product residues but take care not to damage the sealing area. If the sealing area between the seat (B) and the ball (N) is damaged or worn out, there can be product leaks and the valve can be triggered at a pressure value lower than the valve setting; we therefore recommend you replace the seat and, if required, the ball. Steps to be followed for disassembly:

- Insert anti-extrusion ring (A), gasket (B) and anti-extrusion ring (C) in their housing in the head; food-grade Vaseline or other suitable lubricants should be used for easier assembly

- Insert the seat (D) inside the housing in the head, complete with O-ring gasket (E)

- place the ball (N) in position making sure it will not fall down, and fit the complete valve body (J) with its flange (F) so that the middle shaft rests on the ball (N)

4c063e0c.doc 4.6.1

Niro Soavi S.p.A

- the flange (F) will normally be separate from the beat due to the spring preloading; to disassemble it you need to gradually loosen the nuts (G) on the studs (H) until the valve is fully locked

For futher information on operation of the overpressure valve see paragraph 3.7.1. WARNING: it is absolutely FORBIDDEN to modify the overpressure valve setpoint and break the seal, unless with written authorization by NIRO SOAVI.

In case of modification of the valve setpoint without authorization, the warranty on the machine is immediately void, and moreover this may cause ranger for the safety of the personnel using the machine, as the overpressure relief valve is a fundamental safety device for the machine accordino to the CE safety regulations.

CAUTION: It is absolutely FORBIDDEN to close the discharge pipe of the overpressure valve with a valve. The valve discharge must always be unobstructed and turned downwards.

4c063e0c.doc 4.6.2

Niro Soavi S.p.A

FIGURE 4.6.1

4c063e0c.doc 4.6.3

Niro Soavi S.p.A

4.6.2 PRESSURE GAUGE

The pressure gauge installed on the machine is a component of fundamental importance as it makes it possible to measure the machine’s operating pressure and thus keep its operation under control. With a faulty pressure gauge the required working pressure cannot be maintained, so we recommend you keep a spare pressure gauge in stock in case a replacement is needed. The type of pressure gauge installed can vary depending on the machine model or if optional configuretions are used. The standard pressure gauge is analog with Bourdon spring and sanitary baffle separator especially designed by NIRO SOAVI; it is also equipped with a separator used to filter the normal pulsations of the plunger machine to allow steady readings of operating pressure. Never separate the pressure gauge from its separator. Other versions of pressure gauges or pressure measuring devices are available as alternatives: • analog pressure gauge with signal transmitter: with 4÷20 mA output for

remote transmission of pressure signal • pressure transducer: this is a sensor which gives an electric signal to be

amplified in order to obtain a 4÷20 mA output of the pressure signal • digital pressure gauge with built-in display: this transducer has a display to

directly indicate the pressure value measured. Powered by internal battery. The pressure gauge normally requires no maintenance, however we recommend a periodical check to: • verify the condition of the diaphragm which comes into contact with the

product; if it is punctured or damaged the pressure gauge must be replaced • for analog pressure gauges, check the level of glicerine inside the dial; if

necessary fill the dial up to ¾ with 99.5% pure glicerine • replace the gasket between the pressure gauge and the head For instruments provided with electric equipment refer to the wiring diagram, which also indicates the setting range of the instrument.

4c063e0c.doc 4.6.4

Niro Soavi S.p.A Refer to figure 4.6.2: to disassemble the pressure gauge (or pressure gauge with transmitter, or pressure transducer) you need to loosen the nuts (G) and pull out the pressure gauge complete with flange (F). The pressure gauge (A) and flange (F) can be separated once the semi-rings (D) have been removed. Figure 4.6.3 shows the analog configuretion for disassembling the pressure transducer.

FIGURE 4.6.2 Steps to be followed for assembly (figure 4.6.2 or 4.6.3): - insert the gasket (E) on the pressure gauge rod (used only to protect from dirt) -insert the gasket (G) inside its housing in the flange or head; food-grade Vaseline or other suitable lubricants should be used for easier assembly

4c063e0c.doc 4.6.5

Niro Soavi S.p.A

- insert the anti-extrusion ring (C), if used, on the manometer; this ring is used in high-pressure versions from 600 bar upwards

- insert the flange (F) on the pressare gauge body (A) and fit the two semi-rings (D) to hold the flange in position

- insert the pressure gauge prepared in this way into its housing, and place the flange (F) on the studs (H)

- screw the nuts on (G) by hand before tightening them fully.

FIGURE 4.6.3

4c063e0c.doc 4.6.6

Niro Soavi S.p.A In high-pressure versions, equipped with transducer (T) or digital pressure gauge (M) (see figure 4.6.4), a threaded locking ring (D) is used.

FIGURE 4.6.4 For disassembly, unscrew the ring (D) and pull the instrument out; remove also the gasket (B) and anti-extrusion rings (A, C) from their housing. For assembly follow these steps (figure 4.6.4):

- fit anti-extrusion ring (C), gasket (B) and anti-extrusion ring (A) onto the end of the pressure gauge (M) or transducer (T); food-grade Vaseline or other suitable lubricants should be used for easier assembly

- fit the pressure gauge (M) or transducer (T) into its housing; with digital pressure gauges make sure you do not force the element using the head of the instrument to prevent breakages

- tighten the locking ring (D) fully

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Niro Soavi S.p.A

The digital pressure gauge (M) will switch off automatically after a few minutes if no pressure is measured, to preserve the internal battery. To start the pressure gauge simply press the front ZERO/ON push-button; keep this button pressed for a few seconds to reset the instrument to ZERO if the reading given is NEGATIVE. If the display reads “BATT” it means that the battery is down and needs to be replaced. Disassemble the pressure gauge and, on a dry surface, remove the rear screws to lift off the cover on the battery housing. The battery used is a long life 9V lithium battery, size PP3; in special circumstances a standard 9V alkaline battery may be used.

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Niro Soavi S.p.A

4.7. TRANSMISSION

The machine is equipped with a direct trapezoidal belt drive system which uses pulleys on the motor shaft and crankshaft. CAUTION: All inspection and maintenance operations must be carried out with the MACHINE NOT IN OPERATION; the power mains switch must be LOCKED IN THE ON POSITION (with a padlock) for the safety of personnel. The elements of the drive system usually require only a visual inspection, carried out with the machine not in operation, to check for possibile lubrication oil leaks and, more importantly, for loosening of nuts, bolts, belt tensioning components and reduction gear support parts. Excessive movement of drive components, due to loosening of locking elements caused by vibrations, can result in slack couplings and consequent breakage of elements during machine operation. CAUTION: It is important to regularly check tightening of nuts and bolts in the belt tensioning system and reduction gear support system. Abnormal vibrations due to incorrect machine operation or cavitation conditions can cause these components to loosen and damage the drive system. Instructions for maintenance of drive components are given below.

4c072e0c.doc 4.7.1

Niro Soavi S.p.A 4.7.1 INSTALLING THE BELTS

CAUTION: All inspection and maintenance operations must be carried out with the MACHINE NOT IN OPERATION; the power mains switch must be LOCKED IN THE ON POSITION (with a padlock) for the safety of personnel.

INSPECTION OF THE PULLEYS Worn pulleys significantly reduce the life of belts, which can touch the bottom of the groove causing slipping which provokes wear and superficial burning. If the sides of the groove are hollow, the contact between the sides of the belt and the pulley is not uniform, and the lower part of the pulley causes wear of the lower edge of the belt, causing it to break prematurely. Thus, it is necessary to check the state of wear of the pulleys and remove any rust, grease or oil that may be present.

ALIGNMENT CHECK Correct alignment is essential to ensure long-life of the drive belts. This operation must be carried out during assembly by skilled personnel: it is important to check alignment by placing a metal ruler on the 2 pulleys (fig.4.7.2).

FIGURE 4.7.2 If necessary alignment can be corrected by loosening the retaining bolts of the conic bush and slightly move the driven pulley (by a few mm.) to reach optimal position then lock the bushing.

4c072e0c.doc 4.7.2

Niro Soavi S.p.A SELECTION OF BELTS Use at the same time belts of the same make, of the same type and of the same lot, since there may be differences both in size and in performance. Moreover, it is essential not to use new belts with others that have already been used, because of a different extension, adjustment to the grooves of the pulleys, and differences in performance, which would considerably affect the duration of the drive train. In order to ensure correct operation and avoid premature breaking, the belts must be stored without any noticeable bends and must not be exposed to temperatures that are too high or too low, or to a high degree of humidity. ASSEMBLY OF THE BELTS On NIRO SOAVI machines equipped with direct V-belt drive the motor unit which carries the driving pulley is mounted on a mobile support. An adjustable tie rod makes it possible to change the distance between the driving pulley and the driven one to allow installation and tensioning of the driving belts. To ad just the position of the motor support plate, it is necessary to tighten or loose the tensioner with appropriate lever. For correct belts tensioning refer to paragraph 4.7.3. During installation belts must never be forced with a tool into the pulley’s grooves to avoid the risk of damaging both thus reducing the life of the drive. To make this operation easier simply reduce the distance between the pulleys. Fit the belts into the grooves and rotate the pulley to facilitate insertion and prevent damage.

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Niro Soavi S.p.A

FIGURE 4.7.3

4c072e0c.doc 4.7.4

Niro Soavi S.p.A 4.7.2 STRETCHING THE BELTS

WARNING: Control and servicing operations must be carried out WITH THE MACHINE NOT IN OPERATION and with the sectioning switch of the imput line LOCKED (by means of a lock) IN OPEN POSITION for the safety of the personnel.

WARNING: The V-belt transmission may create danger of crushing or entrapment. Use always the necessary fixed protections and in case remove them only after having checked the machine to be completely stopped in any moving part.

The ideal stretch is the lowest at which the belts do not slip under maximum load. During the first 24-48 hours of running-in, check the stretch frequently; remember that excessive stretch reduces the life of the belts and of the bearings that support the drive. Arrange for the stretch to be tightened as soon as any slipping occurs. Belt slipping can cause overheating and create hazard particularly if the machine is designed for operation in danger zones (explosion-proof version). The following are two methods to identify the correct degree of stretching of the belts; the first, which is easier, can be used when a new train of belts is installed, or after loosening them completely; the second allows stretch to be checked even during normal operations of servicing and control. The procedures of the operations are described in paragraph 4.7.1.

4c072e0c.doc 4.7.5

Niro Soavi S.p.A BELTS TENSIONING – FIRST METHOD Before stretching the belts assembled on the pulleys, trace two fine marks across the back of one belt and measure the distance between them; they should be as far from each other as possible but must remain on the straight-line of the belt. Stretch the belts gradually after having them rotate for approx. 1 minute in successive stages; at each stage, tighten the belts so that the distance between the two marks has a percentage increase as shown in table 4.7.4, considering the case of medium diameter pulleys.

Type of transmission Not constant Torque - one small size pulley - short shaft center distance

0,8%

- medium or big size pulleys - medium or big shaft center distance

1%

TABLE 4.7.4

BELTS TENSIONING – SECOND METHOD Measure the length of the free section "t" (figure 4.7.5) and apply to its half-point a force P perpendicular to the belt, that causes a deformation of 1.6 mm every 100 mm. of free length:

F=1,6 x T/100 (mm) The intensity of the force, in Newton, should be in the interval of values shown in table 4.7.6; it is measured by means of a special dynamometer which is not supplied. In order to calculate the peripheral speed value it is sufficient to use the formula:

V = 0.052 X n X d (m/s) where n is the number of revolutions per minute of the crankshaft, as indicated in SECTION 1 – TECHNICAL SPECIFICATIONS, and d is the diameter of the flywheel indicated in metres. It is important to remember that at the first stretching, the correct value is 1.3 times the maximum value shown in table 4.7.6, so as to compensate the natural extension and initial settling of the belts.

4c072e0c.doc 4.7.6

Niro Soavi S.p.A

FIGURE 4.7.5

Forza / Force P (Newton) Tipo / Type D (mm)

V = 0÷10 m/s V = 10÷20 m/s V = 20÷30 m/s

67÷95 12 – 18 10 – 16 8 - 14 SPZ

> 95 19 – 26 17 – 24 15 – 22

100÷140 22 – 32 18 – 26 15 – 22 SPA

> 141 33 – 48 27 – 40 23 – 34

160÷265 38 – 56 32 – 50 28 – 42 SPB

> 266 57 – 72 51 – 64 43 – 58

224÷355 72 – 102 60 – 90 50 – 80 SPC

> 356 103 – 132 91 – 120 81 - 110

TABLE 4.7.6

4c072e0c.doc 4.7.7

Niro Soavi S.p.A 4.7.3 MAINTENANCE OF BELTS

The belt drive is an efficient, reliable means for power transmission. The following are some simple instructions to ensure reliability and long life of the system. LOOK AND LISTEN This allows you to easily identify the defects to be corrected: - Visual check if any oil or grease is present on the belts, since this may cause premature deterioration; excess oil on the supports and bearings may cause the belts to be dirtied, while a lack may cause increased friction and subsequent burning of the belts due to overload. - Listening to the noise during transmission. If there is any screeching when the motor accelerates or during operation at full load, this means that there is insufficent stretch of the belts. Once the correct stretch has been restored, if the noise persists try to identify any overload in transmission (due to wear, seizure, insufficient lubrication...). The presence of a regular squeaking, similar to that of a bearing that is insufficiently lubricated, does not cause any damage to the transmission and may be caused by the presence of dirt. Do not try to eliminate this noise by oiling the belts. DIRT AND FOREIGN MATERIALS Dirt and dust may accelerate wear of the belts and pulleys and obstruct a good traction. It is necessary to regularly clean the drive system and prevent any foreign material from being trapped between the belts and pulleys. OVERLOADS Any overload shortens the life of the belts. Check that operation is taking place under the initial project conditions, and that no overloads occur due to wear or slipping and superficial burning. PROTECTIONS The drive should always be protected by a suitable guard, which not only protects the operators but also protects the parts from dust or dirt and contact with foreign objects which may cause serious damage to the system. BREAKING AND CRACKS Check the condition of the belts, and see if there are any cuts or cracks, that are a sign of excessive wear and the need to replace the part.

4c072e0c.doc 4.7.8

Niro Soavi S.p.A TENSIONING Check and maintain the correct stretch of the belts, to prevent irregular vibrations. EXPOSURE TO HEAT Check that the belts are not exposed to sources of heat; an exposure to temperatures greater than 60°C will shorten their life. WEAR Check the condition of the sides of the belt: an anomalous wear may cause slipping or excessive wear of the grooves of the pulleys.

4c072e0c.doc 4.7.9

Niro Soavi S.p.A 4.7.4 ASSEMBLING AND DISASSEMBLING PULLEYS

Drive pulleys are usually mounted both on the crankshaft drive end and on the motor shaft using a “Taper-Lock” conical bushings. With reference to figure 4.7.6, the procedure for disassembly is the following:

FIGURE 4.7.6 - loosen retaining screws A - use one of the screws in bore B to force the bush open - extract the bush and pulley from the shaft. Assembly procedure: - clean bush and shaft thoroughly - insert “Taper-Lock” bush into pulley - partially insert threaded screws into bores (A) - mount the pulley on the shaft - align the pulleys - tighten screws A fully If the motor pulley is not fitted with a “Taper-Lock” bushing, to install or remove the pulley use a suitable pulley extractor and threaded rod for mounting the shaft, using the threaded bore on the end of it.

4c072e0c.doc 4.7.10

Niro Soavi S.p.A

4.8. POWER END - CRANKCASE

The reciprocating linear motion of the plungers is created by an oversized and sturdy crank mechanism (crankshaft, connecting rod, crosshead). The system is illustrated in the general exploded view (figure 4.8.1) below.

FIGURE 4.8.1 The type of construction, the high-quality materials used and the careful assembly by highly-qualified personnel are a guarantee of excellent reliability and durability. Correct lubrication is fundamental for the life of the drive body and of its components, so it is absolutely necessary to comply with the instructions given in terms of recommended change frequency (Chapter 4.2), filter cleaning, level and type of lubricant used (Chpater 4.9). Under normal conditions the power end does not require servicing. Should you notice abnormal noise levels, irregular machine operation or low pressure of lubrication oil triggering the pressare switch, contact NIRO SOAVI’s Customer Service to request technical service.

4c081e0c.doc 4.8.1

Niro Soavi S.p.A Under normal working conditions and without specific faults, it is recommended to check the sleeve bearings (W) and crank pin bearings (S), the wrist pin (O) and its bearing on the conrod (R) at least every approx 10.000 hours of operation, and to check the roller bearings (B) of the crankshaft at least every 20.000 hours of operation. Such kind of maintenance requires skilled personnel, therefore it is recommended to contact NIRO SOAVI Customer Service for advice and support. The only ordinary maintenance operation required is replacement of guide plunger gaskets, in case of lubrication oil leaks inside the sump. If the surface of the crosshead extension is badly scratched, it is necessary to replace the complet guide pistons. Such kind of maintenance requires skilled personnel, therefore it is recommended to contact NIRO SOAVI Customer Service for advice and support.

CAUTION: All inspection and maintenance operations must be carried out with the MACHINE NOT IN OPERATION; the power mains switch must be LOCKED IN THE ON POSITION (with a padlock) for the safety of personnel.

WARNING: Lubricating oils are extremely harmful to environment and should be disposed of correctly in suitable disposable, in accordance with the local regulations, to avoid environment and water pollution.

4c081e0c.doc 4.8.2

Niro Soavi S.p.A 4.8.1 REPLACING GUIDE PLUNGER GASKETS

Before removing the flanges you need to drain out, at least partially, the oil inside the body to prevent accidental spillage. Refer to figure 4.8.2 for the assembly and disassembly procedures described below.

FIGURA 4.8.2 DISASSEMBLY − remove the plunger following the procedure described in Charter 4.4 − loosen the screws (K) and extract the flange (M) from the guide plunger (Q) − remove the scraping ring (L) and the seal gasket (J) ASSEMBLY − fit the scraping ring (L) and gasket (J) inside the flange (M), in the seat. − check and clean the plunger stem, if the surface is badly scored or the chrome

plate damages the whole plunger must be replaced. The guide plunger stem cannot be supplied separately as spare part

− insert the complete O-Ring flange (H) onto the guide plunger (Q) as far as the edge. During assembly take care not to damage the sealing lip of the gaskets; use lubrication grease for easier assembly

- tighten the screws (K).

4c081e0c.doc 4.8.3

Niro Soavi S.p.A In some models a rubber bellows is installed to protect the guide plunger stem. In this case the bellows must be removed to replace the gaskets, and then inserted onto the guide plunger stem (Q) and snapped on locked against the flange (M) in the seat provided.

4c081e0c.doc 4.8.4

Niro Soavi S.p.A

4.9. LUBRICATION

Proper machine lubrication is required to guarantee its correct operation. For this reason it is absolutely necessari to follow directions for oil change intervals (see Charter 4.2), the cleaning or replacement of filters, check of oil level and use of specified lubricating oil. The lubrication system can be either FORCED or SPLASH, depending on the machine model; see Section 1 – TECHNICAL SPECIFICATIONS to find out type of lubrication used. For topping-up and replacement use ONLY the oils shown in Table 4.9.1; table 4.9.2 indicates the capacity of the lubrication system for the various models. CAUTION: The lubrication oil is suitable for operating temperatures ranging from 5°C and +40°C: please contanct NIRO-SOAVI Customer Service to obtain the type of lubricant suitable for any specific conditions found locally.

CAUTION: Used oils are extremely harmful to environment and should be disposed of correctly, in accordance with the local regulations. CAUTION: All inspection and maintenance operations must be carried out with the MACHINE NOT IN OPERATION; the power mains switch must be LOCKED IN THE ON POSITION (with a padlock) for the safety of personnel.

It is important to periodically ensure there is no foam in the oil as this is a sign that air is being incorporated due to cavitation in the oil pump or to bad sealing of the lubrication circuit. You also need to check for a whitish water/oil emulsion which is caused by inefficient drainage of condensate or water infiltrations inside the body (faulty water/oil exchanger or worn guide plunger gaskets).

4c092e0c.doc 4.9.1

Niro Soavi S.p.A Any type of oil used should have the following specifications: Suitable for hydraulic circuits, of mineral origin, viscosity ISO VG 150 (150 cSt at 40°C) with non-foaming, antioxidative additives, etc.

Class: ISO VG 150 DIN 51524-2-HLP

BRAND TYPE BRAND TYPE

Agip Oso 150 Texaco Rando oil HP 150

IP Hydrus Oil 150 Gulf Harmony 150 AW

BP Energol HLP-HM

150

Amoco American

industrial oil 150

Mobil DTE 19M Total Azolla ZS 150

Mobil DTE Extra Heavy Fina Hyidran 150

Chevron EP Hydr. oil 150 Api Cis 150

Castrol Hyspin AWS 150 Kuwait Petr. Int. Q8 haidn 150

Esso/Exxon Nuto H 150 ELF Olna DS 150

Shell Omala 150 ARAL Motanol HP150

TABLE 4.9.1

MODEL OIL VOLUME (liters)

WITH OIL PUMP

OIL VOLUME (liters)

SPLASH SYSTEM NS 1003 1,2 NS 2006 3,0 1,5 NS 3006 4,5 3,0 NS 3011 8,5 6,0 NS 3015 20 NS 3018 20 NS 4022 24 NS 3037 28 NS 3075 30 NS 3110 38 NS 5132 55 NS 5160 55 NS 6200 125 NS 8315 150

TABLE 4.9.2

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Niro Soavi S.p.A

4.9.1 SPLASH LUBRICATION

Splash-type lubrication is used to lubricate the moving parts by effect of their own movement inside the oil which is contained into the crankcase. In specific the parts subject to splash lubrication are: - Conrod bearings - Sleeve bearings (if present) - Guiding piston (crosshead) - Wrist pin and related bearing - Roller bearings supporting the crankshaft ends Splashing of oil due to moving parts allows to lubricate the various points for which lubrication is required to avoid seizing or damage. Splash lubrication is very simple because there are no mechanical parts to be checked, but is always required to verify the oil level carefully to keep its efficiency. This system is not suitable for machines arranged for variable speed operation, as at low speed slash lubrication cannot allow the sufficient lubricating effect on moving parts in slow motion. The machine is not provided with oil pressure gauge as there is no oil pressure circuit with splash lubrication.

4c092e0c.doc 4.9.3

Niro Soavi S.p.A OIL LEVEL CHECK The oil level needs to be checked every day, before the machine is started; the oil should reach the mid level indicated on the sightglass located or inside the machine on the crankcase or on the machine front panel. The oil level must be checked with the machine stopped for at least 1 hour. See for reference figure 4.9.3.

FIGURE 4.9.3 It is normal at the start of the machine to observe a lowering of the oil level on the sightglass. If oil drops below the required level top it up through the orange filler located inside the machine on the crankcase lid. To reach the fill you need to remove the side panel of the machine.

4c092e0c.doc 4.9.4

Niro Soavi S.p.A OIL CHANGE The frequency of oil change intervals is given in the "Tables for Regular Servicing" at Chapter 4.2. Use only oil as specified in Table 4.9.1. To change the oil (see figure 4.9.1): - prepare a reservoir to collect the oil, and of a size that is suitable to contain

the amount of oil found in the machine according to table 4.9.2; - open the filling tap on the crankase cover - open the bottom drain plug and let the oil drain out. - once the oil has drained out completely, close the bottom plug and pour in

the new oil through the filler plug - check the oil level through the sightglass. CAUTION: Used oils are extremely harmful to environment and should be disposed of correctly, in accordance with the local regulations.

VAPOUR CONDENSATE DISCHARGE Inside the crankase it is possible to have condensation of vapours depending on the characteristics of the ambient where the machine is working in, therefore it is necessary to remove regularly the condensate to avoid any mixing with lubricating oil. The frequency of the discharge depends on the amount of condensate formed in the drive unit (which depends on the working temperature, relative humidity, frequency of starting and stopping the system); however, refer to the "Tables for Regular Servicing", chapter 4.2. The condensate drain can be done when the machine is stopped for at least 4 hours. To drain the condensate: - Prepare a basin for collection and open the bottom drain valve - Water is heavier than oil, therefore it is collected at the bottom of the oil

tank; once the oil starts to pour out, close again the drain valve - Check the oil level again and, if necessary, top it up through the filler plug Presence of water into the oil may be caused by cooling water entering trough the crosshead seals; it is recommended to check the surface of crosshead extensions for scratches, and to replace the crosshead seals in case of oil leakage or oil into the water, according to what is mentioned in paragraph 4.8.1.

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Niro Soavi S.p.A

4.10. PNEUMATIC PLANT

Machines provided with pneumatic control system of the homogenizing pressure are supplied with specific hydraulic dampening system of the homogenizing valve. The force required to close the homogenizing valve and consequently achieve the homogenizing pressure is applied through a pneumatic actuator using compressed air on its upper part; the lower part of the actuator is connected with the pressurized oil dampening system. The dampening system is not installed on the machine when the pneumatic valve installed is type NanoValve®. The pneumatic actuator does not requie any periodical maintenance but it is recommended to protect it from extreme temperatures (which may damage the gaskets) and corrosive fluids, as its body is made with Aluminium alloys and not in stainless steel. In case the pneumatic actuator is not working properly we recommed its replacement; it’s anyway available upon request to Niro Soavi Spare Parts Dept. the complete gaskets spare kit. The pneumatic plant can be configured in various versions, according to the options installed; on figure 4.10.1 it is shown a basic version for single stage homogenizer with manual pneumatic adjustment of the homogenizing pressure installed on the machine front panel. The scheme of the plant actually installed on the machine is given in Section 5 – SPARE PARTS CATALOG with components list; you can also check the Flow-sheet (P&ID) given in Section 1 – TECHNICAL SPECIFICATIONS.

4c101e0c.doc 4.10.1

Niro Soavi S.p.A

FIGURE 4.10.1 The components present on the circuit accordino to the scheme presented in figure 4.10.1 are: - Inlet air pre-treatment unit (A) with pressure gauge (B) - One pneumatic switch (C) (or as option a solenoid valve) to give pressure to

the actuator (G) - One manual pressure regulator (D) (or as option a proportional valve for

remote controls - Throttle valves (E, H) to achieve a stable operation of the pneumatic system

and to adjust the speed of the raise of the homogenizing pressure by throttling the oil backflow

- A pressure gauge (F) installed on the machine front panel, indicating the pressure effectively supplied to the pneumatic actuator

- A damper tank (K) for oil and pressurized air The effect of dampening of the vibrations induced on the homogenizing valve by the normal reciprocating movement of the plungers is granted by a suitable air/oil damper vessel (K) which is connected to the lower part of the pneumatic actuator of the homogenizing group. This damper tank is preloaded with compressed air, pressure 0,5 bar. The gauge (L) allows to check the pressure in the tank, and ina case of need it is possibile to use the quick connection (M) to restore the correct pressure inside the tank. If the pneumatic dampening system is checked on a regular basis for correct preload pressure and oil level, it is possible to avoid problems of valve

4c101e0c.doc 4.10.2

Niro Soavi S.p.A vibrations and resonance, which may cause reduction of homogenizing efficiency and can be dangerous for the machine itself. Ordinary maintenance operations are listed below: - Check regularly the oil level inside the damper tank through the sightglass - Check regularly into the damper tank the correct pressure value: must be

0,5 bar with machine stopped - In case refilling of oil is required, close the valve (J) and open slowly the

upper filling plug (there is pressure inside); once the pressure is gone, fill the necessary oil quantity. The pscifications of the suitable oil are listed on table 4.10.2

WARNING: the damper tank containing oil is under pressare; open carefuly and slowly to allow air pressare go down and avoid danger for personnel.

- Close the upper plug and connect a compressed air source to the quick

connection (M) to restore the pressure of 0,5 bar inside the damper tank - Open the valve (J) and check if the air pressure is still at the set value of 0,5

bar Pressure inside the camper tank cannot be higher than 0,6 bar when the machine is stopped. Oil into this circuit does not requie any ch’ange but only refilling in case the level is low. If during the above mentioned procedures of filling up, or during the homogenizing valve maintenance some air bubbles are present into the plastic pipes, it is possible toeliminate the same by application and release of the pressure to the actuator through the pneumatic switch (C), with machine stopped and with the manual pressure regulato set to allow some air to go through (not at zero). The presence of air bubbles, anyway, cannot prevent the system to work properly, even if the dampening effect may be sometimes reduced. The adjustment of the throttle valve (E, H) allows to regulate the speed of the homogenizing pressare raise. Usually the setting of this valve is made during the machine test, in order to avoid a sudden raise of the homogenizing pressure which may cause the opening of the overpressure relief valve. Before making any modification to the setting, please tae note of the original setting on the scale in order to recover the original setpoint in case of need. As general information the closing of the valve (H) is slowing down the pressure raise, its opening is making it faster.

4c101e0c.doc 4.10.3

Niro Soavi S.p.A

4c101e0c.doc 4.10.4

CAUTION: Used oils are extremely harmful to environment and should be disposed of correctly, in accordance with the local regulations.

Class: ISO VG 32 DIN 51524-2-HLP

BRAND TYPE BRAND TYPE

Agip

Oso 32 Texaco Rando oil HP 32

IP

Hydrus Oil 32 Gulf Harmony 32 AW

Shell Tellus V 32 Amoco American industrial oil 32

Mobil DTE 24 Total Azolla ZS 32

BP Energol HLP 32 Fina Hyidran 32

Chevron EP Hydr. oil 32 Api CIS 32

Castrol Hyspin AWS 32 Kuwait Petr. Int.

Q8 haidn 32

Esso/Exxon Nuto H 32 ELF Olna DS 32

TABLE 4.10.2

4.10.1 PNEUMATIC PLANT WITH LOCAL MANUAL ADJUSTMENT

The pneumatic plant for local and manual pressure adjustment allows to adjust the homogenizing pressure from the machine front panel through a pneumatic regulator and pneumatic switch. No maintenance is required on these components, and in case of evident malfunctioning replacement of faulty parts is recommended.

Niro Soavi S.p.A 4.10.2 PNEUMATIC PLANT WITH REMOTE PRESSURE ADJUSTMENT

The pneumatic plant with remote pressure adjustment is using a proportional valve (or I/P converter) to ad just the homogenizing pressare. This proportional valve requires a suitable ramp signal on a 4÷20 mA scale; the signal must be isolated and amplified, with electrical connection to the proportional valve accordino to the following diagram shown in figure 4.10.3.

FIGURE 4.10.3 It is anyway always recommended to follow the indications in the specific wiring diagram supplied in the manual, which is showing also the numbering of terminals on the terminal board for proper connection. In case of malfunctioning of the system, it is possible to follow the below listed indications: - Wrong connection: make sure the wiring is made according to the supplied

diagram - Not enough air pressure supply (required minimum 7,5 bar air pressure) - Moisture or oil into the supplied air, which is necessary to eliminate - Not enough power in the signal coming from valve pilot source (especially if

directly connected to a PLC output): it is necessary to install a suitable signal amplifier

4c101e0c.doc 4.10.5

Niro Soavi S.p.A The proportional valve is tested and calibrated durino the machine test run. The setting is related to the range of pneumatic signal output related to the electrical signal input; in case of need it is possible to modify the factory settings by adjusting the “ZERO” and “SPAN” screws located on the proportional valve body under a protection cover (see figure 4.10.4). The proportional valve is installed inside the machine cabinet, on left hand side, and it is possible to access to it by removing the left side panel of the machine. Usually it is not required to have any maintenance on these components, and in case of faulty operation their replacement is recommended.

FIGURE 4.10.4

4c101e0c.doc 4.10.6

Niro Soavi S.p.A

4.11. ASEPTIC PLANT

The machine, being supplied in SANITARY execution is NOT equipped with aseptic plant.

4c112e0c.doc 4.11.1

Niro Soavi S.p.A

SECTION 5

SPARE PARTS CATALOGUE - INDEX

5.1. HOW TO USE THE SPARE PARTS CATALOGUE

5.2. HOW TO ORDER SPARE PARTS

5.3. RECOMMENDED SPARE PARTS

5.4. MAINTENANCE BOX

5.5. SPARE PARTS LISTS AND ASSEMBLY DRAWINGS

5C001E0C.DOC 5.1.0

Niro Soavi S.p.A

5.1. HOW TO USE THE SPARE PARTS CATALOGUE

To ensure that effective operation and quality characteristics are maintained only original spare parts must be used on NIRO SOAVI machines. The use of non original spare parts shall instantly invalidate the guarantee. This catalogue has information on how to order spare parts, selecting the parts in the attached tables and their code number in the relative tables.

5C001E0C.DOC 5.1.1

Niro Soavi S.p.A

5.2. HOW TO ORDER SPARE PARTS

Spare parts can be ordered directly from NIRO SOAVI, Service Department, or through your local NIRO SOAVI agent or Authorized Dealer, who can provide useful advice and forward your request immediately. When placing an order please specify: • SERIAL NUMBER of the machine • spare part code number • if necessary, a brief description of the component for easier identification • if applicable, the item number on the assembly drawing in the SPARE

PARTS CATALOGUE • the means of transport or dispatch requested; if this is not specified NIRO

SOAVI will arrange suitable transport at their discretion • whether urgent, as this may affect cost • exact address and name of contact person To order spare parts or request quotations for spare parts, copy the standard form below and send it by fax.

5C001E0C.DOC 5.2.1

Niro Soavi S.p.A

NIRO SOAVI ORIGINAL SPARE PARTS INQUIRY FORM

To:

Fax No.

From:

Name:

Reply Fax No.

e-mail:

Model:

Serial No.

! URGENT ! QUOTATION ! ORDER No.

Part CODE Qty Description

Shipping Specs.

5C001E0C.DOC 5.2.2

Niro Soavi S.p.A

5.3. RECOMMENDED SPARE PARTS

. In order to limit the number of shutdowns during production, and the time required for maintenance of the machine, we recommend you stock a set of spare parts to replace elements which are normally subject to wear. The number of spare parts to be stocked will depend on production needs and on how important it is to avoid long shutdowns due to unavailable spare parts. In specific, in case of homogenizing valves, the replacement at due time allows to keep the homogenizing efficiency and consequently the quality of the processed product. NIRO SOAVI cannot guarantee that a given spare part will be in stock either at their central warehouse or at the Dealer’s due to problems with material availability or to special requirements for dispatch. Please note that shipment is no guarantee of successful delivery and that delays may occurr due to customs problems or miscarriage. In any case NIRO SOAVI shall not be responsible for delays occurring due to the shipment of spare parts. The following is a list of spare parts which, in our experience, is important to have in stock: • a complete set of gaskets, two sets in case of VHP high-pressure

compression blocks • two sets of packings, including packing washers and anti-extrusion rings • one or two plungers, if ceramic plungers are used • a homogenizing valve set for each stage (for homogenizers) • a set of balls and valve seats, for VHP high-pressure heads • a set of seats and pumping valves, if the machine is used with abrasive

products • a set of pumping valve springs • a pressure gauge for the compression block • seat and ball for overpressure relief valve • oil filters • a set of guide plunger gaskets • crankshaft oil guard In addition to the ordinary maintenance operations described in Section 4 - MAINTENANCE, below you will find a table with checklist for machine inspection that you can use to check which spare parts are needed before performing ordinary maintenance on the machine.

5C001E0C.DOC 5.3.1

Niro Soavi S.p.A

5C001E0C.DOC 5.3.2

NIRO SOAVI - CHECKLIST FOR MACHINE INSPECTION

Machine Type : Serial Number :

Working Hours : Date :

Checke

d Replace

d Checke

d Replace

d 1 Compression head 34 Transmission 2 Suction Valves 35 Main motor 3 Suction Springs 36 Auxiliary motors 4 Suction valve seats 37 Gear box 5 Delivery Valves 38 Gear box tightening kit 6 Delivery Springs 39 Gear box oil level 7 Delivery valve seats 40 Belts 8 Gaskets 41 Pulley 9 Plungers 42 Water plant 10 Plunger Packings 43 Water filter

11 Overpressure cleaning/seat 44 Water solenoid valve

12 Homogenizing group 45 Water drain check 13 Passage head 1°st 46 14 Impact ring 1°st 47 Lubrication plant 15 Impact head 1°st 48 Lubrication unit 16 Gaskets 1°st 49 Pump driven by crankshaft 17 Passage head 2°st 50 Heat exchanger (oil/water) 18 Impact ring 2°st 51 Suction oil filter 19 Impact head 2°st 52 Delivery oil filter 20 Gaskets 2°st 53 Condensate discharge 21 54 Gaskets 22 55 Oil level 23 56 Oil piping check 24 Transmission body 58 Dampening system check

25 Crankshaft 59Air filter/Pressure regulator

26 Conrods 60 Accessories 27 Guide pistons 61 Tightening of the nuts 28 Conrod bronze bearings 62 Tightening of plungers 29 Main bronze bearings 63 Pressure gauges 30 Pins 64 Aseptic plant 31 Bearings 65 Steam heat exchanger 32 Gaskets 66 Steam valve 33 Oil splash guards 67 Aseptic chambers gaskets

Notes:

Niro Soavi S.p.A

5C001E0C.DOC 5.3.3

Niro Soavi S.p.A

5.4. MAINTENANCE BOX

The machine is supplied complete with a set of spanners and tools to be used during ordinary maintenance; they include special tools for installing or removing plungers and packings, where required. The set of spanners DOES NOT INCLUDE a Torque Wrench, which is recommended for correct tightening of nuts and studs to the torque values given in Section 4 - MAINTENANCE. The maintenance box includes a basic set of spare gaskets. Please find attached a list of the tools supplied for ordinary maintenance.

5C001E0C.DOC 5.4.1

Niro Soavi S.p.A.Item Description Description Qty Part Code- CHIAVE COMB 24X24 MIXED WRENCH 24X24 1 810224- CHIAVE COMB 30X30 MIXED WRENCH 30X30 1 810230- CHIAVE COMB 19X19 MIXED WRENCH 19X19 1 810219- CHIAVE ESAGONALE AD " L " 8 EXAGONAL KEY " L " 8 1 810308- GIRAVITE A CROCE 8X150 SCREWDRIVER 8X150 1 810010- CHIAVE UNIFAST UNIFAST KEY 1 350229- FONDELLO PIEDE FOOT BASE 4 350457- MOLLA SPRING 6 0124804-1- RONDELLA WASHER 6 0133563- PACCHETTO PACKING 3 150101CX- ORING ORING 18 140205PU- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 18 0130254- ORING ORING 1 140027PU- ORING ORING 1 140022PU- ORING ORING 1 140030PU- ORING ORING 1 140035PU- ORING ORING 1 140026PU- ORING ORING 1 140330PU- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130176- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130982- ORING ORING 1 140013PU- ORING ORING 3 140030PU- ORING ORING 1 130031S- ORING ORING 1 130027PU- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0127432- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130175- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0124748- ORING ORING 1 140022PU- ORING ORING 1 140205PU- GUARNIZIONE GASKET 2 140358- GUARNIZIONE GASKET 1 140353

TOOLS_4537 .xls 1/1

Niro Soavi S.p.A

5.5. SPARE PARTS LIST AND ASSEMBLY DRAWINGS

You will find attached assembly drawings and a list of components and spare parts. The first code of each spare parts list indicates the assembly drawing which the components refer to.

5C001E0C.DOC 5.5.1

Item Description Description Qty Part Code\ ASS. TESTATA DI COMPRESSIONE COMPRESSION HEAD ASS. DRW. 1 0130237-22 PIASTRA PLATE 1 0131376-103 PACCHETTO PACKING 3 150101CX4 RONDELLA WASHER 6 01335635 FLANGIA FLANGE 3 0129632-96 PRIGIONIERO STUD 12 01229267 DADO NUT 12 7600068 PRIGIONIERO STUD 4 01310639 DADO NUT 4 76000610 PRIGIONIERO STUD 8 013085211 DADO NUT 8 76000812 TESTATA COMPRESSION HEAD 1 013328813 ORING ORING 3 140205PU14 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 3 013025415 GRUPPO VALVOLA VALVE GROUP 3 DRW.2911216 GRUPPO VALVOLA VALVE GROUP 3 DRW.2911217 PRIGIONIERO STUD 8 013106718 DADO NUT 8 76000819 PRIGIONIERO STUD 8 013106820 DADO NUT 8 76000821 ASSIEME ASSEMBLY DRAWING 3 0201BKB722 COLLETTORE MANIFOLD 1 0133689-223 COLLETTORE MANIFOLD 1 0133283-2

SPARES_4537 .xls COMPRESSION HEAD

Item Description Description Qty Part Code1 ASSIEME GRUPPO VALVOLA VALVE GROUP ASS. DRW. 3+3 01302702 SEDE VALVOLA VALVE SEAT 3+3 01230593 SFERA BALL 3+3 1900624 MOLLA SPRING 3+3 0124804-15 COPERCHIO VALVOLA VALVE COVER 3+3 0130241-26 ORING ORING 3+3 140205PU7 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 3+3 01302548 CONTENTITORE SEDE VALVOLA VALVE SEAT HOUSING 3+3 0131064-29 ORING ORING 3+3 140205PU10 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 3+3 0130254

SPARES_4537 .xls VALVE GROUP

Item Description Description Qty Part Code1 ASS. GRUPPO PISTONE PLUNGER GROUP ASS. DRW. 3 01266642 PISTONE PLUNGER 3 0124559-0023 ANELLO RING 3 01268864 ANELLO RING 3 01268875 GHIERA NUT 3 0125397-16 ORING ORING 3 140008

SPARES_4537 .xls PLUNGER GROUP

Item Description Description Qty Part Code1 ASS. GRUPPO OMOGENEIZZANTE HOMOGENEIZING GROUP 1 01323382 CAMERA OMOGENEIZZANTE HOMOGENEIZING CHAMBER 1 0132320-23 ANELLO RING 1 0132321-24 ORING ORING 1 140027PU5 ORING ORING 1 140022PU6 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 01301767 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 01309828 TESTINA DI PASSAGGIO PASSAGE HEAD 1 01301859 ANELLO DI URTO IMPACT RING 1 012666010 CONTENITORE ANELLO URTO IMPACT RING HOUSING 1 0132328-211 ORING ORING 1 140030PU12 ORING ORING 1 140035PU13 DISTANZIERE SPACER 1 0132329-214 TESTINA D'URTO IMPACT HEAD 1 012278015 ALBERINO SHAFT 1 0132330-216 GUIDA GUIDE 1 0132333-217 ORING ORING 1 140026PU18 ORING ORING 1 140330PU19 BOCCOLA BUSHING 2 26035820 BOCCOLA BUSHING 1 26035921 FLANGIA FLANGE 1 013126822 PRIGIONIERO STUD 4 012537723 DADO NUT 4 76000624 SUPPORTO SUPPORT 1 013233725 VITE SCREW 4 69TE12X3026 FLANGIA FLANGE 1 013232327 PROLUNGA EXTENSION 1 013233928 CILINDRO PNEUMATICO PNEUMATIC ACTUATOR 1 012560229 VITE SCREW 4 69TCE16X10530 RACCORDO CONNECTION 1 26046831 RIDUZIONE REDUCTION 2 26015132 RACCORDO CONNECTION 1 260271

SPARES_4537 .xls HOMOGENEIZING GROUP 1 ST.

Item Description Description Qty Part Code1 ASS. GRUPPO OMOGENEIZZANTE HOMOGENEIZING GROUP ASS. DRW 1 01323382 CAMERA OMOGENEIZZANTE HOMOGENEIZING CHAMBER. 1 0132320-23 ANELLO RING 1 0132321-24 ORING ORING 1 140027PU5 ORING ORING 1 140022PU6 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 01301767 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 01309828 TESTINA DI PASSAGGIO PASSAGE HEAD 1 01301859 ANELLO DI URTO IMPACT RING 1 012666010 CONTENITORE ANELLO URTO IMPACT RING HOUSING 1 0132328-211 ORING ORING 1 140030PU12 ORING ORING 1 140035PU13 DISTANZIERE SPACER 1 0132329-214 TESTINA D'URTO IMPACT HEAD 1 012278015 ALBERINO SHAFT 1 0132330-216 GUIDA GUIDE 1 0132333-217 ORING ORING 1 140026PU18 ORING ORING 1 140330PU19 BOCCOLA BUSHING 2 26035820 BOCCOLA BUSHING 1 26035921 FLANGIA FLANGE 1 013126822 PRIGIONIERO STUD 4 012537723 DADO NUT 4 76000624 SUPPORTO SUPPORT 1 013233725 VITE SCREW 4 69TE12X3026 FLANGIA FLANGE 1 013232327 PROLUNGA EXTENSION 1 013233928 CILINDRO PNEUMATICO PNEUMATIC ACTUATOR 1 012560229 VITE SCREW 4 69TCE16X10530 RACCORDO CONNECTION 1 26046831 RIDUZIONE REDUCTION 2 26015132 RACCORDO CONNECTION 1 260271

SPARES_4537 .xls HOMOGENEIZNG GROUP 2 ST.

Item Description Description Qty Part Code1 ASS. GRUPPO TRASMETTITORE TRANSMITTER GROUP ASS. DRW. 1 0124219-42 TRASMETTITORE TRANSMITTER 1 3201273 RONDELLA WASHER 1 01234864 FLANGIA FLANGE 1 01336885 ORING ORING 1 130031S6 ORING ORING 1 130027PU7 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 01247488 PRIGIONIERO STUD 4 01262739 DADO NUT 4 760008

SPARES_4537 .xls TRANSMITTER

Item Description Description Qty Part Code1 ASS. VALVOLA DI SICUREZZA RELIEF VALVE ASS. DRW. 1 01302592 SEDE VALVOLA VALVE SEAT 1 0130260-23 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 01274324 ORING ORING 1 140013PU5 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 01301756 SFERA BALL 1 1900097 ALBERINO SHAFT 1 0130261-38 ORING ORING 1 140030PU9 ANELLO ELASTICO SNAP RING 1 21003010 ORING ORING 2 140030PU11 CUSCINETTO BEARING 1 22019712 MOLLA SPRING 1 013026313 CORPO BODY 1 0131526-315 DISTANZIERE SPACER 1 013026416 COPERCRCHIO VALVOLA VALVE COVER 1 013026617 FLANGIA FLANGE 1 013060418 DADO NUT 4 76000619 PRIGIONIERO STUD 4 012292620 TUBO PIPE 1 0124722

SPARES_4537 .xls RELIEF VALVE

Item Description Description Qty Part Code1 ASS:GRUPPO COLLETTORE MANIFOLD ASS. DRW. 1 01314082 CODICE NON PRESENTE NOT EXISTING CODE - -3 ORING ORING 1 140022PU4 FLANGIA FLANGE 1 0134000-25 VITE SCREW 2 69TE10X206 MORSETTO CLAMP 1 3509017 GUARNIZIONE GASKET 1 1403588 TRONCHETTO FERRULE 1 2603899 CODICE NON PRESENTE NOT EXISTING CODE - -10 CODICE NON PRESENTE NOT EXISTING CODE - -11 ORING ORING 1 140205PU12 FLANGIA FLANGE 1 0134001-213 VITE SCREW 4 69TE16X2514 MORSETTO CLAMP 1 35090115 GUARNIZIONE GASKET 1 14035816 TRONCHETTO FERRULE 1 260389

SPARES_4537 .xls MANIFOLD

Item Description Description Qty Part Code1 ASS. CORPO DI TRASMISSIONE TRASMISSION BODY ASS .DRW. 1 01203822 CORPO DI TRASMISSIONE TRANSMISSION BODY 1 01314003 ALBERO A GOMITI CRANKSHAFT 1 01270734 CUSCINETTO BEARING 2 2203065 FLANGIA FLANGE 1 01089276 VITE SCREW 16 70TCE10X257 ORING ORING 2 1401098 FLANGIA FLANGE 1 01202229 GUARNIZIONE GASKET 1 18005110 PISTONE DI GUIDA GUIDE PLUNGER 3 012661111 SPINOTTO WHRIST PIN 3 25000612 RONDELLA WASHER 6 010011913 BIELLA CONROD 3 010968014 BRONZINA BRONZE BEARING 3 011317515 FLANGIA FLANGE 3 013352016 ANELLO RASCHIATORE ROD SCRAPER 3 16010817 VITE SCREW 12 70TE6X2518 PARASPRUZZI SPLASH GUARD 3 012033219 COPERCHIO COVER 1 010009220 CORDINO GASKET 1 63000521 VITE SCREW 8 70TE8X2522 VITE SCREW 4 70TE12X3523 PULEGGIA PULLEY 1 012187324 BUSSOLA BUSHING 1 61060925 SPINA PIN 2 011180026 LINGUETTA FEATHER KEY 1 81086827 TAPPO PLUG 1 12091928 CONVOGLIATORE OLIO OIL CONVEYOR 2 010015529 CODICE NON PRESENTE NOT EXISTING CODE- - -30 NIPPLO NIPPLE 1 12085931 RACCORDO A T TEE CONNECTION 2 12039432 LIVELLO OLIO OIL LEVEL 1 17001733 TAPPO PLUG 1 12091934 TAPPO PLUG 2 17000135 RIDUZIONE REDUCTION 1 12071136 ORING ORING 3 14019437 GUARNIZIONE GASKET 3 160105

SPARES_4537 .xls TRASMISSION BODY

Item Description Description Qty Part Code1 ASS. MOTORIZZAZIONE DRIVE END ASS. DRW. 1 01229672 MOTORE MOTOR 1 MB6111Y23 PULEGGIA PULLEY 1 0121879-0014 DISTANZIERE SPACER 1 01204035 RONDELLA WASHER 1 01229666 PIASTRA PLATE 1 0133159-97 SUPPORTO SUPPORT 1 0133158-98 TIRANTE TRUMBUCKLE 1 3500269 SUPPORTO SUPPORT 1 012143510 ANELLO RING 2 012347911 CINGHIA BELT 6 40SPZ1900X12 VENTOLA FAN 1 990011

SPARES_4537 .xls DRIVE END

Item Description Description Qty Part Code1 ASS. IMPIANTO PNEUMATICO PNEUMATIC PLANT ASS. DRW. 1 0133613-22 NIPPLO NIPPLE 1 2601893 RONDELLA EWASHER 1 6800444 RIDUTTORE PRESSIONE PRESSURE REDUCER 1 3902505 MANOMETRO MANOMETER 1 3200816 DISOLEATORE MIST SEPARATOR 1 3902517 BLOCCHETTO BLOCK 1 2602508 PRESSOSTATO PRESSURE SWITCH 1 EF00439 CODICE NON PRESENTE NOT EXISTING CODE - -10 ELETTROVALVOLA ELECTROVALVE 1 39026311 ELETTROVALVOLA ELECTROVALVE 1 39023012 DOSATORE FLOW BATCHER 1 39004613 MANOMETRO MANOMETER 1 32036114 GIUNTO COUPLING 1 26031015 GIUNTO COUPLING 2 26031316 CODICE NON PRESENTE NOT EXISTING CODE - -17 GIUNTO COUPLING 1 26031018 GIUNTO COUPLING 1 26031419 STROZZATORE CHOCKER 1 35016720 RUBINETTO BALL TAP 1 58000221 OLIO OIL 2 53000622 LIVELLO LEVEL 1 17001723 SERBATOIO TANK 1 26120224 SUPPORTO SUPPORT 1 26120325 PROLUNGA XRTENSION 1 26120426 MANOMETRO MANOMETER 1 320080

SPARES_4537 .xls PNEUMATIC PLANT

Item Description Description Qty Part Code1 IMPIANTO DELL'ACAQUA WATER PLANT ASS. DRW. 1 0133601-112 FILTRO FILTER 1 2300143 RONDELLA WASHER 1 6800444 NIPPLO NIPPLE 1 2604175 ELETTROVALVOLA ELECTROVALVE 1 3900356 RUBINETTO BALL TAP 1 5800107 FLUSSOSTATO FLOW SWITCH 1 EFB0388 PORTAGOMMA HOSE COUPLING 1 2600109 TUBO PIPE 1 79000310 PORTAGOMMA HOSE COUPLING 1 26001012 NIPPLO NIPPLE 1 26030013 RONDELLA WASHER 1 68004514 CODICE NON PRESENTE NOT EXISTING CODE - -15 NIPPLO NIPPLE 1 26030016 CODICE NON PRESENTE NOT EXISTING CODE - -17 CODICE NON PRESENTE NOT EXISTING CODE - -18 CODICE NON PRESENTE NOT EXISTING CODE - -19 CODICE NON PRESENTE NOT EXISTING CODE - -20 CODICE NON PRESENTE NOT EXISTING CODE - -21 CODICE NON PRESENTE NOT EXISTING CODE - -22 CODICE NON PRESENTE NOT EXISTING CODE - -23 CODICE NON PRESENTE NOT EXISTING CODE - -24 CODICE NON PRESENTE NOT EXISTING CODE - -25 CODICE NON PRESENTE NOT EXISTING CODE - -26 CODICE NON PRESENTE NOT EXISTING CODE - -27 CODICE NON PRESENTE NOT EXISTING CODE - -

SPARES_4537 .xls WATER PLANT

Niro Soavi S.p.A

SECTION 6

ELECTRICAL DIAGRAMS - INDEX

6.1. ELECTRICAL DIAGRAMS

6C001E0C.DOC 6.1.0

Niro Soavi S.p.A

6.1. ELECTRICAL DIAGRAMS

In the following pages it is possibile to find the wiring diagrams of the electrical devices installed on-board the machine, or as an alternative, the complete electrical diagram of the Electric Power Board if the same or its engineering is supplied by Niro Soavi. We recommend to check carefully the wiring diagrams to proceed with correct connection of the machinhe and its components. The wiring of the machine and its components must be done by qualified personnel who must be able to understand properly the supplied electrical documentation and wiring diagrams.

6C001E0C.DOC 6.1.1

Niro Soavi S.p.A

SECTION 7

SUPPLIERS CATALOGUE - INDEX

7.1. SUB-SUPPLIERS AND COMPONENTS CATALOGUE

7C001E0C.DOC 7.1.0

Niro Soavi S.p.A

7.1. SUB-SUPPLIERS AND COMPONENTS CATALOGUE

We have included copies of the suppliers’ catalogues and of components installed in the machine. In addition to the maintenance guidelines provided in this USE AND MAINTENANCE MANUAL, you should refer to the specific instructions of any installed components.

7C001E0C.DOC 7.1.1

ISTRUZIONI D’USO E MANUTENZIONE INSTRUCTIONS FOR USE … · omogeneizzatore/pompa ad alta...

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