OMOGENEIZZATORE/POMPA AD ALTA PRESSIONE
HOMOGENIZER/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/A
43100 Parma, Italy
Tel: +39 0521/965411
Fax: +39 0521/242819
Internet: htttp://www.niro-soavi.it
E-mail: niro-soavi@niro-soavi.it
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: niro-soavi@niro-soavi.it
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
1.1 TECHNICAL DATA SHEET
1 GENERAL
1.1 Serial Number 4759
1.2 Kind of Machine HOMOGENIZER
1.3 Model ARIETE
1.4 Type NS3018H
1.5 Execution Aseptic
1.6 Special Features CGMP+ELECTRUPOLISHED+3A+FDA
1.7 MAX Operating Pressure 1000 bar
1.8 Flow Rate Type V
1.9 MIN Flow Rate 150 l/h @ 15,5 Hz
1.10 MAX Flow Rate 500 l/h @ 51,6 Hz
1.11 MIN Feed Pressure 6-7 bar
1.12 MAX Backpressure 5 bar
2 OPERATING CONDITIONS
2.1 Product
CELL RUPTURE(PRODUCT
SOLUTION IN WATER)
2.2 MAX Viscosity 2-3 cP
2.3 MAX Relative Humidity 40 %
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 MULTIBLOCK VHP
3.1.2 Number of plungers 3
3.1.3 Material of plungers CERAMIC
3.1.4 Plunger diameter 20 mm
3.1.5 Stroke 70 mm
3.1.6 Pumping valve type PVB 3\4"
3.1.7 Overpressure valve
SPRING LOADED
VALVE
setpoint
1100
bar
3.1.8 Connection, Inlet 1" TRICLAMP
3.1.9 Connection, Outlet 1" TRICLAMP
3.2 HOMOGENIZING VALVE
3.2.1 Number of Stages 1
3.2.2 Type of actuator PNEUMATIC
3.2.3 Type of control PNEUMATIC
3.2.4 Homogenizing Valve Type 11,9-30 HP
3.3 DRIVE END
3.3.1 Main Motor (frame size; type) AC180M/4P
3.3.2 Main Motor Power 18,5 kW
3.3.3 RPM Crankshaft 44 MIN
3.3.4 RPM Crankshaft 145 MAX
3.3.5 Drive Type ROSSI REDUCER
3.3.6 Gearbox speed reduction ratio 5
3.4 LUBRICATION
3.4.1 Type FORCED
3.4.2 Lubricating system TP3A GR.1/6,1
3.4.3 Oil Cooling system YES
3.5 MAIN ELECTRICAL CIRCUIT
3.5.1 Number of phases 3
3.5.2 Voltage 400 V
3.5.3 Frequency 50 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 /
LEGEND
TO CONCEPT FLOW SHEET
SPEC - 102 C
____________________ REV.
DATE
Page 1 of 2
____________________
SIG.
0
1. INSTRUMENT SYMBOLS
LOCAL
IN MAIN PANEL
LIMIT VALUE
H: HIGH OR OPEN
L: LOW OR CLOSED
POINT OF MEASUREMENT
WITHOUT 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 SUPPLY
CIP CLEANING IN PLACE
CS CONDENSATE SUPPLY
CWS CHILLED WATER SUPPLY
ES ELECTRIC SUPPLY
GS GAS SUPPLY
NS NITROGEN SUPPLY
OS OIL SUPPLY
SS STEAM SUPPLY
WS WATER SUPPLY
. R RETURN
5. MACHINERY AND EQUIPMENT
AUTOMATIC ACTUATOR FOR REMOTE
CONTROL, GENERAL
MANUAL ACTUATOR NOT FOR REMOTE
CONTROL
AUTOMATIC ACTUATOR WITH INTEGRATED
MANUAL 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 CROSS
FLOW e.g. ELECTRIC HEATER
LIGHT SOURCE
VALVE CLOSES (FC)
VALVE OPENS (FO)
VALVE RETAINS POSITION
FAIL-OPEN INDICATION FOR A 3-WAY VALVE
H
PHONE : +39.0521.965411 - FAX : +39.0 521.242819
Niro-Soavi S.p.A.
via M. da Erba Edoari, 29/A
43100 PARMA (ITALY)
Speci alty Produ cts
Division
LEGEND
TO 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 ALARM
B DISPLAY OF STATE (2)
C CONTROLLING (4)
D DENSITY DIFFERENCE
E ALL ELECTRICAL VARIABLES (5) SENSING ELEMENT
F FLOW RATE RATIO
G GAUGING, POSITION OR LENGTH
H HAND (MANUALLY INITIATED) OPERATED
I INDICATING (3)
J SCAN
K TIME OR PROGRAMMED TIME
L LEVEL
M MOISTURE OR HUMIDITY
N USER'S CHOICE USER'S CHOICE
O USER'S CHOICE
P PRESSURE OR VACUUM TEST-POINT CONNECTION
Q QUALITY (5) INTEGRATE OR TOTALIZE INTEGRATING OR SUMMATING
R NUCLEAR RADIATION RECORDING
S SPEED OR FREQUENCY SWITCHING (2)
T TEMPERATURE TRANSMITTING
U MULTIVARIABLE MULTIFUNCTION UNIT
V VISCOSITY VALVE, DAMPER, ACTU, ELEMENT
W WEIGHT OR FORCE
X UNSPECIFIED (5) UNCLASSIFIED FUNCTIONS
Y VIBRATION COMPUTING RELAY, RELAY
Z EMERG. / SAFETY ACTING (2)
EXAMPLE : PDIRC DIFFERENTIAL PRESSURE INDICATION, RECORDING AND CONTROL
FIRST 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/OFF
3) SIGNAL TYPE : CONTINUOUS
4) 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 : +39.0 521.242819
Niro-Soavi S.p.A.
via M. da Erba Edoari, 29/A
43100 PARMA (ITALY)
Speci alty Produ cts
Division
0
23.01.03 1
DATE REV.
1/220217 4759
JOB NIRO SOAVI MACHINE SERIAL NO.
Required Min Max
Pressure (Bar) 2 4
Temperature (°C) 10 60
Consumption (l/h)
75 95
Pressure (Bar)
Temperature (°C)
Consumption (l/h)
Pressure (Bar) 2 3
Temperature (°C) 1 4
Consumption (l/h)
120
Pressure (Bar)
Temperature (°C)
Consumption (l/h)
Required Min Max
Pressure (Bar) 5 10
Consumption(Nm
3
/h)
0
Pressure (Bar)
Temperature (°C)
Consumption(Nm
3
/h)
Required Min Max
Pressure (Bar)
(1)
Temperature (°C)
Consumption (kg/h)
Pressure (Bar)
(2)
Temperature (°C)
Consumption (kg/h)
V = 3x 400 Hz = 50
kW = 22
A = 45
Note :
WATER YES
NO
YES
PISTONS
LUBRICATING & COOLING FLUID
STERILE
CONDENSATE
SPEC-103C
UTILITY SPECIFICATION
SIG.
MIB
MACHINE MODEL
NS 3018HA
OIL EXCHANGER
GEAR BOX
YES
COMPRESSED AIR
STEAM
ELECTRICITY
Electrical supply (V/Hz)
Power absorbed (kW)
Current absorbed (A)
(1) THE CLIENT MUST INSTALL A PRESSURE REDUCER AT THE STEAM INLET CONNECTION TO ADAPT THE PRESSURE TO THE MACHINE'S REQUIREMENTS
NO
NO
STERILE CONDENSATE
PRODUCTION
PULSATION DAMPER
STERILE CONDENSATE
EXCHANGER
NO
COMPRESSED AIR
Note : max. hardness < 15°fH ; max. particle size = 60 microns .
PHONE : +39.0521.965411 - FAX : +39.0521.242819
Niro-Soavi S.p.A.
via M. da Erba Edoari, 29/A
43100 PARMA (ITALY)
Specialty Products
Division
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
e-mail: niro-soavi@niro-soavi.it
DECLARATION OF CONFORMITY
MACHINE: HOMOGENIZER ARIETE
Model: NS3018H
Serial number: 4759
Machine TAG number 242X1100
Cabinet TAG number 242MC1100
Max Press. (MPa): 100
Rated Flow (dm
3
/h): 150-500
Year: 2003
The undersigned
DECLARES
under his own responsibility that the above mentioned Machine, object of this
declaration,
IS IN CONFORMITY
with the precepts of the following EEC directives and standard norms:
• 98/37/EEC
• 73/23/EEC and following updated 93/68 EEC
• 89/336/EEC
• EN 292-2/A1
• EN 60204-1
The above identified Machine has successfully passed all the trials and tests to
which it has been submitted.
PARMA 24/01/2003
D_ce_r2c baxter.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.
Y
EAR
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 NIROSOAVI'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.
2C001E0C.DOC 2.5.3
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, NIROSOAVI 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.
2C001E0C.DOC 2.6.1
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.
2C001E0C.DOC 2.7.1
Niro Soavi S.p.A
2.8. INSTALLATION
2.8.1 POSITIONING
The correct positioning of the machine within the production line is a precondition 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.
2C001E0C.DOC 2.8.1
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.
FIGURE 2.8.1
2C001E0C.DOC 2.8.3
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 feeding pump must have a net positive suction head 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.
2C001E0C.DOC 2.8.11
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.
2C001E0C.DOC 2.9.1
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).
2C001E0C.DOC 2.10.1
Niro Soavi S.p.A
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.
2C001E0C.DOC 2.11.1
Niro Soavi S.p.A
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.
2C001E0C.DOC 2.12.1
Niro Soavi S.p.A
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) (airoperated 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 PUSHBUTTON 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 (1
st
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
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 unt il 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 1
st
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
G
R
E
M
E
E
N
C
Y
O
P
T
S
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 us e 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 reestablished, 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 pushbutton (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
• replace (Section 4 MAINTENANCE)
• 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
• feed properly the
machine
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
• not enough feeding
pressure
• 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
• not enough feeding
pressure
• feed properly the
machine
• damaged or worn out
pumping valves
• replace (Section 4 MAINTENANCE)
• pump valves not
suitable for the product
• Contact NIRO SOAVI
• valves springs not
suitable for the product
• Contact NIRO SOAVI
• 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
• Contact NIRO SOAVI
• 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
• Contact NIRO SOAVI
• 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 startup
• 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)
Action required Mach.
hrs
Operator Date
4500 • 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
6000 • check / replace springs and
pumping valves
• check / replace homogenizing
valve
7500 • 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
9000 • check / replace springs and
pumping valves
• check / replace homogenizing
valve
10500 • 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
12000 • check / replace springs and
pumping valves
• check / replace homogenizing
valve
4c010e0c.doc 4.2.3
Niro Soavi S.p.A
When
(hrs)
Action required Mach.
hrs
Operator Date
13500 • 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
15000 • check / replace springs and
pumping valves
• check / replace homogenizing
valve
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 highpressure 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)
Action required Mach.
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
4C042E0C.DOC 4.4.1
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).
Niro Soavi S.p.A
4C042E0C.DOC 4.4.2
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.
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
4C042E0C.DOC 4.4.4
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.
Niro Soavi S.p.A
4C042E0C.DOC 4.4.5
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
Niro Soavi S.p.A
4C042E0C.DOC 4.4.6
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 antiextrusion 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.
Niro Soavi S.p.A
4C042E0C.DOC 4.4.7
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).
Niro Soavi S.p.A
4C042E0C.DOC 4.4.8
FIGURE 4.4.3
FIGURE 4.4.3
Niro Soavi S.p.A
4C042E0C.DOC 4.4.9
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
Niro Soavi S.p.A
4C042E0C.DOC 4.4.10
• 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 troublefree 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)
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4C042E0C.DOC 4.4.11
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.
Niro Soavi S.p.A
4C042E0C.DOC 4.4.12
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
L
H
A
P
N
B
C
D
E
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4C042E0C.DOC 4.4.13
• 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).
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
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