Della Toffola OMNIA Series, OMNIA 80, OMNIA 50, OMNIA 130, OMNIA 170 Use And Maintenance Instruction Manual

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USE AND MAINTENANCE

INSTRUCTIONS MANUAL

OMNIA crossflow filter

OMNIA_0314R02EN-II.docx

Azienda: Della Toffola S.p.A

Indirizzo: Via Feltrina, 72 – 31040 Signoressa di Trevignano (TV) (Italia) Tel: +39 0423 6772 Web: www.dellatoffola.it

Read all the following safety recommendations very carefully before undertaking any action whatsoever with your machine.

FIRST LEARN AND THEN ALWAYS FOLLOW ALL THE SAFETY RECOMMENDATIONS

Read these safety recommendations very carefully before installing and using the machine.

Also read all the explanatory and warning signs attached to the machine itself. Make sure that they are always easy to read, replacing any damaged or missing signs without delay.

Read this manual carefully before using the machine to make sure that you are thoroughly familiar with how it works and all the controls.

Never postpone learning this important information until you are already working with the machine.

Never allow any unauthorized persons unfamiliar with the equipment to come into the vicinity or operate the machine.

Always keep this manual readily available so that anyone taking action on the machine can refer to it.

If the machine is sold or transferred to third parties, it is compulsory to hand over all the related technical documentation, use and maintenance

EXPLANATION OF THE SYMBOLS

Several symbols are used in this manual and on the machine itself to accompany hazard warnings and safety recommendations. These warnings and recommendations serve primarily to ensure the safety of Installers, Technicians and Operators, but also to avoid the machine being damaged.

IMPORTANT

This word is used to identify paragraphs in the manual containing essential information concerning the machine. Read the related information

THIS SYMBOL IS USED TO DRAW YOUR ATTENTION TO THE RISK OF FATAL ACCIDENTS, SEVERE INJURIES AND EXTENSIVE DAMAGE IN THE EVENT OF THE SPECIFIED SAFETY MEASURES BEING DISREGARDED.

THIS SYMBOL DRAWS ATTENTION TO RISKS OF A GENERAL NATURE.

THIS SYMBOL IS USED TO DRAW YOUR ATTENTION TO THE RISK OF FATAL ACCIDENTS, SEVERE INJURIES AND EXTENSIVE DAMAGE IN THE EVENT OF THE SPECIFIED SAFETY MEASURES BEING DISREGARDED.

THIS SYMBOL DRAWS ATTENTION TO RISKS DERIVING FROM THE PRESENCE AND USE OF ELECTRICITY.

DEFINITIONS

The following are definitions of the individual and legal entities involved in handling and using the machine.

OWNWER: In this user manual, the OWNER is the legal representative of the company or body, or the individual, that purchased the

INSTALLER: In this user manual, the INSTALLER is the legal representative of the company appointed by the OWNER to install and connect

OPERATOR: In this user manual, the OPERATOR is the person authorized by the OWNER or MANAGER to take all action on the machine for

TECHNICIAN: In this user manual, the TECHNICIAN is the person directly authorized by the Manufacturer or, failing this (and entirely under the

machine. The Owner is responsible for ensuring compliance with all the safety requirements specified in the present manual and in the current legislation in the country where the machine is installed. This last aspect is waived if the Owner appoints a plant MANAGER, who thus takes responsibility for implementing the safety recommendations and for compliance with the safety standards relating to the use of the machine and relations with the OPERATOR.

the machine to the hydraulic, electrical and compressed air supply networks (etc.) at the plant. The Installer is responsible for correctly handling and installing the machine in compliance with the recommendations of this manual and with the current legal requirements in the country where the machine is used.

its usage, adjustment, control and routine servicing, as detailed in this manual (with which Operators must strictly comply, limiting their action to the explicitly allowable procedures).

latter's responsibility), by the Manufacturer's Dealer in the various European Community states outside Italy, to carry out all extraordinary servicing procedures, as well as any adjustments, tests, repairs and replacements of parts proving necessary during the working life of the machine.

GENERAL SAFETY RECOMMENDATIONS

! In unloading the machine on arrival, lifting and positioning it at the workplace, and all other handling procedures, comply scrupulously with the

recommendations of the relevant section of this manual.

Pay particular attention when handling wheel-mounted machines, which have to be moved by hand once they are on the ground. To prevent any risk of crushing, only move the machine by pushing it, never by pulling it, so that nobody can ever come to be in the path of the machine as it moves. Anyone handling the machine must be supervised by another person uninvolved in the procedure, who shall keep a constant watch to ensure that no obstacles or persons get in the machine's way and no other hazardous situations occur. This supervisor must promptly alert the person moving the machine of any hazards so that the machine can be stopped immediately.

! The surface on which the machine slides, like the surface on which it is used, must meet all the essential safety requirements: it must be perfectly

horizontal and smooth, with nothing to interfere with the machine's movements. Check in advance to ensure that the whole distance to cover with the machine meets all the above-mentioned requirements. Make sure that the sliding and supporting surfaces have a load-bearing capacity sufficient to withstand the weight of the machine both empty and in use. Any discontinuity in the floor, e.g. expansion joints, grids and manholes, must meet the specified requirements.

! Never, for any reason whatsoever, lift the machine by any hoisting points other than those indicated.

! Before the machine is used, it must always be immobilized using the fixing devices provided.

! The machine must be placed in an area accessible only to the OPERATORS and TECHNICIANS; failing this, it must be protected by a barrier

situated at least 2 m away from its outer edge. OPERATORS and TECHNICIANS may access the area where the machine is used providing they are adequately clothed and equipped with the personal protective equipment specified by law (safety shoes, gloves, helmet, etc.). The INSTALLER's personnel, or any visitors, must always be accompanied by an OPERATOR. Unauthorized personnel must never be allowed to remain alone in the vicinity of the machine. The place of installation must be made inaccessible to children.

! OPERATORS shall restrict themselves to taking action on the machine's controls, so they must not open any of the panels, except for the one for

accessing the controls (if any).

! The INSTALLER shall restrict himself to taking action on the connections between the plant and the machine, so he must not open any panels, or

operate any controls.

! In all handling, usage, servicing or repairs on the machine, it is compulsory to comply with all current safety standards in the country where the

machine is used. This applies both to the equipment and to the operating methods adopted.

! Always disconnect the electric power supply before taking any action to install, service, repair or move the machine. This is of fundamental

importance to prevent the risk of death, severe injury and extensive damage to the plant.

! In certain stages of normal use, some of the containers comprising the machine are under pressure (e.g. the filter vessel, plenum chamber,

erosion-type dosing units, etc.). Never open such containers or remove any components connected to them before you have completely vented said pressure. Venting must be done through the valves provided on the machine specifically for this purpose.

! Never move the machine during normal working cycles.

! Before each new working cycle, make sure that any mobile electric connections (power cords, plugs, etc.) are sound and efficient. If they show

any signs of damage, repairs must be made only by a specialized TECHNICIAN.

! Never take any action not mentioned in this manual under your own initiative.

! Connect the machine to the mains electric power supply according to the recommendations of this manual.

! Before starting the machine, check the efficiency of the earthing for the electric circuitry and machine frame or structure.

! Never use power cords of inadequate cross-section or provisional connections, not even briefly, and certainly not in the event of an emergency.

! Start the machine only after you have made sure of its perfectly safe connection to the systems providing the energy and anything else it needs to

function properly (mains electricity and water, compressed gas supply, water drainage network, etc.).

! Keep a safe distance from any mechanical parts in motion.

! Immediately report any alarms or the tripping of any automatic machine safety devices to the TECHNICIAN.

! Never manually reset the machine after an alarm or an automatic safety device has been tripped without first identifying and dealing with the

problem that caused them.

! Never remove the guards over moving parts while the machine is in operation.

! Before starting the machine, make sure all guards are correctly installed.

! Routinely perform all the scheduled servicing operations.

! Dispose of the packaging material for the machine at a suitable landfill, taking particular care over any film and plastic bags, which can expose

children to the risk of suffocation.

! Never release the processing waste deriving from the working process directly into the environment.

REGULATIONS FOR USING THE MACHINE IN THE FOODSTUFFS SECTOR

The following considerations apply only to machines used with foodstuffs, i.e. destined to come into contact with products for human consumption:

! The machine in your possession has been designed and built to make it suitable for contact with foodstuffs, and fluids in particular. If in doubt

about the intended uses of your machine, refer to the relevant chapter in this manual.

! For logistic reasons related to the phases prior to its use (e.g. transport to the user's premises, storage in warehouses, etc.), it is impossible to

guarantee the delivery of the machine in conditions suitable to enable its immediate use without an accurate, preliminary sanitization. This is the responsibility of the end user, who may have to comply with any established protocols, e.g. HACCP.

DEMOLITION AND DISPOSAL OF THE MACHINE

! At the end of its working life, the machine must be demolished and disposed of.

! THE MACHINE MUST ONLY BE DEMOLISHED AND DISPOSED OF BY ADEQUATELY-TRAINED AND PROPERLY-EQUIPPED PERSONNEL IN

COMPLIANCE WITH THE FOLLOWING PROCEDURE.

! 1. Divide the machine into its constituent parts, separating the materials it is made of:

! mechanical parts (reducers, pump bodies, etc.);

! metal parts (structure, piping, etc.)

! electrical parts;

! rubber parts;

! plastic and synthetic parts.

! 2. All resulting materials must be treated and disposed of in accordance with the legal requirements in the country where the machine is used.

! 3. All components contaminated by oil and oily residues must be considered as special waste and disposed of by authorized consortiums. The

same applies to the lubricants that periodically have to be changed.

! 4. In the event of the machine being placed out of commission, even only temporarily, it must be stored in an area inaccessible to children. All

circuit breakers and isolators must be segregated and disconnected.

Make a thorough check and release any built-up residual energy, e.g. liquids or gases under pressure inside containers or piping. The

machine must also be checked from the static standpoint, to eliminate the risk of any single machine parts moving unexpectedly.

! THE MANUFACTURER ACCEPTS NO LIABILITY FOR DAMAGE TO PERSONS OR PROPERTY DUE TO THE RE-USE OF SINGLE MACHINE

PARTS FOR ANY OTHER THAN THE ORIGINAL PURPOSES OR IN OTHER ASSEMBLY CONDITIONS.

INSPECTION OF THE GOODS ON RECEIPT

When it is delivered, the machine must be checked by the Customer to identify any signs of damage that it may have suffered in transit and ensure that the machine is complete in every part, as listed on the order form. If there are signs of damage, make an immediate note of the anomalies detected on the transport document (delivery note or CMR), adding the wording “RECEIVED WITH RESERVE DUE TO EVIDENT DAMAGE TO THE MACHINE”. Delivery ex works includes insurance coverage for any damage in accordance with the Italian law 450 of 22.08.1985 "Compensation limit". In the event of complaints, the Customer must be able to produce an adequate photographic documentation of the most obvious damage.

GUARANTEE

The Manufacturer guarantees the machine for the period indicated in the order form. The GUARANTEE consists exclusively in the replacement or repair, free of charge, of any parts acknowledged as being defective. The GUARANTEE does not cover electrical parts. The GUARANTEE is valid only if all installation and usage instructions have been followed (not only those stated by the Manufacturer, but also those suggested by current practice). The GUARANTEE becomes null and void in the event of any servicing procedures being undertaken by personnel not authorized by the Manufacturer. If the machine alarm sounds or one of the automatic safety devices is tripped, the machine must not be reset manually until the cause of the shutdown has been dealt with. Repeated manual resets can be sufficient reason for the Guarantee to become null and void. The GUARANTEE is valid providing any flaws or defects are reported within eight days of their detection; moreover, the GUARANTEE takes effect providing the use of the machine was suspended immediately after the fault was discovered.

AFTER-SALES ASSISTANCE

When requesting any information, servicing, or other services, it is essential to specify the SERIAL NUMBER of your machine.

It is impossible to provide accurate instructions or schedule servicing measures unless this information is provided.

RECOMMENDATIONS FOR PROTECTION AGAINST FREEZING

If there is a danger of the ambient temperature dropping to 0°C / 32°F, be sure to empty any liquids (water or product to treat) from all of the machine's hydraulic circuits to prevent ice forming in the piping and damaging parts of the machine.

NOTES

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

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CONTENTS

1 GENERAL INFORMATION ...................................................................................................................... 8

1.1 SCOPE OF THE USE AND MAINTENANCE INSTRUCTION MANUAL .............................................................. 8

1.2 HOW TO CONSULT THIS MANUAL .................................................................................................................... 9

1.2.1 NUMERATION OF FIGURES ..................................................................................................................... 9

1.2.2 NUMERATION OF TABLES ........................................................................................................................ 9

1.3 CONSERVING THIS MANUAL ........................................................................................................................... 10

1.4 MANUAL REVISION METHOD .......................................................................................................................... 10

1.5 ADDRESSEES ................................................................................................................................................... 10

1.6 PASSWORD ....................................................................................................................................................... 11

1.6.1 User (Level 0) – no password required ..................................................................................................... 11

1.6.2 Machine operator – Client Technician (Level 1) - User “A” (password level 1) .......................................... 11

1.6.3 Advanced Client Technician - (Level 2) – User “B” (password level 2) ...................................................... 11

1.6.4 Della Toffola Technician (Level 3) – User “DT” (password level 3) ........................................................... 11

1.7 GLOSSARY AND PICTOGRAMS ....................................................................................................................... 12

1.7.1 GLOSSARY: .............................................................................................................................................. 12

1.7.2 PICTOGRAMS REGARDING OPERATOR QUALIFICATIONS ................................................................ 13

1.7.3 PICTOGRAMS REGARDING SAFETY ..................................................................................................... 14

2 GENERAL INFORMATION .................................................................................................................... 15

2.1 MANUFACTURER IDENTIFICATION DATA ...................................................................................................... 15

2.2 MACHINE IDENTIFICATION DATA AND NAMEPLATES .................................................................................. 15

2.2.1 CE nameplate ............................................................................................................................................ 15

2.2.2 PED inspection plate ................................................................................................................................. 16

2.3 CERTIFICATION ................................................................................................................................................ 17

2.3.1 EC Statement of conformity ....................................................................................................................... 17

2.4 WARRANTY ....................................................................................................................................................... 17

2.4.1 Centro di assistenza tecnica ...................................................................................................................... 17

2.5 PRELIMINARY OPERATIONS AT THE USER’S RESPONSIBILITY ................................................................. 18

3 SAFETY .................................................................................................................................................. 19

3.1 SAFETY RULES ................................................................................................................................................. 19

3.2 GENERAL SAFETY RECOMMENDATIONS ...................................................................................................... 19

3.2.1 Control operations and inspections ........................................................................................................... 22

3.3 DANGER ZONES ............................................................................................................................................... 23

3.4 SAFETY DEVICES ............................................................................................................................................. 23

3.4.1 Pressure-switches and safety valves ........................................................................................................ 23

3.5 RESIDUAL RISKS .............................................................................................................................................. 24

3.5.1 Risk of contaminating the product ............................................................................................................. 25

4 INSTALLATION ...................................................................................................................................... 26

4.1 INSTALLATION SITE REQUIREMENTS ............................................................................................................ 26

4.2 OPERATOR WORK AREAS .............................................................................................................................. 27

4.3 SHIPPING AND MOVING ................................................................................................................................... 28

4.3.1 Transport ................................................................................................................................................... 28

4.3.2 Lifting and moving the machine ................................................................................................................. 29

4.3.3 Assembly ................................................................................................................................................... 30

4.4 LEVELLING ........................................................................................................................................................ 31

4.5 CONNECTIONS ................................................................................................................................................. 31

4.5.1 Hydraulic system connections ................................................................................................................... 31

4.5.2 Pneumatic system connections ................................................................................................................. 35

4.5.3 Electric system connections ...................................................................................................................... 37

4.6 PRELIMINARY OPERATIONS ........................................................................................................................... 38

4.6.1 Checking the phase balance ..................................................................................................................... 39

4.6.2 Checking the cycle of the power supply phases ........................................................................................ 39

4.7 LOADLESS TESTING ........................................................................................................................................ 40

5 MACHINE DESCRIPTION ...................................................................................................................... 41

5.1 INTENDED USE ................................................................................................................................................. 43

5.2 MISUSE (uses that are not allowable) ................................................................................................................ 44

5.3 RECOMMENDATIONS FOR USE ...................................................................................................................... 44

5.4 FLOW CHART .................................................................................................................................................... 45

5.4.1 Key to components .................................................................................................................................... 45

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6 TECHNICAL FEATURES ....................................................................................................................... 48

6.1 PERFORMANCE ................................................................................................................................................ 48

6.2 SERVOMECHANISMS ....................................................................................................................................... 48

6.3 CONSUMPTION ................................................................................................................................................. 49

6.3.1 Decalcified mains water (hardness ≤15°F) for washing ............................................................................. 49

6.3.2 Filtered and dry compressed air ................................................................................................................ 49

6.3.3 Nitrogen ..................................................................................................................................................... 50

6.3.4 Chemical detergents ................................................................................................................................. 50

6.4 TECHNICAL DATA ............................................................................................................................................. 50

6.5 DIMENSIONS ..................................................................................................................................................... 51

6.6 VIBRATION ........................................................................................................................................................ 52

6.7 NOISE EMISSION .............................................................................................................................................. 52

7 OPERATOR CONTROL PANEL ............................................................................................................ 53

7.1 OPERATOR CONTROL PANEL ......................................................................................................................... 53

7.1.1 Electric control panel component key ........................................................................................................ 53

7.2 EMERGENCY STOPPING ................................................................................................................................. 54

8 OPERATION ........................................................................................................................................... 54

8.1 NOTIONS ON THE PROCESS........................................................................................................................... 54

8.2 PRELIMINARY OPERATIONS ........................................................................................................................... 54

8.3 STARTING .......................................................................................................................................................... 54

8.4 INTERRUPTING THE WORK CYCLE ................................................................................................................ 55

8.5 MACHINE STOPPING ........................................................................................................................................ 55

9 WORKING STAGES .............................................................................................................................. 56

9.1 FILLING .............................................................................................................................................................. 56

9.2 PRESSURIZATION ............................................................................................................................................ 57

9.3 FILTRATION ....................................................................................................................................................... 57

9.3.1 Internal recirculation/External recirculation: ............................................................................................... 57

9.3.2 Backwashing during filtration ..................................................................................................................... 58

9.3.3 Automatic discharge by the rotating screener SRB ................................................................................... 58

9.4 EMPTYING PRODUCT ...................................................................................................................................... 58

9.4.1 Discharge of clean product from rotating screener SRB ........................................................................... 58

9.4.2 Discharge from the filter ............................................................................................................................ 58

9.5 PRESSURE VENTING ....................................................................................................................................... 59

9.6 WASHING ........................................................................................................................................................... 59

9.6.1 Cold washing ............................................................................................................................................. 59

9.6.2 Washing with hot water ............................................................................................................................. 59

9.6.3 Chemical washing ..................................................................................................................................... 60

9.7 WASHING CHECK ............................................................................................................................................. 62

10 DETAILED DESCRIPTION OF THE CONTROLS ................................................................................. 62

11 MAINTENANCE OPERATIONS ............................................................................................................. 63

FOREWORD ................................................................................................................................................................ 63

11.1.1 Precautions ........................................................................................................................................... 63

11.1.2 General rules ........................................................................................................................................ 64

11.2 PROGRAMMED MAINTENANCE ...................................................................................................................... 65

11.2.1 General ................................................................................................................................................. 65

11.2.2 Counter-current system rubber sleeve ................................................................................................. 65

11.2.3 Tank SE wash ball ................................................................................................................................ 65

11.2.4 Safety valves ........................................................................................................................................ 65

11.2.5 Wiring and electric components ............................................................................................................ 65

11.3 EXTRAORDINARY MAINTENANCE .................................................................................................................. 66

11.3.1 Changing the mechanical seals ............................................................................................................ 66

11.3.2 Changing the rotating brush ................................................................................................................. 66

12 TROUBLESHOOTING ........................................................................................................................... 67

12.1 MESSAGES ........................................................................................................................................................ 67

12.2 ALARMS ............................................................................................................................................................. 68

13 PUTTING THE FILTER OUT OF OPERATION ..................................................................................... 73

14 SPARE PARTS....................................................................................................................................... 73

14.1 TECHNICAL ASSISTANCE ................................................................................................................................ 73

14.2 SPARE PARTS ................................................................................................................................................... 74

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15 ADDITIONAL INSTRUCTIONS .............................................................................................................. 74

15.1 WASTE ELIMINATION ....................................................................................................................................... 74

15.2 DEMOLITION AND DISPOSAL .......................................................................................................................... 74

16 FLOW CHART ........................................................................................................................................ 75

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This manual is the property of Della Toffola S.p.A. No part of this publication may be reproduced, circulated, translated into any language, transmitted or copied in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without prior permission from Della Toffola S.p.A.

ENQUIRIES AND FURTHER INFORMATION:

For any enquiries or further information concerning the use of the machine or the contents of this manual, or for any technical support, please contact the Della Toffola S.p.A. Customer Support Service, using the following references:

Della Toffola S.p.A – Servizio Assistenza

Via Feltrina 72 - 31040, Signoressa di Trevignano (TV) (Italia)

Tel.: +39 0423 6772 Fax: +39 0423 670841

PRESERVATION:

Always keep a copy of this manual near the machine and readily available to the user, and store a spare copy in a safe place.

If the manual is lost or damaged, contact Della Toffola S.p.A. for a replacement.

This manual reflects the state of the machine as at the time when it was developed.

Bear in mind that, in accordance with current legislation, this instructions manual forms an integral part of the machine and must accompany the machine at all times.

DOCUMENT ID:

Use and maintenance instructions manual

Title Machine Models Nome file OMNIA_0314R02EN-II.docx Machine code Serial number IC. Rev. No. 02 – 01.2015

Crossflow filter OMNIA 50/80/130/170

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1 GENERAL INFORMATION

All the data provided in this manual regard European units of measure.

This manual regards only European standards and regulations. The client is responsible for adapting it to the standards and regulations adopted in the nation of use.

This manual contains the instructions for the standard version of the filter and it may be that the machine in your possession does not include certain components or optionals illustrated here at no expense to its satisfactory operation.

1.1 SCOPE OF THE USE AND MAINTENANCE INSTRUCTION MANUAL

This manual is an integral part of the machine and has been provided to supply all the information necessary for:

● correctly informing operators of all aspects regarding safety;

● correct machine installation;

● detailed knowledge of machine operation and limits to use;

● use of the machine correctly and in conditions of safety;

● servicing the machine correctly and safely;

● dismantling the machine in conditions of safety and in respect of the laws in force governing

the safety of the workers and the workplace.

The persons in charge of the company departments where this machine will be installed are required by the laws in force to carefully read this manual and to ensure that the sections pertinent to the machine’s operators and maintenance personnel are read by the same.

This manual has been prepared under the assumption that the rules in force for workplace safety and hygiene are regularly respected at the plants for which the machine is destined.

The instructions, drawings and documents contained in this manual are of reserved technical nature and the exclusive property of the Manufacturer, and cannot be fully or partially reproduced.

The client is also responsible for making sure that whenever it is emended by the Manufacturer, only updated versions of the manual are rendered available for consultation wherever the machine is used.

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1.2 HOW TO CONSULT THIS MANUAL

This manual has been divided into separate chapters, each of which is dedicated to a specific type of operator (INSTALLER, OPERATOR AND MAINTENANCE MAN) and defines the skills necessary for such to conduct operations on the machine in conditions of safety.

The terms, abbreviations and pictograms used with the meanings indicated in par. 1.7 are intended to make the text immediately comprehensible.

This manual is composed of a cover, a table of contents, a set of chapters, figures, diagrams, and tables.

Page 4 provides the machine’s identification data, model, serial number, and the manual’s revision number.

This document makes frequent use of the numbering of parts provided in the figure on page

45. For quick consultation, we recommend keeping the respective figure always in sight.

1.2.1 NUMERATION OF FIGURES

Each figure is provided with progressive numeration.

The numbers start from “1” at the start of each new chapter.

Numbers are composed as follows:

Chapter

1.1

Progressive numeration of figure

1.2.2 NUMERATION OF TABLES

Each table is provided with progressive numeration.

The numbers start from “1” at the start of each new chapter.

Numbers are composed as follows:

Chapter

1-1

Progressive numeration of table

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1.3 CONSERVING THIS MANUAL

This Instruction Manual is certified to CE conformity and must be conserved with care and ALWAYS accompany the machine through all its changes of ownership for its entire working life.

Conservation must by ensured by handling it carefully with clean hands and never leaving it on dirty surfaces

No parts of the manual must ever be removed, torn out or arbitrarily modified.

This manual must be stored in an area free from humidity and sources of heat, and in the immediate vicinity of the machine.

Whenever requested by the user, the manufacturer can provide additional copies of this manual.

1.4 MANUAL REVISION METHOD

The Manufacturer reserves the right to modify the design and improve the machine without notifying the client and without revising the manual previously delivered to the same

The Manufacturer is responsible only for descriptions provided in the Italian language. Given that translations into other languages cannot be completely verified, whenever an incongruence appears, greater attention should be given to the wording in Italian. Della Toffola can be notified in order to make any modifications deemed necessary.

1.5 ADDRESSEES

This manual is addressed to the machine Installer, Operator, and Qualified Personnel for maintenance.

The term “OPERATOR” means the person operating, adjusting, cleaning, and performing the

ordinary maintenance of the machine.

“QUALIFIED PERSONNEL or QUALIFIED OPERATOR” means the person or persons that have

completed training and specialization courses, etc. and have acquired experience in installing, operating, maintaining, repairing, and moving the machine.

“DANGER ZONE” means any zone within and/or around machinery in which a person is subject

to a risk to his or her health or safety;

“EXPOSED PERSON” means any person wholly or partially in a danger zone

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Qualification of addressees

The machine has been designed and constructed for industrial, and therefore professional, not general use. For such reason, it can be entrusted for use to a qualified personnel, in particular, those who:

● have reached adult age,

● are physically and psychologically capable of performing tasks of particular technical difficulty,

● have received adequate training in the operation and maintenance of the machine,

● have been deemed capable by the employer of performing the task(s) assigned,

● are capable of understanding and interpreting the operation manual and its safety rules,

● are familiar with the respective emergency procedures and their implementation,

● possess the ability to operate the specific type of equipment in question,

● have experience in applying the specific rules required,

● have understood the operating procedures defined by the machine Manufacturer.

1.6 PASSWORD

The 4 levels of access to the operator panel are :

1.6.1 User (Level 0) – no password required

This is the person at client premises who uses the machine in complete safety with the default parameters. The User can start all the work phases but cannot access the machine parameters.

1.6.2 Machine operator – Client Technician (Level 1) - User “A” (password level 1)

This is the person at client premises who uses the machine in complete safety. User “A” can start all the work phases, entering and modifying the process parameters of the various work phases but cannot access the machine parameters.

1.6.3 Advanced Client Technician - (Level 2) – User “B” (password level 2)

This is the person at client premises who in addition to being qualified to enter and modify typical process passwords during the various work phases can also access some of the advanced machine parameters.

1.6.4 Della Toffola Technician (Level 3) – User “DT” (password level 3)

This is the Della Toffola Project Manager with access to all the machine setting parameters, the various logs, and the definition and modification of the passwords.

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1.7 GLOSSARY AND PICTOGRAMS

This paragraph lists the terms in this manual not commonly used and the terms used herein with uncommon meaning.

Abbreviations and the meanings of the pictograms used to indicate the qualifications of the operator and the status of the machine are also explained below, the use of which permits the rapid and unequivocal presentation of all the information required for the correct use of the machine in conditions of safety.

1.7.1 GLOSSARY:

The following terms were used in accordance with Paragraph 1.1.1 of Directive 2006/42/CE during the design of this machine:

HAZARD: a potential source of injury or health damage;

DANGER ZONE: means any zone within and/or around machinery in which a person is subject to

a risk to his or her health or safety;

EXPOSED PERSON: means any person wholly or partially in a danger zone;

OPERATOR: means the person or persons installing, operating, adjusting, maintaining, cleaning,

repairing or moving machinery;

MAN-MACHINE INTERFACE: means any situation in which the operator must interact with the machine in any moment or any operative phase of the working life of the same;

RISK: means a combination of the probability and the degree of an injury or damage to health that can arise in a hazardous situation ;

SAFETY GUARD: means a part of the machinery used specifically to provide protection by means of a physical barrier;

PROTECTIVE DEVICE: means a device (other than a guard) that reduces the risk, either alone or in conjunction with a guard;

INTENDED USE: means the use of machinery in accordance with the information provided in the instructions for use;

REASONABLY FORESEEABLE MISUSE: means the use of machinery in a way not intended in the instructions for use, but which may result from readily predictable human behavior.

RESIDUAL RISKS: risks that cannot be totally eliminated or sufficiently reduced through the design of efficacious means of protection and the complementary protection measures adopted.

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1.7.2 PICTOGRAMS REGARDING OPERATOR QUALIFICATIONS

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Symbol

Description

Unskilled laborer: operator without specific skills capable of performing only simple

tasks upon instruction by qualified technicians.

Lifting and moving equipment operator qualified for the use of lifting and moving equipment for the materials and the machine (while scrupulously following the Manufacturer’s instructions) in compliance with the laws in force in the nation of use.

Level 0 machine operator (User): operator without specific skills capable of performing only simple tasks, such as the operation of the machine using the operator panel without the use of the password

Valve opening/closing operations and device enabling/disabling operations with safety guards installed and enabled; this operator is not qualified to modify PROCESS PARAMETERS for the various work phases.

Level 1 machine operator (Client technician): operator capable of performing all the

tasks of a Level 0 machine operator and qualified to modify the PROCESS PARAMETERS for the various work phases (Password level 1).

Not qualified to modify MACHINE CONFIGURATION PARAMETERS.

Level 2 machine operator (Advanced client technician): operator capable of

performing all the tasks of a 1st level machine operator and qualified to modify MACHINE CONFIGURATION PARAMETERS (Password level 2).

Table 1–1

Level 3 Manufacturer’s technician: a qualified technician provided by the

Manufacturer to conduct operations of complex nature in particular situations or whenever agreed with the user. This person may vaunt mechanical and/or electric and/or electronic and/or software skills as required.

This person can access all MACHINE SETTING PARAMETERS protected by Password level 3.

Mechanical maintenance man: a qualified technician capable of operating the machine under normal conditions, with the safety guards disabled, and intervening on the mechanical organs for the adjustment, maintenance, and repairs necessary. This

person is not usually enabled to perform operations on the electric system with voltage connected

Electric maintenance man: a qualified technician capable of operating the machine

under normal conditions and with the safety guards disabled, and assigned to all the electrical operations regarding adjustment, maintenance This person is enabled to

perform operations inside the electric cabinets and cutout boxes with voltage connected.

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1.7.3 PICTOGRAMS REGARDING SAFETY

● Pictograms inside a triangle indicate DANGER.

● Pictograms in a circle indicate an OBLIGATION or a PROHIBITION.

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Symbol

Name

High voltage The presence of this symbol is intended to draw the attention of personnel to the possibility of serious damage and injury and even death whenever the safety measures specified are not applied. This symbol draws attention to the risks posed by the presence and use of electricity.

Risk This symbol is used to highlight extremely important information/prescriptions with particular regard to safety which if not respected can lead to injury.

Irritants/corrosive substances The acid substances used for the chemical washing of the machine are capable of

producing toxic and corrosive reactions on human tissue in case of contact, and their fumes can cause serious irritation to the eyes, the respiratory tract, and the mucosa.

Read the safety information provided on the label by the producer and adopt all the measures indicated prior to using such substances.

Cleaning, repairing or setting moving parts by hand prohibited.

Performing operations before first disconnecting all voltage through the use of the main power switch prohibited.

Safety gloves must be worn.

Safety footwear must be worn.

Goggles or facemask must be worn.

Protective clothing must be worn.

Table1–2

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2 GENERAL INFORMATION

2.1 MANUFACTURER IDENTIFICATION DATA

MANUFACTURER

Della Toffola S.p.A

Via Feltrina 72

31040 Signoressa di Trevignano (TV) (Italia)

CONTACT PERSONS

Tel.: +39 0423 6772

Fax: +39 0423 670841

Email: dtgroup@dellatoffola.it

2.2 MACHINE IDENTIFICATION DATA AND NAMEPLATES

2.2.1 CE nameplate

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The machine is identified by means of a CE nameplate on which its identification data are indelibly printed.

Figure 2–1

The CE nameplate must be kept intact and visible because it specifies the main characteristics of the machine, such as:

- manufacturer's name and address;

- name of the machine;

- serial number;

- year of manufacture;

- weight.

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Always provide this reference data in any communication with the Manufacturer or Assistance Centers.

The CE nameplate is positioned as shown in the figure below (Figure 2–2):

Figure 2–2

2.2.2 PED inspection plate

The machine is also equipped with PED inspection plate.

Figure 2–3

The PED inspection plate must be kept in good condition and visible because it contains the following data:

- Model

- Serial number

- Maximum permissible pressure

- Minimum/Maximum permissible temperature

- Volume

- Fluid

- Product tested (date)

- Bar (test pressure)

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2.3 CERTIFICATION

2.3.1 EC Statement of conformity

This machine has been designed and constructed in compliance with the European Community Directives applicable and pertinent at the moment of its launching in the market and/or production.

Given that the system is not covered by ANNEX IV of DIRECTIVE 2006/42/EC, the Manufacturer has proceeded to Self-certification for the application of the EC Mark.

The EC Statement of conformity is delivered in a plastic envelope separately from the Instruction manual.

2.4 WARRANTY

These machines are covered by the warranty specified in the General Terms of Sale. Whenever during the period of warranty validity malfunction or breakdowns occur in parts of the machine that are included in the cases indicated for coverage, after conducting the necessary control operations on the machine, the Manufacturer will proceed to the repair or the replacement of the defective parts.

Modifications made to the machine by the client without express authorization from the Manufacturer make the warranty immediately null and void and release the Manufacturer from any and all liability for damages caused by defects in the product.

This holds particularly true whenever such unauthorized modifications are made to safety devices and jeopardize their effectiveness.

The sane conditions apply whenever non-original spare parts or parts that differ from those expressly indicated by the Manufacturer as “SAFETY DEVICES” are used.

For all the reasons above, we advise our client to always contact our Customer Support Service when necessary.

Filtering with products that have a high content of bentonite, perlite, activated carbon or similar materials could cause erosion of the ceramic membranes. The warranty for the membranes does not cover any damage caused by the use of such products.

2.4.1 Centro di assistenza tecnica

DELLA TOFFOLA S.p.A.

Via Feltrina 72 31040 Signoressa di Trevignano (TV) (Italia) Tel. +39 0423 6772

Fax. +39 0423 670841 E-mail dtgroup@dellatoffola.it

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Customer Support Service must provided with:

- the machine’s serial number;

- its year of manufacture

- a description of the defects/malfunctions observed;

- any checking operations already performed;

- any adjustments and modifications made, together with their effects and consequences;

- any other information deemed useful in solving the problem.

2.5 PRELIMINARY OPERATIONS AT THE USER’S RESPONSIBILITY

Barring contractual agreements otherwise, the following preliminary operations are usually the responsibility of the user:

● Preparation of the rooms, including any masonry and/or cable chasing work required;

● Connecting electrical power supply in compliance with the regulations in force in the nation of

use;

● Connecting pneumatic power supply with compressed air (backwashing);

● Nitrogen supply

● Feeding of hot and cold water for machine washing;

● Chemical washing substances

● Feeding of the product to be treated;

● Wash water drainage and elimination systems;

● Systems or piping to receive the product treated.

● Systems to receive the solids separated

The machine is delivered in perfect working order and ready for use.

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3 SAFETY

3.1 SAFETY RULES

The system has been constructed in compliance with the Harmonized Technical Standards below:

UNI EN ISO 12100-1

UNI EN ISO 12100-2

UNI EN ISO 13857

UNI EN ISO 13850

CEI EN 60204-1

UNI EN ISO 14121-1

UNI EN 982

UNI EN 983

UNI EN 953

UNI EN 349

Table 3–1

Safety of machinery – Basic concepts, general principles of design (Part 1: Terms, methods). Safety of machinery – Basic concepts, general principles of design (Part 2: Specifications and Technical Principles).

Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs.

Safety of machinery – Emergency stop – Principles for design and operation.

Safety of machinery – Electrical equipment of machines. Part I: General Requirements..

Safety of machinery – Risk assessment - Part 1: Principles.

Safety of machinery - Safety requirements for fluid power systems and their components – Hydraulics.

Safety of machinery - Safety requirements for fluid power systems and their components – Pneumatics

Safety of machinery - Guards - General requirements for the design and construction of fixed and movable guards.

Safety of machinery - Minimum gaps to avoid crushing of parts of the human body.

3.2 GENERAL SAFETY RECOMMENDATIONS

Before rendering the machine operative, read this manual carefully and follow all the instructions provided.

Job safety is one of the main concerns of Della Toffola's designers.

In the manufacture of this machine, every effort has been made to provide for all possible hazardous situations and, of course, to adopt suitable safety measures. Nonetheless, some risk of accident derived mainly from a careless or improper use of the machine remains.

That is why it is essential to read this section very carefully before proceeding to action of any kind on the machine.

Carefully reading this manual and consequently making proper use of the machine are essential to its safe operation, otherwise Della Toffola S.p.A. can accept no liability for any accidents or damage.

Likewise, Della Toffola S.p.A. declines all liability for changes made to the machine without its prior written permission since they may compromise the marking and consequently make the corresponding manufacturer's conformity declaration null and void.

For such purpose, each chapter provides the following information required for man-machine operation whenever necessary:

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● the minimum operator qualification required;

● the number of operators necessary;

● the maneuvers to be performed on the chine in complete safety;

● remaining dangers;

● personal protective equipment necessary or recommended;

● ways to prevent human error;

● prohibitions/obligations regarding reasonably predictable incorrect behaviour.

This information must be scrupulously respected.

The user can integrate the information provided by the Manufacturer with additional work instructions, obviously whenever not in contrast with those provided in this manual as a contribution to the safe use of the machine.

Careful attention must be given to the following points in regards to the clothing worn by anyone who has anything to do with the machine:

● avoid the use of clothes with catches that might get caught on parts of the machine;

● avoid wearing ties or other loose types of clothing;

● avoid wearing bulky rings or bracelets that might led to the hands getting caught on parts of the

machine.

Wherever necessary, this manual also provides additional suggestions to be adopted by the user regarding preventive measures, personal protection equipment, ways to prevent human error, and prohibitions/obligations regarding reasonably predictable incorrect behaviour.

The following indications must absolutely be scrupulously respected:

● The removal and/or disabling of the protective devices installed in the machine is absolutely prohibited;

● Operations conducted under reduced safety conditions must be conducted with scrupulous respect for the indications provided in the respective descriptions;

● Following an operation conducted under reduced safety conditions, the status of the machine with its safety guards enabled must be restored as soon as possible and in any case before the machine returns to operation;

● No parts of the machine must be modified for any reason; modifications compromise the marking and invalidate the respective conformity certificate. The Manufacturer declines any and all liability as a result of the same. Any modifications required must be requested directly from the Manufacturer;

● Clean the machines casing, panels, and controls with soft, dry cloths or others lightly dipped in mild detergent solution; never use any type of solvent such as alcohol or petrol that might damage its surfaces;

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● Position the machine as established at the moment of order and in accordance with the diagrams provided by the Manufacturer, who will decline all liability for damage or injury otherwise.

● The greatest attention is required during the normal operation of the machine.

● The feed pumps must never be allowed to run dry. The mechanical seals can easily be

damaged if they are operated without any fluid in the pump, even for short periods of time.

● Pay careful attention when manually cleaning the machine with water. Always disconnect the electric power supply before aiming jets of water against any part of the machine. Never aim jets of water at the electric control panels.

● It is forbidden for anyone to take independent action or perform maneuvers other than those for which they have been authorized, or that may affect their own or other people's safety.

● Never dismantle, modify or disable parts of the machine (functional parts, control systems or safety devices).

● In the workplace, it is forbidden to use clothes or personal belongings that, given the nature of the process and the characteristics of the machine might constitute a hazard for personal safety. Personal clothing worn at the workplace must consequently have no loose parts that may be drawn in by any moving parts.

● Never wear bracelets, necklaces or other objects that may become caught up in moving parts.

● While at work, personnel must remain in the right position and always avoid exposing

themselves to any risk.

● Work stations must be kept clean and tidy; all waste of any kind must be placed in suitable containers.

● Use powder-type fire extinguishers to stop the further spread of fire whenever fire breaks out.

● In case of emergency, every worker must make his or her own contribution on the basis of his

or her own ability, experience, and skills to collaborating with the personnel designated for the implementation of fire-prevention and fire-fighting measures, building evacuation, rescue and first aid.

IMPORTANT!

Della Toffola declines all liability for damage or injury caused by the machine in the case of:

- the use of the machine by inadequately trained personnel;

- inappropriate use;

- defects in the electric, hydraulic or pneumatic power supply;

- inadequate maintenance;

- unauthorized modification or repair;

- the use of non-original spare parts or others not specific for the model;

- the total or partial failure to respect these instructions;

- use of the machine in contrast to specific laws/regulations in the nation of use;

- calamities and unforeseeable events.

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3.2.1 Control operations and inspections

Personnel assigned to the machine:

Level 1 Machine operator (Client technician)

Mechanical maintenance man

Electric maintenance man

Control operations and inspections must be conducted as indicated in Chapter 4.6 of this Instruction manual.

The Manufacturer declines liability for damage or injury derived from the failure to promptly replace worn out or damaged parts.

Such checks must be conducted by expert personnel and include both visual inspection and operational testing in order to ensure the safe operation of the machine.

Such operations include:

● Checking the framework and walkway, which must not have any cracks, breakage, damage, deformation, corrosion, wear or alteration of original characteristics;

● checking all mechanical and electric parts;

● checking all connections made with pins and screws (vibration might have caused loosening);

● operational testing of the machine;

● checking the status of the machine;

● checking the seal and efficiency of the hydraulic systems.

● checking the efficiency and good condition of the electric system.

The results of such checking must be provided in the respective data sheet.

CAUTION! Any anomalies observed must be eliminated prior to returning the machine to

operation; the expert in charge of checking must make a note of the repairs performed in the data sheet in sign of approval for the machine’s use.

Personnel assigned to checking the machine must promptly report any cracks or dangerous anomalies observed to the machine Manufacturer.

Put the machine out of service whenever malfunctions are observed and then proceed to the respective inspections and/or repairs.

Make sure that no foreign objects have been left inside the machine after any maintenance operation has been performed

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3.3 DANGER ZONES

The danger zone is limited by the dotted line indicated in the following overhead drawing of the machine, which covers an outer perimeter allowing for at least 2000 mm on all sides.

Figure 3–1

3.4 SAFETY DEVICES

The following safety devices are positioned on the main electric control panel and elsewhere:

Checks on the safety devices are fundamental to the safety of the operator and the machine and therefore require the greatest accuracy

3.4.1 Pressure-switches and safety valves

The machine is equipped with a number of pressure-switches that stop the machine whenever the pressure exceeds the acceptable limits set.

The machine is also equipped with safety valves that intervene whenever the pressure-switches or electric system malfunction.

Whenever the pressure in the filtration circuit reaches values of higher than 13.5 Bar, the safety valve Vs2 opens in order to prevent dangerous over-pressures for occurring.

Whenever an over-pressure of more than 6 Bar arises in the tank SE, the safety valve Vs1 opens to vent the excess pressure.

Whenever an over-pressure of more than 6 Bar arises in the rotating screener SRB, the safety valve Vs3 opens.

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In the same way, the air circuit is equipped with a safety valve for pressures of more than 10 Bar.

The machine is built with an IP 55 Protection Rating to CEI EN 60529 Standard, and is for such reason protected against sprays of water and the risk of electric shock by direct or indirect contact.

3.5 RESIDUAL RISKS

RESIDUAL RISK: a risk that cannot be totally eliminated or sufficiently reduced through the design

of efficacious means of protection. The Instruction manual provides information on residual risks and the instructions and warnings required.

The machine does not pose any residual risks that may induce the operator to perform operations that place himself or the machine in danger.

Careful attention must be given to the following residual risks that arise when the machine is placed into operation that cannot be eliminated.

WARNING: ACID SUBSTANCES

Chemical detergents are used to wash the machine.

Chemical detergents can cause serious burning of the skin in the event of contact.

Use only the doses recommended by the producer and consult the product’s safety sheet.

Never touch any chemical detergent that comes out with your hands or any other part of the body and rinse any part that has come into contact with abundant sprays of water.

Consult the product safety sheet whenever any area of your skin has come into contact with acid.

Always wear the appropriate PPE (Personal Protective Equipment)

CAUTION: RISK OF BURNING

During hot water and chemical washings, the surfaces of the machine can reach elevated temperatures of up to 70°C. Carefully avoid all contact with parts of the machine involved in washing in order to avoid the risk of burns.

CAUTION: ELECTRIC RISKS FOR PARTS UNDER VOLTAGE

Operations on the general control panel must be performed only by competent personnel and with the electric power supply disconnected.

CAUTION: MACHINE IN OPERATION

No unauthorized persons must be in the vicinity of the machine, where only the presence of the operator is permitted. Any unauthorized persons in the vicinity of the machine must be sent away, and the machine must be stopped if necessary.

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3.5.1 Risk of contaminating the product

Machines with automatically operated cycles using detergents for washing or acid substances for the regeneration of filtration modules are subject to residual risk of contaminating the product

whenever one or more phases are run incorrectly or whenever any particular problem arises.

The machine setting parameters offer the operator the possibility to choose the desired type of operation in order to either let the operator decide whether to start a work cycle with a stop and then request confirmation to continue after the washing/regeneration phase or to start a work cycle that continues automatically without requesting confirmation to continue or other control operations by the operator but which might lead to the contamination of the product.

These two types of operation are:

1 Stop with confirmation request: before starting a new work cycle, the machine stops for a pause and waits for the operator to provide confirmation of the message that appears on the display. Prior to confirming this message, the operator must check the machine and make sure that it is ready to receive the product to be filtered. The operator must therefore make sure that no residual contaminants have remained inside the machine and that all its parts (valves, pressure-switches etc.) are in perfect working order.

2 Automatic continuation: the machine executes all the work phases for an indefinite number of cycles automatically without requiring confirmation or other control operations by the operator. In

this type of operation, the residual risk of contaminating the product is present whenever one or more phases are run incorrectly or whenever any particular problem arises.

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4 INSTALLATION

Unskilled labourer

Level 2 machine operator (Advanced client technician)

Lifting and movement equipment operator

Mechanical maintenance man

Electric maintenance man

4.1 INSTALLATION SITE REQUIREMENTS

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The machine has been designed and constructed for installation in areas with the following characteristics:

● The installation area must be perfectly level and capable of withstanding its weight when

loaded with product to be worked.

● The machine must be positioned under roofing in a luminous and ventilated area large enough

to ensure the workplace with optimum ergonomics and safety.

● The machine and its electronic parts and Touch-screen panel in particular must absolutely be

protected against exposure to direct sunlight and high temperatures in order to prevent malfunction or irreparable damage.

● An area sufficient to permit easy use, maintenance, and work instruments/connection piping

movement operations must be left around the machine.

● The ambient temperature must be such to ensure the comfort of the operator but never under

any circumstances drop below zero in order to avoid freezing

● The machine has not been designed to work in areas with explosive or corrosive atmospheres

or wherever excess dust is present.

● The machine must be positioned in such way as to permit washing by sprays of water; the

installation room must be provided with adequate drainage systems.

● The lighting in the installation room must comply with the regulations in force in the nation of

use and must ensure good visibility in every point sufficient for the clear reading of the operator panel and in every point and the identification of the emergency buttons while avoiding the creation of hazardous glare.

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4.2 OPERATOR WORK AREAS

This machine does not have any fixed operator work area because the operator can access any part of it for operation, even if the position adopted most commonly is in front of the touchscreen on the control panel.

The figure below shows the areas needed for normal crossflow filter use and maintenance operations.

Figure 4–1

A Area for working and control of electric devices, management of processing phases and

machine parameter configuration

B Area for control of processing phases. C Area for control of processing phases and fixed and movable hydraulic connections. D Area for control of processing phases and fixed and movable hydraulic/pneumatic

connections.

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4.3 SHIPPING AND MOVING

Lifting and moving equipment operator

Make sure that equipment used for unloading and moving has adequate load capacity for the load to be lifted (see the weights indicated in Table 4–1).

THE TRANSPORT, UNLOADING AND ASSEMBLY OF THE MACHINE MUST BE PERFORMED ONLY BY SPECIALIZED PERSONNEL AUTHORIZED FOR THE PURPOSE.

4.3.1 Transport

At the request of the client, and depending on the type of transport envisioned (by land, sea, etc.), the machine is supplied with the most appropriate type of packaging; in any case, it is no danger of damage by the weather because it is constructed in corrosion-resistant materials with an IP Protection Rating.

In any case however, keep the machine away from salty atmospheres (such as those in marine environments) that may damages the stainless steel with which it is made.

Also make sure to fasten the load securely to the transport vehicle in such way that it will never move even when the vehicles accelerates or decelerates abruptly.

Make sure that no parts of the machine are in contact with one another or with the transport vehicle apart from the resting points foreseen (support feet, frame, etc.) in order to avoid damage or movement caused by vibrations or impact etc.

The machine has one or more filtration modules MF/x that contain membranes in ceramic material. Take every precaution necessary to avoid impact or vibrations that may damage these modules.

The filtration modules must be transported upright (the same position they must be in for normal operation); remember this whenever the machine must be disassembled for transport or

movement.

Upon the arrival of the machine at destination, make sure that it has not undergone any damage, and if so, immediately contact DELLA TOFFOLA S.p.A.

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4.3.2 Lifting and moving the machine

4.3.2.1 Lifting

DANGER

Before unloading the machine make sure that the surface on which the machine will rest is capable of withstanding its weight.

The surface on which the machine is installed must have a load capacity equal to the SUM of the machine’s weight and the load of the product to be processed by consulting the Technical Data Table before proceeding.

Makes sure that the vehicles and equipment used for the unloading and movement of the machine have adequate load capacity for the weight of the machine.

● For the lifting and movement of the machine, use a lift truck of adequate load capacity with

long forks spread wide. The forks must rest on the machine’s frame and protrude from the opposite side by a few centimeters (see Figure 4–2).

● During all lifting phases, make sure that no one is under or in the vicinity of a suspended load.

● Make sure that the lift truck forks do not apply leverage on deformable parts, plastic parts, or

electric cables.

● Constantly check the correct balancing of the raised load in order to prevent shifting,

unexpected unbalancing, or dropping to the ground.

The machine’s weight is indicated in the table below:

Model 50 85 130 170

Weight kg

Table 4–1

Figure 4–2

950 1100 1750 1890

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The Manufacturer declines all liability for damage or injury caused by the use of lifting systems other than those described above.

Machines can be shipped on wooden pallets or inside wooden crates upon request; in this case as well a lift truck with adequate load capacity can be used.

4.3.2.2 Movement

Machines equipped with adjustable support feet must be moved only by means of lift trucks with adequate load capacities (see the paragraph entitled “Lifting”).

Machines equipped with wheels, instead, can be easily moved by hand once they have been unloaded form the transport vehicle.

Be extremely careful when moving machines on wheels by hand.

In order to avoid risks of crushing, these machines must be shifted only by pushing from behind and never pulled, in order to make sure that no one is ever on the trajectory of the machine’s movement.

The person moving the machine must be supervised by another person who does not participate in propulsion but continuously checks the path of the machine’s movement instead for the arrival of obstacles, persons, or any other risk that appears.

The supervising person must promptly warn the mover of the machine of any risk in its path in order to permit the rapid stopping of all movement.

CAUTION

Once the machine has been positioned in the workplace and all parts have been assembled, scrupulously check stability.

4.3.3 Assembly

The filter is sometimes delivered partially disassembled for better shipping. In this case, the parts must be reassembled upon arrival by consulting the assembly drawings enclosed at the end of the manual.

Whenever the wheels have been disassembled, they must be reassembled by making sure that those provided with swivel support are positioned on the electric control panel side.

Whenever the adjustable support feet have been disassembled, they must be reassembled by screwing them all the way into the frame

The assembly of machine components (with the exception of the wheels or support feet) must be performed exclusively by authorized DELLA TOFFOLA S.p.A. technical personnel.

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4.4 LEVELLING

Unskilled labourer

After positioning the machine at the workplace, check levelling by using a spirit level.

If the filter is not perfectly aligned, adjust the support feet (if available) or position the machine on more level ground.

4.5 CONNECTIONS

4.5.1 Hydraulic system connections

Mechanical maintenance man

The filter must be suitably connected in the work circuit. Connect the inlet circuit for the product to be filtered, the wash water inlet line, and the outlets for the filtrate and the concentrate, and all the accessory connections.

Consult the flow chart at the end of the manual and the figures and the table below for hydraulic connections (Table 4–2 Connections)

● Both fixed (steel pipe) and mobile (flexible plastic conduit) connections can be used;

● Rigid connection piping must be fixed independently of the machine so that its weight does not

come to bear on the inlet and outlet couplings;

● Use flexible couplings to connect rigid pipes in order to prevent the reciprocal transmission of vibrations between the machine and its piping;

● The piping must be compatible with legal requirements concerning the product being processed (e.g. suitable for beverages or aggressive liquids);

● The piping and conduits must be capable of withstanding the mechanical stress produced by the machine; for instance, it must not suffer crushing due to the suction force of the feed pump;

● The piping must be suitably sized, with a diameter proportional to the machine’s flow rate and never smaller than the inlet and outlet couplings;

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● Whatever type of fixed piping or mobile tubing you use, routinely check the couplings for leaks to keep the pumps from sucking air through cracks.

Water connections:

- Connect the coupling A0 to a partially concentrated product discharge line.

- Connect the coupling A1 to the filtered product storage tank.

- Connect the coupling A2 to a wash water drainage pipe, being careful to avoid creating

counter-pressure or leakage of liquid. Wash waters must be channeled into an accumulation or purification system in compliance with the laws in force.

- Connect the coupling A3 to the storage tank for the product to filter. As a general rule, this

piping should be no longer than 10 meters long.

- Connect the coupling A4 to the discharge collection tank (solid parts such as fibre, seeds,

skins, etc) coming from the rotating screener.

- Depending on the type of product to filter (whether clarified product or high solids product)

connect the coupling A5 to either one or the other following tank:

● A) product to be filtered storage tank – external recirculation for clarified products

● B) lees collection tank (product that cannot be filtered) – for products with high

suspended solids. This tank must have a capacity greater than or equal to the volume indicated on the “Concentrate tank volume” parameters page.

- Connect the coupling A8 to the cold water inlet piping (see the paragraph entitled

Servomechanisms for the respective characteristics)

- Connect the coupling A7 to the hot water inlet piping coming from a distribution mains or a

storage tank (see the paragraph entitled Servomechanisms for the respective characteristics).

- Connect the coupling A9 to the basic detergent tank (caustic tank). As a general rule, this

piping must be kept to a minimum length and every measure necessary must be taken (heating and/or insulation) in order to prevent crystallization of the product that might block suction.

- Connect the coupling A10 to the acid detergent tank (phosphoric acid)

- Connect the coupling A11 to the neutralizer detergent tank (citric acid)

- Connect the coupling A12 to the booster detergent tank.

Crossflow filter

The sizes and types of coupling are shown in the following table.

Table 4–2 Connections

Pag. 33/75

Model

50 85 130 170

A0 – Concentrate suction/discharge