GEA Niro Soavi - Instruction manual
Instruction manual
Model:
Model:
Designation: Clarifying decanter
S.N.:
S.N.:
Type: waterMaster CF 4000
Revision:
Revision:
No. 8416-9001-815 | Edition 26.09.2012
One7TS
8066
00
Translation of the original instructions
GEA Mechanical Equipmentengineering for a better world
Instructions for use and maintenance
Introduction
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 rst having read and
understood the following Instructions for Use & Maintenance.
Yours faithfully,
For any further support or information, you may contact us at the below listed address.
GEA Mechanical Equipment Italia S.p.A.
Via A. M. da Erba Edoari 29, 43123 Parma - Italia
Tel. +39 0521 965411
Fax +39 0521 242819
e-mail: info.geanirosoavi@gea.com
Internet: http://www.niro-soavi.com
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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GEA Niro Soavi1
Instructions for use and maintenance
Introduction ................................................................................................................................. 1
1. General information ............................................................................. 6
1.1. Declaration of Conformity ................................................................................................ 7
1.2. Introduction ......................................................................................................................9
1.3. Warranty and testing .......................................................................................................10
1.3.1 Warranty ......................................................................................................................... 10
1.3.1.1 Warranty duration ..........................................................................................................10
1.3.1.2 Application mode ........................................................................................................... 11
1.3.1.3 Exceptions and limitations ............................................................................................. 11
1.3.1.4Materialefciency ..........................................................................................................11
1.3.2 Testing .............................................................................................................................13
1.4. Introduction ......................................................................................................................14
1.5. How to use the manual ....................................................................................................14
1.6 Reproduction and copyright terms ..................................................................................14
1.7. Revisions ......................................................................................................................... 15
1.8. User manual storage ....................................................................................................... 15
1.9. Customer in charge of the prearrangement ....................................................................15
1.10. Instructions for request actions .......................................................................................16
1.11 Instruction for ordering spare parts ................................................................................16
1.12 Operator characteristics and language used ...................................................................16
2. Description of the machine, technical data ....................................... 17
2.1 General description .........................................................................................................18
2.1.1 Operating principle ..........................................................................................................18
2.2 Main components of the machine ...................................................................................19
2.2.1 Monoblock compression head .........................................................................................21
2.2.2 Homogenising unit ...........................................................................................................22
2.2.3 Pressure Gauge ..............................................................................................................25
2.2.4 Compression head safety valve ......................................................................................26
2.2.5 Manifold Groups .............................................................................................................. 27
2.2.6 Water plant for sanitised machine ...................................................................................28
2.2.7 Pneumatic plant ...............................................................................................................29
2.2.8 Transmission assembly ...................................................................................................34
2.2.9 Drive ............................................................................................................................... 35
2.2.10 Housing ...........................................................................................................................36
2.2.11 Operator control panel .....................................................................................................37
2.2.12 Electrical equipment ........................................................................................................ 38
2.3 Standards,certications,limitsofuse,ergonomics,environmentalissues .....................41
2.3.1 Applicable technical standards ........................................................................................ 41
2.4 Ambient operating conditions .......................................................................................... 42
2.5 Atmosphereswithriskofexplosion/re ........................................................................... 42
2.6 Illumination ......................................................................................................................42
2.7 Vibration ..........................................................................................................................42
2.8 Noise ...............................................................................................................................42
2.9 Residue and environmental contamination .....................................................................43
2.10 Scrapping and disposal of materials ..............................................................................43
2.11 Disposal ..........................................................................................................................44
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
3. Safety and accident prevention .......................................................... 45
3.1 Applications, intended use ................................................................................................... 46
3.2 Intended, improper and permitted uses ................................................................................ 46
3.3 Work area, control area, danger zones ................................................................................. 47
3.4 Risks, dangers and residual risks in the area ....................................................................... 54
3.4.1 General safety ................................................................................................................. 54
3.4.2 Residual risks and hazards on the machine ....................................................................54
3.5 Safety equipment used ......................................................................................................... 55
3.5.1 Pressure relief valve ........................................................................................................ 55
3.5.2 Protections on the main motor .......................................................................................58
3.5.3 Emergency stop button ..................................................................................................58
3.5.4 Housing ...........................................................................................................................60
3.6 Safety notices .......................................................................................................................61
4. Installation............................................................................................. 63
4.1 Shipping ................................................................................................................................ 64
4.1.1 Shipping by ground over medium to long distances ........................................................65
4.2 Receiving and checking ........................................................................................................ 68
4.3 Storage .................................................................................................................................69
4.3.1 Storage prior to installation ..............................................................................................69
4.3.2 Storage for longer than 6 months ................................................................................... 70
4.4 Setting up the installation site ............................................................................................... 71
4.5 Hookup and cabling .............................................................................................................. 73
4.5.1 Hookup ............................................................................................................................ 73
4.5.2 Electrical hookup ............................................................................................................. 75
4.5.3 Grounding system (provided by client) ............................................................................ 76
4.6 Installation and assembly ...................................................................................................... 77
4.6.1 Installation instructions ................................................................................................... 77
4.6.2 Positioning ....................................................................................................................... 79
4.6.3 Levelling the machine .....................................................................................................80
4.6.4 Positioning the electrical equipment ............................................................................... 81
5. Commissioning and rst startup ........................................................ 82
5.1 Procedure .............................................................................................................................83
6. Operation and use ................................................................................ 88
6.1 Operator's responsibilities ..................................................................................................... 89
6.2 Electrical enclosure and control panel .................................................................................. 90
6.2.1 Control Panel on the machine ......................................................................................... 91
6.3 Startup procedure .................................................................................................................92
6.3.1 Position of operator .........................................................................................................92
6.3.2 Startup ............................................................................................................................. 94
6.3.3 Operation and adjustment ............................................................................................... 95
6.3.3.1 Regulating the homogenizing pressure - 1 stage ........................................................... 95
6.3.3.2 Regulating the homogenizing pressure - 2 stages ......................................................... 97
6.4 Stopping the machine ........................................................................................................... 99
6.4.1 Normal stop .................................................................................................................... 99
6.4.2 Emergency stop .............................................................................................................99
6.5 Washing ................................................................................................................................100
6.6 Checks after starting up the machine ................................................................................... 101
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
7. Maintenance .......................................................................................... 102
7.1 General Information ..............................................................................................................103
7.1.1 DenitionofSTAFFRESPONSIBILITIES .......................................................................103
7.2. Directions for correct maintenance ..................................................................................104
7.2.1 Forpropermaintenance: ................................................................................................. 104
7.2.2 Maintenance plan ............................................................................................................ 104
7.3 Safety, precautions and maintenance shutdown ..................................................................106
7.3.1 General safety warnings .................................................................................................. 106
7.3.2 Safety symbols ................................................................................................................ 107
7.3.3 Maintenance shutdown ...................................................................................................108
7.4 Maintenance during running-in period .................................................................................. 11 0
7.5 Planned routine maintenance during operation .................................................................... 110
7.5.1 General Information .........................................................................................................110
7.6Frequencyofmaintenancework ........................................................................................... 11 2
7.7 Maintenance sheets .............................................................................................................. 118
SHEET 00[a] ............................................................................................................................... 120
GENERAL MACHINE - Check noise and vibration ................................................................ 120
SHEET 00[b] ............................................................................................................................... 121
GENERAL MACHINE - Check protections and safety devices .............................................121
SHEET 00[c] ............................................................................................................................... 122
GENERAL MACHINE - Tighten nuts and stud bolts ...............................................................122
SHEET A .....................................................................................................................................125
COMPRESSION HEAD ..............................................................................................................125
SHEET A[a] ................................................................................................................................127
COMPRESSION HEAD - Visually check for seal and gasket leakage .................................. 127
SHEET A[b] ................................................................................................................................129
COMPRESSION HEAD - Replace pumping piston gaskets ..................................................129
SHEET A[c] ................................................................................................................................. 138
COMPRESSION HEAD - Check tightness of pumping pistons and nuts ............................138
SHEET A[d] ................................................................................................................................139
COMPRESSION HEAD - Check wear and if necessary renew the pumping pistons .........139
SHEET A[e] ................................................................................................................................144
COMPRESSION HEAD - Check and if necessary renew the pumping valves ....................144
SHEET A[f] .................................................................................................................................147
COMPRESSION HEAD - Visually check for leakage from the packings and from the gaskets of the head ......... 147
SHEET A[g] ................................................................................................................................148
COMPRESSION HEAD - Check and if necessary renew the pumping valve seats ............ 148
SHEETB ....................................................................................................................................152
HOMOGENIZING UNIT .............................................................................................................. 152
SHEETB[a] ................................................................................................................................154
HOMOGENIZING UNIT - Checking/renewing homogenizing valves .................................... 154
SHEET C[a] ................................................................................................................................ 159
PRESSURE GAUGE - Check state and operation .................................................................159
SHEET D[a] ................................................................................................................................ 163
HEADSAFETYVALVE-Check operation ...............................................................................163
SHEET E[a] ................................................................................................................................167
MANIFOLDGROUP-Check gaskets ......................................................................................167
SHEETF ....................................................................................................................................169
LUBRICATIONSYSTEM ............................................................................................................ 169
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
SHEETF[a] ................................................................................................................................170
LUBRICATIONSYSTEM-Change oil ......................................................................................170
SHEETF[b] ................................................................................................................................172
LUBRICATIONSYSTEM-Check and top up oil level ............................................................172
SHEET G[a] ................................................................................................................................ 176
WATERSYSTEM-Clean and/or renew lters ........................................................................ 176
SHEET G[b] ................................................................................................................................ 178
WATERSYSTEM-Check: piston lubrication water pipes - checkwaterowrate.................... 178
SHEET H .................................................................................................................................... 182
PNEUMATIC PLANT ..................................................................................................................182
SHEET H[a] ................................................................................................................................ 185
PNEUMATIC PLANT - Clean and/or renew lters ................................................................... 185
SHEET I [a] ................................................................................................................................. 188
BODYANDCRANKMECHANISM-General check of components ...................................... 188
SHEET L .....................................................................................................................................192
DRIVE ........................................................................................................................................192
SHEET L[a] ................................................................................................................................. 193
DRIVE - Check tension and service belts...............................................................................193
SHEET L[b] ................................................................................................................................. 197
DRIVE - Check tightness of the transmission elements ...................................................... 197
SHEET L[c] ................................................................................................................................. 198
DRIVE - Check V-belt wear and renew if necessary ..............................................................198
SHEET L[d] ................................................................................................................................. 200
DRIVE - Check pulley alignment .............................................................................................200
SHEET M[a] ................................................................................................................................ 203
HOUSING - General visual check ............................................................................................ 203
SHEET N[a] ................................................................................................................................ 206
ELECTRICALSYSTEMONTHEMACHINE-Check the electrical system on the machine .............206
8. Troubleshooting ................................................................................... 207
8.1 Troubleshooting ....................................................................................................................208
9. Waste disposal .....................................................................................212
9.1Denitionofwaste ................................................................................................................. 213
9.1.1 Special waste ..................................................................................................................213
9.1.2 Toxic-harmful waste ......................................................................................................... 213
9.2 Temporary storage ................................................................................................................ 213
9.3 Characteristics of the containers ........................................................................................... 213
9.4 Required registration ............................................................................................................. 214
9.5 Disposal ................................................................................................................................214
10. Spare parts .......................................................................................... 215
10.1 Recommended spare parts ............................................................................................. 216
10.2 How to order the spare parts ........................................................................................... 217
10.3 Safety warnings ............................................................................................................... 218
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
1. General information
Index
1.1. Declaration of Conformity
1.2. Introduction
1.3. Warranty and testing
1.3.1 Warranty
1.3.1.1 Warranty duration
1.3.1.2. Application mode
1.3.1.3 Exceptions and limitations
1.3.1.4 Materialefciency
1.3.2 Testing
1.4. Introduction
1.5. How to use the manual
1.6 Reproduction and copyright terms
1.7. Revisions
1.8. User manual storage
1.9. Customer in charge of the prearrangement
1.10. Instructions for request actions
1.11 Instruction for ordering spare parts
1.12 Operator characteristics and language used
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
1.1. Declaration of Conformity
What follows is the “Declaration of conformity” FACSIMILE. The ofcial copy will be lled in and
supplied with the machine.
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
In addition to this, GEA Niro Soavi is certied according to UNI EN ISO 9001 for Design, Manufacture
and Servicing of Homogenisers and high pressure piston pumps, therefore your machine has been
engineered and produced according to the approved quality procedures.
See the following gure for the UNI EN ISO 9001 Quality System Certicate FACSIMILE.
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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GEA Niro Soavi8
Instructions for use and maintenance
1.2. Introduction
This manual is aimed at operators and specialised personnel to allow correct use of the machine.
Inside the manual, the operator will nd the instructions and indications for:
• correct installation of the machine;
• functional description of the machine and each of its parts;
• performing adjustments in the set-up and start-up phases;
• correct scheduled maintenance;
• pay attention to the most elementary safety and accident prevention rules;
In this way the operator will be able to understand the problems related to the machine and the
product being processed.
In order to facilitate understanding of the content of this manual, we provide a list of terms used in it:
• DANGER ZONE:
Any zone within or around the machine in which an exposed person is subject to a risk to their
health and safety.
• EXPOSED PERSON:
Any person who is wholly or partially in a danger zone.
• OPERATOR:
Person in charge of installing, operating, adjusting, servicing and cleaning the machine.
• QUALIFIED TECHNICIAN:
This is a skilled technician specially trained to carry out special maintenance or repairs
that require knowledge of the machine, its functioning, proper safety measures and work
procedures.
WARNING: Accident prevention regulations for the operator.
WARNING: It can damage the machine and/or its components.
PRECAUTION: Further information about the operation in progress.
NOTE: Useful information provided.
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
1.3. Warranty and testing
If not specied otherwise in the order conrmation, the terms and conditions of the warranty are as
follows:
1.3.1 Warranty
GEA Niro Soavi guarantees the good quality and construction of its machines, and agrees to repair
and replace, at their own expense, any part that breaks or show signs of early wear due to the
bad quality of the materials used, manufacturing errors or incorrect assembly during the specied
warranty period.
The warranty does not cover parts that break or wear due to:
• user negligence related to level checking, lter cleaning, auxiliary services, insufcient feed
pressure of the machine;
• use of the machine with operating values exceeding the ones specied in the contract,
especially with respect to maximum pressure, ow, product treated, operating and cleaning
temperatures, feed pressure, specications of required utilities;
• use of incorrect tools for ordinary and extraordinary maintenance;
• lack of or incorrect maintenance;
• alterations or modications carried out - whether directly or indirectly - without specic written
authorization from GEA 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 from 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 & MAINTENANCE imply integral
acceptance of Warranty conditions.
For further information about application of the Warranty, see General Terms of Sale.
1.3.1.1 Warranty duration
The warranty shall last for 12 MONTHS from the date of delivery of the machine, unless otherwise
specied in the Order Conrmation.
Such period shall remain unchanged even in the event that spare parts replacements or repairs are
carried out during the 12-month period.
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
1.3.1.2. Application mode
As a condition of the applied warranty, any parts claimed to be defective by the customer must be
provided to GEA 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 warranty shall be executed - according to GEA Niro
Soavi, on the manufacturer’s premises, on thirds party’s or directly on the spot.
The cost of shipping materials to the customer’s premises 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
accommodation of GEA Niro Soavi technicians.
1.3.1.3 Exceptions and limitations
The warranty 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, pumping piston gaskets and related packing
and support washers, safety valve seat, lters, etc., as well as those parts whose life can not be
estimated beforehand - such as lamps, fuses, plungers - together with any coating, pumping valve
and their seats, homogenizing valve, pressure gauges.
For the components and accessories bought from independent Vendors, the warranty shall be the
one granted to GEA Niro Soavi by such Vendors.
1.3.1.4 Materialefciency
Before returning to GEA Niro Soavi any part for which a replacement/repair under warranty is
claimed, the necessary approval shall be obtained from Customer Service.
Reported below is the correct procedure for material efciency:
1. Complete the authorization module (see document below) before the material efciency.
2. Send the complete module to the e-mail address: returns.geanirosoavi@geagroup.com.
3. Wait for conrmation from GEA Niro Soavi
4. After receiving the conrmation: print the module and attach it to the material to send together
with the shipping documents.
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
ID_claim
(if present)
Area to be
completed by
GEA NS
Description of the fault/
problem (***)
ID_claim
(In case of wrong
order caused
by GEANSOA
mistake)
Area to be completed by GEA NS
order
GEANS
conrm.
Reason for return
(ll in the column on the right,
Serial
Number
choosing the related cause) X
(machine)
Q.ty
Repair on warranty
Repair under payment
Inspection
Replacement (*)
Credit without restocking charge (**)
order
GEANS
conrm. \
Reason for return
(ll in the column on the right, choo-
sing the related cause) X
Credit with restocking charge (***)
Calibration
Serial
Wrong order
Number
ID returns
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Code (*) Description
GEA Niro Soavi12
Acronym: Note:
Authorization
\(**) \ \
(acronym)
Instructions for use and maintenance
All parts shall be properly packed to avoid any damage in transit, and accompanied by:
• reference to the purchase order;
• machine serial number;
• part code number;
• detailed description of the defect and how it was discovered;
• authorization module to the document completed and approved.
All parts recognized to be under guarantee are delivered ex works; replaced parts are the property
of GEA Niro Soavi and shall be returned ex works.
1.3.2 Testing
Before shipment all of our machines are accurately tested at GEA Niro Soavi premises by qualied
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 performance of the machine (ow 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 ow rate compared to the rated
value ± 5% with product, according to the different temperatures and viscosity of the product treated.
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
1.4. Introduction
The employer must provide information to the personnel about the following topics concerning safe
use of the machine:
• Risk of accidents.
• Operator safety devices.
• General or foreseen accident prevention measures by international directives and by the
legislation of the Country where the machine is installed.
The operator, the maintenance and cleaning personnel, etc. must strictly adhere to the accident
prevention standards of the Country the where machine is installed.
WARNING:
Before starting the operation, the operator should know the arrangement and the functioning
of the controls and the characteristics of the machine, and should have completely read this
manual.
Instructions, warnings, general accident prevention measures contained in this manual must
be strictly observed.
The possible change or replacement of parts of the machines, not authorized by GEA Niro
Soavi, can result in a risk of accident and releases GEA Niro Soavi from any civil or penal
liability.
1.5. How to use the manual
This manual is easy to consult since on the rst page there is an index page that allows immediate
localization of the topics of interest. Chapters are organized in a hierarchical structure that facilitates
desired information research. Each chapter is always preceded by the index.
As regards maintenance information, it is structured in charts and divided by topics, this allows the
operator a:
• comfortable consultation;
• possibility to group the necessary information to the intervention to be carried out.
1.6 Reproduction and copyright terms
All rights reserved by GEA Niro Soavi
Partial or total reproduction of this manual or its recording on any device (magnetic, magnetic-optic,
optic, microlm, photocopy, etc.) is prohibited; unless otherwise authorised by GEA Niro Soavi.
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
1.7. Revisions
Further revisions of the manual, if any, follows the operation changes or replacements of the machine
and are managed and supplied to the customer by GEA Niro Soavi.
1.8. User manual storage
Storage obligation
Keep this manual and all the attached literature in a readily accessible place, near the machine and
known to all the users (operators and maintenance personnel).
The operators and the maintenance persons must be able to quickly nd and consult the manual and
the annexes in any situation.
WARNING:
The manual is an integral part of the machine for safety purposes.
Therefore it:
• shouldbekeptcompletely(inallitsparts)
• shouldaccompanythemachineuptoitsdestruction(alsoincaseofshipping,sales,
hiring, lease, etc.);
• thepossiblechangesenteredshouldbekeptupdatedandinformed.
1.9. Customer in charge of the prearrangement
The Customer (user) should prearrange, by themselves, the installation place and the whole electric
and pneumatic supply necessary for the machine functioning as described below:
• Prearrangement of the rooms.
• Prearrangement of the electric-power supply, up to the power supply connection of the
machine according to the regulations in force.
• Prearrangement of the auxiliary services appropriate for the machine needs (such as air
network).
• Eventual safety devices upstream and downstream from the power supply line (i.e. switch,
differential, earth connection, etc.) as stated by the law in force.
• Suitable lifting equipment to move the machine.
WARNING:
All the above listed prearrangements, unless otherwise indicated, should be performed in
compliance with the regulations in force in the country of installation.
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
1.10. Instructions for request actions
Request for interventions by Customer Technical Service should be sent via fax to the following address:
GEA Niro Soavi Via Da Erba Edoari, 29 - 43123 - PARMA (Italy) - Telephone +39 0521 965411,
Fax +39 0521 242819, e-mail: info.geanirosoavi@geagroup.com, http//www.niro-soavi.com:
• type of machine, serial number, installation year;
• fault detected;
• exact address of the premises where the machine is installed.
1.11 Instruction for ordering spare parts
For the method of ordering spare parts, see chapter 10, points 10.1 and 10.2.
1.12 Operator characteristics and language used
To understand the instructions (text and gures) the machine operator must have (or acquire, by
proper education and training) at least the following characteristics:
• Enough general knowledge and technique to read and understand the manual content in the
parts of their concern and to correctly interpret the layout and diagrams.
• Ability to understand and interpret the symbols, pictograms and video messages.
• Knowledge of the main hygienic, accident prevention and technology standards.
WARNING:
The responsible person of the safety in the Customer premises must:
• check that the knowledge possessed is in fact sufcient for reading and full
understanding of the manual;
• performingproperpracticaltraining andensuring,evenbya test,thattheoperators
have the capacity to operate the machine correctly and safely, both in normal operation
and emergency situations.
WARNING:
Theoperatorsmustnotcarryoutoperationsreservedformaintenancepersonsorqualied
technicians.
The manufacturer is not liable for damages deriving from the failure to adhere to this
prohibition.
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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Instructions for use and maintenance
2. Description of the machine, technical data
Contents
2.1 General description
2.1.1 Operating principle
2.2 Main components of the machine
2.2.1 Monoblock compression head
2.2.2 Homogenising unit
2.2.3 Pressure Gauge
2.2.4 Compression head safety valve
2.2.5 Manifold Groups
2.2.6 Water plant for sanitised machine
2.2.7 Pneumatic plant
2.2.8 Transmission assembly
2.2.9 Drive
2.2.10 Housing
2.2.11 Operator control panel
2.2.12 Electrical equipment
2.3 Standards,certications,limitsofuse,ergonomics,environmental
issues
2.3.1 Applicable technical standards
2.4 Ambient operating conditions
2.5 Atmosphereswithriskofexplosion/re
2.6 Illumination
2.7 Vibration
2.8 Noise
2.9 Residue and environmental contamination
2.10 Scrapping and disposal of materials
2.11 Disposal
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GEA Niro Soavi17
Instructions for use and maintenance
2.1 General description
The GEA 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 uids and achieve homogeneous dimensional distribution.
This process can be applied to a wide range of products of varying viscosities, and yields more
stable suspensions by micronizing and dispersing the particles, depending on the pressure.
For the specic conguration of the machine, model, technical data, accessories and optional
equipment, refer to the TECHNICAL SPECIFICATIONS enclosed with Chapter 11 of this manual.
CAUTION
The machine may not be utilised for any other purpose than that given in Chapter 3.1 of this
manual. The manufacturer is not liable for damage or injury resulting from improper use.
2.1.1 Operating principle
The machine's operating principle is shown schematically in the following gure.
OPERATING PRINCIPLE
FIG. 2.1
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2.2 Main components of the machine
The main components of the machine are shown in the following gures, for a “Homogenizing unit”
machine (standard and optional versions)
COMPONENTS OF THE HOMOGENIZING UNIT MACHINE (STANDARD / GREEN - OPTIONAL
VERSION / RED)
FIG. 2- 2
NOTE:Theasterisk(*)inthisgureindicatessomeofthecomponentsinthestandardand
optional versions, which are not shown on the drawing
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Legend, Figure 2.2, Components of the machine (Homogenizing unit)
STANDARD CONFORMATION
Group HOMOGENIZING UNIT
1) Compression head std
2) Stage 1 Homogenizing Unit std
3) Stage 1 Head Pressure Gauge std
4) Head safety valve std
5) Manifold group std
6) Water system std
7) Pneumatic system std
8) Transmission assembly std
9) Drive std
10) Housing std
11) Control panel std
OPTIONS
12) On-board electrical equipment opt
13) Stage 2 homogenizing unit opt
14) Suction pressure gauge opt
15) Suction pulsation damper opt
16) Delivery pulsation damper opt
17) Head transmitter opt
18) Tri-clamp connections opt
19) Lube water circuit ON/OFF SV. opt
20) Pneum. circuit air inlet ON/OFF SV. opt
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2.2.1 Monoblock compression head
The Head (1) is the machine's principal assembly, where the product is pumped at high pressure,
rst sucked in and then driven by the pistons, themselves driven by the crank gear system with conrods and crankshaft.
The product enters the compression chamber of the Head, impelled by a special external pump,
initially at a low pressure of 5/6 Bar, which, depending on the operating pressure for which the
machine has been designed, is gradually increased to reach up to 250 bar. In the rst stage of
processing, the product enters the compression chamber as the specic suction valves (2) in the
head open and subsequently the pressure generated by the action of the piston (6) pushes the
product so that the suction valves close, while the delivery valves (3) open, so as to release the
product towards the Homogenizing Unit.
The head is also tted with a pressure gauge whose function is to measure the pressure in the Head.
FIG. 2.3
1) Forged solid block – cross section
2) Suction pump valve unit
3) Delivery pump valve unit
4) Pumping piston gasket
5) Upper and lower removable anges
6) Pumping pistons
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2.2.2 Homogenising unit
The function of the Homogenising Unit is to homogenise the product, i.e. to reduce the size of the
particles, through high pressure applied by a specic valve.
The homogenising valve represents the fulcrum of the process. Thanks to this high pressure
adjustable valve, the liquid product is transformed by means of the combination of the following
effects:
- turbulence
- local cavitation
- cutting stress
- high speed
This guarantees the homogeneous granulometric distribution of the micronised particles thanks to
high pressure in continuous dynamic conditions.
To create the pressure, it is necessary to apply a force "F" in order to partially close the passage of
the ow of liquid through the homogenizing valve. The valve is never completely closed, but there is
always a gap to allow ow: in the same conditions of ow, the greater the pressure, the smaller the
gap will be.
NOTE: The type of valve installed on the machine described in this manual is specied in detail in
the technical information sheet attached to chapter 11.
HOMOGENISING UNITS
FIG. 2- 4
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2.2.3 Pressure Gauge
The pressure gauge installed on the machine is a critical component inasmuch as it measures the
machine's operating pressure and hence its operation.
A defective or inoperative pressure gauge means the machine cannot operate at the required
pressure; make sure to keep a spare pressure gauge on hand in case of need.
The type of pressure gauge depends on the model of machine or optional congurations.
The standard pressure gauge is the analogue type with a Bourdon spring, with an aseptic design
diaphragm separator, with specic design and dimensions for GEA Niro Soavi; it is also equipped
with a separator with the function of ltering the normal pulsations of the piston machine to allow a
stable reading of the operating pressure.
Never separate the pressure gauge from its separator.
Other versions of pressure gauges or pressure meters are available as an alternative:
• analogue pressure gauge with signal transmitter: equipped with a 4-20 mA output for remote
transmission of the pressure signal
FIRST STAGE HEAD PRESSURE GAUGE
FIG. 2.5
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2.2.4 Compression head safety valve
The safety valve (1) is installed on the compression head to protect the machine and its operators
against accidental excess pressures that can cause hazardous situations.
SAFETY VALVE
FIG. 2.6
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2.2.5 Manifold Groups
The term "manifold groups" refers to the set of pipes and anges intended to receive the product in
the inlet side (1) and send it through the outlet ange (2) to the production line.
MANIFOLD GROUP
FIG. 2- 7
1) Inlet ange
2) Outlet ange
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2.2.6 Water plant for sanitised machine
The Water plant has the function of lubricating the pistons of the Compression Head. In this sense,
the water is conveyed to the back of the Head and sprayed onto the pistons, to keep their surface
wet and cool, so as not to damage the piston gaskets inside the Head.
FIG. 2.8
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2.2.7 Pneumatic plant
The pneumatic plant pneumatically drives the machine's homogenizing units, STAGE I and II (if
present) by controlling their air pressure.
Machines equipped with pneumatic control of the homogenizing unit have a system with an oil
pulsation damper.
The actuation force required to close the homogenizing valve and achieve the operating pressure is
applied by a pneumatic cylinder with compressed air in the upper chamber; the lower section of the
pneumatic cylinder is connected to the pressurised oil pulsation damper circuit.
The actuator does not require regular maintenance, but should be protected against high temperatures
(which can damage its gaskets) and corrosive uids, since it is made in aluminium and stainless
materials.
Replace the actuator immediately if it fails.
The following gure is a schematic diagram with one pneumatic stage with manual adjustment on
the machine's control panel.
The conguration of the system actually present on the machine is enclosed with Chapter 11 of this
manual
PNEUMATIC DIAGRAM
FIG. 2.9
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With reference to Figure 2-9, the following are present:
- an air treatment and shut off unit (4) with pressure gauge (5);
- a manual control valve (6) to pressurize the actuator;
- a manual pressure regulator (7);
- one-way reducers (8) which give sensitive but stable operation of the system and adjust the
homogenizing pressure ramp;
- a tank containing air and oil
Damping of the vibrations, induced on the homogenizing valve due to the normal pulsations caused
by the alternating motion of the pumping pistons, is ensured by an oil/air pressure accumulator
connected with the lower chamber of the actuator of the homogenizing unit.
The accumulator is pre-loaded with air at 0.5 bar.
The pressure gauge enables checking the pre-load pressure and the quick coupler enables bringing
the pressure back to its correct value.
Frequently checking the damping system enables preventing the onset of vibrations and resonance
that, besides producing annoying noise, are harmful both for the machine and for the homogenization
efciency.
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Pneumatic plant with local manual adjustment
The pneumatic plant with local manual adjustment enables regulating the homogenizing pressure
from the machine's front control panel with two pneumatic regulators (1) and (2) and two pneumatic
switches (3) and (4). No maintenance is required on these components and in the event of
malfunctioning it is advisable to replace them.
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FIG. 2.10
NOTE: The image shows a typical standard panel, the conguration of which will depend on its
interior components.
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2.2.8 Transmission assembly
The Transmission Assembly contains the crankshaft (1), con-rods and crank mechanism and
transforms the rotary motion of the crankshaft into the alternating motion of the pistons.
The gure shows a typical system.
The type of construction, high quality materials employed and assembly by our highly specialised
staff ensure long and reliable service.
Proper lubrication is critical to the long life of the transmission assembly and its components: make
sure you observe the specied change intervals, along with the uid levels and lubricant types.
In normal conditions, the crank gear system requires no maintenance. If you encounter abnormal
noise or uneven operation of the machine, or the lubrication oil pressure is low and the pressure
switch trips, contact the GEA Niro Soavi service department for technical assistance.
TRANSMISSION ASSEMBLY
FIG. 2.11
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2.2.9 Drive
This part of the machine includes the main electric motor (1), pulleys (2) and drive belts (3) which
convert the motor output speed to the crankshaft speed.
DRIVE
FIG. 2.12
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2.2.10 Housing
The Housing is composed of the machine frame and the protective panelling (1) of the internal parts,
equipped with the handles (2), and it has the function of containing all the transmission assembly and
the various systems interlocked with the main units, as shown in the following gure.
At the bottom there are 4 adjustable feet (3) supporting it.
HOUSING
FIG. 2.13
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2.2.11 Operator control panel
The control panel (1), with which it is possible to start up in local / manual mode or adjust the
homogenizing pressure via the relevant pneumatic control devices, is located at the front of the
machine.
(For more details, on its operation and use, please refer to Chapter 6 in this manual).
OPERATOR CONTROL PANEL
FIG. 2.14
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2.2.12 Electrical equipment
The machines are supplied in a standard execution without an electrical enclosure, which is designed
and fabricated in relation to the machine's specications as an optional accessory; in any case, on
the back of the machine there is a terminal block which connects the on-board electrical equipment,
excluding the motors, and a local control panel (2) (g. 2-15).
If the enclosure is supplied, it is contained in the stainless steel electrical housing, (1) in gure 2-15,
on the back of the machine.
It is recommended to locate the machine in a place that is as clean and dry as possible, ventilated,
well away from fumes, airborne dust, corrosive fumes, and in any case its characteristics of protection
from external agents must be suitable for the installation environment.
In addition, it is necessary to keep away from sources of heat so as to cause no local overheating
and to permit appropriate cooling of the electrical equipment.
With regard to the type, overall dimensions, weight and installation requirements of the electrical
enclosure, if supplied by GEA Niro Soavi, refer to the TECHNICAL SPECIFICATIONS enclosed with
Chapter 11 of this manual.
The enclosure's power line must be sized according to the length, type of installation, ambient
temperature, nature of the load and in any case in compliance with the regulations in force in the
country of installation.
Unless otherwise agreed in writing with GEA Niro Soavi, the user is responsible for rating the power
line and earthing system to the electrical enclosure's terminal block, as well as selecting the short
circuit and contact voltage protection equipment.
If GEA Niro Soavi supplies the electrical enclosure, we also supply a list of cables rated for a length
of 50 metres, routed in closed ducting with three-pole cable and ambient temperature 40°C.
With regard to the machine's power supply rating and connection diagrams, refer to the electrical
specications and WIRING DIAGRAMS given in the enclosed Technical Specications Dossier.
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ELECTRICAL SYSTEM
FIG. 2.15
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2.3 Standards,certications,limitsofuse,ergonomics,environmental
issues
2.3.1 Applicable technical standards
The machine falls within the scope of Directive 98/37/EEC and subsequent amendments (Chapter I
Article 1), implemented in Italy by Presidential Decree D.P.R. 459 dated 24/7/1996.
The essential health and safety requirements in relation to the design and fabrication of the machine
contained in Annex I of the Directive thus apply to the machine.
So far the machine has not been listed in Annex IV of the Machinery Directive; it is thus subject only
to the requirement of the Manufacturer's Declaration of Conformity (article 8).
The numbering used in the following paragraphs is that of the relevant "Machinery Directive" annexes.
The conformities and any non-conformities, where possible, have been expressed in relation to
European legislation, draft standards, national standards or working group documents.
We give below the bibliography of applicable standards.
Community standards
Reference Title
2006/42/EC Machinery Directive
2006/95/EC Low Voltage Directive
2004/108/EC Electromagnetic Compatibility Directive
Harmonised standards and draft standards, national technical standards
Reference Title
EN 12100 Safety of machinery – Basic concepts; general design principles
EN 60204-1 Safety of machinery – Electrical equipment of machines
EN 13849-1 Safety of machinery – Safety related parts of control systems, General
principles for design
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2.4 Ambient operating conditions
The machine does not require special ambient conditions.
It must be installed inside a suitably large industrial building which is lit, ventilated and equipped with
a level, solid oor rated to bear the concentrated weight of the machine.
Temperatures: + 5° to + 40°C.
Relative humidity: 30% - max. 90% non-condensing
Max altitude 1000 m asl
NOTE: Unless otherwise indicated in the technical data sheet.
2.5 Atmosphereswithriskofexplosion/re
CAUTION:
The machine is not designed to operate in a potentially explosive atmosphere. Do not operate
the machine in a fully or partially potentially explosive atmosphere.
2.6 Illumination
The worksite must be adequately lit with natural light and equipped with sufcient articial lighting to
guarantee the health and safety of the workers.
The lighting must comply with local legislation and must be even and provide good visibility of all
parts of the machine without hazardous reections, and enable clear legibility of the control panel
and view of the emergency stop button.
2.7 Vibration
In proper use, as explained in this manual, any vibrations are non-hazardous.
However, the operator must stop the machine immediately in case of hazardous vibration and notify
GEA Niro Soavi accordingly.
2.8 Noise
The equivalent continuous A-weighted sound pressure level at the position occupied by the operator
(at a distance of 1 m and a height of 1.69 m) is greater than 70db, measured while testing the
machine.
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2.9 Residue and environmental contamination
The machine does not emit oil residue in the waste water, which must be disposed in accordance
with local legislation.
2.10 Scrapping and disposal of materials
The materials must be disposed of in accordance with local legislation and regulations in the country
of destination.
CAUTION:
The machine must be scrapped by specialised staff. Before disassembling the machine,
provide sufcient clear and tidy space around it for all work to proceed without further
hazards from the surroundings.
Proceed as follows:
• drain the lubricant and hydraulic oil for sorted disposal;
• disassemble the electrical equipment (components, cables and sheathing) and all plastic parts
for sorted disposal.
The machine has been constructed with variable amounts of the following materials:
• stainless steels;
• construction and alloy steels;
• aluminium;
CAUTION:
Make sure to dispose of these materials in accordance with the local legislation in force at
the time of scrapping.
CAUTION:
Scrupulously observe all safety regulations during the scrapping process.
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2.11 Disposal
The machine's materials must be disposed of according to their type. We list the materials used in
the various parts of the machine to facilitate disposal in accordance with local legislation.
1. The machine has been constructed with variable amounts of the following materials:
- Aluminium – parts.
- Stainless steel – parts and frame.
- Rubber and plastics – components.
2. Other materials present in smaller quantities:
- Tempered materials – pinions, shafts.
- Steel – nuts and bolts.
- Alloys.
- Cast iron
- Copper (electrical cables).
3. The machine contains lubricating oil:
Drain them off for sorted disposal
4. Electrical components:
Disassemble the electrical equipment (devices, cables, sheathing, tubes, etc.) for sorted disposal.
5. Plastic components:
Separate all plastic parts for sorted disposal.
CAUTION:
All these materials must be disposed of in accordance with local legislation in the country in
which the disposal is being done.
For sites and procedures, contact the local authorities.
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3. Safety and accident prevention
Contents
3.1 Applications, intended use
3.2 Intended, improper and permitted uses
3.3 Work area, control area, danger zones
In order to facilitate comprehension of the matters handled in this
paragraph, the following denitions of Machinery Directive 98/37/EEC
apply:
3.4 Risks, dangers and residual risks in the area
3.4.1 General safety
3.4.2 Residual risks and hazards on the machine
3.5 Safety equipment used
3.5.1 Pressure relief valve
3.5.2 Protections on the main motor
3.5.3 Emergency stop button
3.5.4 Housing
3.6 Safety notices
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3.1 Applications, intended use
The GEA 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 uids and achieve homogeneous dimensional distribution.
This process can be applied to a wide range of products of varying viscosities, and yields more
stable suspensions by micronizing and dispersing the particles, depending on the pressure.
For the specic conguration of the machine, model, technical data, accessories and optional
equipment, refer to the Technical Specications enclosed with Chapter 11 of this manual.
3.2 Intended, improper and permitted uses
WARNING:
Any use other than that for which the machine is designed and described in this manual is
non-conforming, and GEA Niro Soavi is not liable for any consequences thereof.
CAUTION:
- The machine is not designed for use in explosive atmospheres.
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3.3 Work area, control area, danger zones
In order to facilitate comprehension of the matters handled in this paragraph, the following denitions
of Machinery Directive 98/37/EEC apply:
- “Work areas”
areas in which the operators may stay during startup and normal operation.
These areas also enable them to take prompt action in case of need or emergency, within the
limits of their job descriptions and established procedures.
The work areas are located around the system in the areas to which access is permitted during
operation.
- “Control areas”
areas in which operators may control, monitor and adjust the system, using the provided control
panels.
- “Danger zones”
any zone inside or in the vicinity of the machine, in which the presence of an exposed person
constitutes a hazard for the health and safety of the person in question.
The danger zones are located around the system.
- “Exposed person”
any person entirely or partly in a danger zone.
- “Operator”
a person charged with installing, operating, adjusting or servicing, cleaning, repairing and handling
the system.
CAUTION:
The machine may be operated and monitored in normal working conditions only from the
designated control area.
The control, work and danger areas are shown in the gure on the next page.
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CONTROL, WORK AREAS
FIG. 3.1
A) CONTROL AND WORK AREA
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The following points give some important warnings in relation to the above.
CAUTION:
Before starting the work process, the operator must be fully familiar with:
- the position, function and use of all electrical and pneumatic controls;
- the position, function and use of all safety equipment;
- the characteristics of the machine;
- this manual and its use.
He must furthermore:
- have been properly trained on site by the manufacturer's or authorised service centre's
technicians;
- have completed operating tests under the supervision of GEA Niro Soavi technicians.
NOTE for the operator
The operator must instruct all assistants regarding their exact jobs as well as any regulations
inrelationtoclothingasshownintheguresonthefollowingpages.
CAUTION:
CLOTHING
Operators assigned to operation and maintenance must wear work clothes (with closely
tting sleeves), personal protective equipment (gloves, eyewear) in conformity with the
current legislation and safety regulations.
The following gures show the recommended individual safety clothing for maintenance staff charged
with entering danger zones.
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USE SAFETY FOOTWEAR
FIG. 3.2
USE PROTECTIVE GLOVES
Fig. 3.3
CAUTION:
It is mandatory to wear suitable protective gloves in areas at high temperatures, such as the
compression head
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WEAR OVERALLS IN GOOD CONDITION
FIG. 3.4
DO NOT ALLOW ANY OBJECTS TO PROTRUDE FROM YOUR POCKETS
FIG. 3.5
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DO NOT WEAR JEWELLERY
FIG. 3.6
CAUTION:
NEVER leave tools or other obstacles in the work area. Do not allow anything to impede the
freedom of movement of the operators.
In case of emergency, staff must have free and quick access to the line. The operators must
observe the instructions and report any violations to their superiors.
WEAR EAR DEFENDERS/PLUGS
FIG. 3.7
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WORK AREA - NO ACCESS FOR UNAUTHORISED PERSONS
FIG. 3.8
CAUTION:
Unauthorised persons may not stay in the work areas while the machine is operating.
Maintenance staff may work around and inside the machine only when it is in "maintenance"
(safety shutdown).
The line maintenance shutdown procedure is implemented by following the instructions given in
chapter 7 "maintenance" further on in this manual.
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3.4 Risks, dangers and residual risks in the area
3.4.1 General safety
Obligatory information and training
This manual does not describe the general safety issues which must already have been dealt with in
the factory in observance of established safety legislation.
However, we recall the main points to prevent their being neglected in the manual and in the factory
safety plan.
CAUTION:
“Protection against risks starts with information and training”.
Informing the workforce
The employer must make sure that all employees are informed regarding:
- health and safety risks connected with the company's processes in general;
- protection and prevention measures and procedures in force;
- specic risks to which they are exposed as a result of the processes, and general and company
safety regulations in their regard;
- rst aid procedures, re regulations and evacuation procedures.
Training the workforce
The employer, in relation to their job descriptions and responsibilities, must make sure that operators
and maintenance staff receive adequate training in health and safety matters with special reference
to their work places and tasks.
3.4.2 Residual risks and hazards on the machine
The machine presents the following residual risks:
- Noise (wear suitable personal protective equipment (PPE), such as ear plugs and gloves)
- Risk of burns from hot parts of the machine (it is mandatory to wear protective gloves) in areas
at high temperatures such as the compression head.
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3.5 Safety equipment used
The machine is equipped with safety equipment which prevents critical conditions arising which may
result in unexpected mechanical failures which endanger the users.
Intrinsic safety is provided by the design of the machine which is rated with a large safety margin, in
consideration of the high pressures which may result from incorrect operation by the users or faults
on the line of which the machine is part.
The main safety devices present on the machine, described below, are a safety valve on the
compression head, electrical protection equipment on the main motor and an emergency stop button.
WARNING:
If the machine is equipped with a disconnectable electrical enclosure, the lockable switch is
located on the front door.
If the machine is supplied without an electrical enclosure, the user must provide a lockable
safety switch on the power supply line.
3.5.1 Pressure relief valve
The pressure relief valve (1) has been designed by GEA Niro Soavi to protect the machine from the
possibility of overpressure which might be produced inside the compression head as a consequence
of the pumping action of the machine.
CAUTION:
The safety valve is intended to protect the machine; only a line safety valve will protect the
pipes down line of the machine itself.
CAUTION:
The valve protects only the high pressure areas on which it is installed.
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It has the following advantages:
- reduced maintenance;
- it closes automatically in case the overpressure is released to allow the immediate resumption of
production;
- accurate calibration and repeatable actuation.
- designed to 3A standards, suitable for C.I.P. (Cleaning in Place)
PRESSURE RELIEF VALVE LOCATION
FIG. 3.9
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Operation
The valve is composed of a ball held in position in its seating by a spring which allows it to open only
when the load on it exceeds its factory setting.
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 GEA Niro Soavi and the guarantee.
Therefore a seal has been applied to the spring preload adjustment nut.
In the event the calibration setting is exceeded, the valve opens automatically and lets the product
ow out of the discharge pipe; it closes again when pressure reduces below the opening value.
Therefore it is necessary to use the pressure regulating device to decrease the pressure in the
compression head until the valve closes, or reducing the pump speed in case of piston pumps.
Once the pressure relief valve has closed again, normal operating pressure can be re-established,
provided the machine has not been damaged such as to cause an immediate stop.
CAUTION:
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
CAUTION:
Dispose of ejected product properly according to local legislation.
CAUTION:
The valve seat of the pressure relief valve is damaged to some extent each and every time
the valve blows. This will lower the pressure setpoint of the safety valve. Therefore it is
periodically necessary to replace the seat and ball to recover the original setpoint conditions.
Washing
The part in contact with the product is normally cleaned during machine washing (C.I.P.).
CAUTION:
It is ALWAYS necessary to disassemble the valve from the compression head and clean it
manually after any overpressure relief valve discharge.
CAUTION:
Do not disassemble the valve body nor remove its 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 GEA Niro Soavi.
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3.5.2 Protections on the main motor
The machine is equipped with electrical protection equipment rated for the motor power, starting
type and operating conditions, consisting of thermal cutouts, quick acting fuses and circuit breakers
against short circuits, circuit breakers and the inverter itself for protection against overheating.
3.5.3 Emergency stop button
On the front panel of the machine there is installed an emergency stop push-button (1) of the colour
prescribed by the safety standards in force.
Pressing this button immediately stops the machine in danger situations, including: malfunctions,
anomalous noise, failure of mechanical parts.
EMERGENCY BUTTON
FIG. 3.10
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In case of danger, the master power switch (2) on the electrical enclosure can also be used as an
emergency stop, as shown in the following gure.
MAIN SWITCH
FIG. 3.11
CAUTION:
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.
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3.5.4 Housing
The machine is equipped with a housing (1) in stainless steel sheeting which:
- protects internal parts from dirt, water and soiling by the product;
- allows for external cleaning;
- protects the operators from moving parts, live parts and hot parts which may be hazardous to
staff as required by established EC standards and local safety legislation.
CAUTION:
The machine must ONLY operate with its housing or guards completely closed in order to
avoid the hazard of operator accidents. Therefore, these guards must never be opened while
the machine is running.
The panels can be removed for maintenance and installations.
The side panels are tted with handles (2) and screws for access to the machine's interior for
maintenance.
CAUTION:
Make sure that ALL locks are shut before starting the machine to guard against accidents;
use only the provided handles when moving the panels. Depending on the size of the panels,
twopersonsmayberequiredtoremoveortthem.
CAUTION:
Before removing the protective panels the personnel in charge of installation and maintenance
must cut off the machine's power line with the disconnecting device, locking it with a padlock.
HOUSING
FIG. 3.12
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3.6 Safety notices
The machine is tted with a set of danger notices as reminders to the operator and exposed persons.
WARNING:
The warnings and signs on the machine perform an important safety function; the operator
and the skilled maintenance technician must follow the instructions provided by these notices.
The safety notices are located on the machine as shown in the gure on the following page.
CAUTION:
Do not remove the safety notices.
Failure to enforce this regulation voids the warranty and relieves the manufacturer of any
liability. The user must replace any notices which have been removed unintentionally or have
fallen off.
LOCATION OF SOME SAFETY NOTICES ON THE MACHINE
FIG. 3.13
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NO ACCESS NOTICE
• No access to the work area for unauthorised persons
DANGER NOTICE
• Voltage present
INSTRUCTION NOTICE
• Wear ear defenders
DANGER NOTICE
• Danger of burns or scalds due to the high temperature of the compression
head
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4. Installation
Contents
4.1 Shipping
4.1.1 Shipping by ground over medium to long distances
4.2 Receiving and checking
4.3 Storage
4.3.1 Storage prior to installation
4.3.2 Storage for longer than 6 months
4.4 Setting up the installation site
4.5 Hookup and cabling
4.5.1 Hookup
4.5.2 Electrical hookup
4.5.3 Grounding system (provided by client)
4.6 Installation and assembly
4.6.1 Installation instructions
4.6.2 Positioning
4.6.3 Levelling the machine
4.6.4 Positioning the electrical equipment
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4.1 Shipping
GEA Niro Soavi provides packaging, in agreement with the client and in relation to the type of
shipping, designed to protect the machine during transport.
WARNING:
Packaging, shipping and storage.
Any packaging, lifting, handling, shipping and unpacking may be done only by expert staff
(load harnessing, crane operation, lift truck operation, etc.) assisted by persons familiar with
the machine itself.
CAUTION:
During such work, staff must wear individual safety equipment: gloves, safety boots, work
overalls.
CAUTION:
Staff must observe the following general rules:
- keep away from loads before lifting and lowering;
- do not stand under suspended loads;
- keep unauthorised persons away from the handling area
If the load must be guided during lifting, use appropriate equipment to maintain the safety
distance from the suspended load.
CAUTION:
Failure to observe these rules can cause serious damage and injury.
Shipping must also be done by qualied staff who will be precisely instructed about the loading of
the machine on the vehicle.
The machine must be secured with straps or other equipment onto the vehicle's load bed to prevent
it tipping over.
The machine will be shipped as follows, depending on the destination:
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4.1.1 Shipping by ground over medium to long distances
CAUTION:
Inform all staff involved in shipping and installing the machine.
The machine is normally shipped to the client in a wooden crate (1) wrapped in plastic sheeting,
unless otherwise specied in the order conrmation.
The crate is designed to allow handling with a lift truck, crane or bridge crane, the latter by passing
steel ropes under the crate as shown (2) on the packaging, where symbol (3) indicates the centre of
gravity of the load.
PACKING CRATE
FIG. 4.1
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If the machine is shipped without any packing, it must be handled with forklifts (3) or transpallets,
so that the head is on the operator's side; the forks must be spaced apart at the pictograms (4) and
be of such a length as to support the entire base of the frame so as not to cause any damage to the
machine's structure or the panelling.
The side panels can be removed during transport to prevent damaging them.
HANDLING WITH A FORKLIFT TRUCK
FIG. 4.2
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CAUTION:
All handling movements must be done slowly by expert staff, to prevent the load overbalancing,
which can cause damage and injury; personnel must use the appropriate protective equipment
and follow the safety rules.
CAUTION:
Before moving the machine, make sure the route and installation area are free of obstacles.
CAUTION:
Use only controlled lifting equipment, rated for the load in question. The weight is shown on
theinstallationdrawingintheenclosedTechnicalSpecicationsDossier.
CAUTION:
Theoormustberatedtosupportatleast150%ofthemachine'sweight.
The weight is shown onthe installationdrawing in the enclosed Technical Specications
Dossier.
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4.2 Receiving and checking
On delivery, check the following:
- that the Packing List corresponds to the actual contents of the packages;
- that the packaging is in good condition, without signs of damage;
FIG. 4.3
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4.3 Storage
4.3.1 Storage prior to installation
Before installation, the machine and its equipment must be stored in a dry area indoors to prevent
damage and functional degradation.
FIG. 4.4
If the machine must be stored outdoors, take measures to prevent dust, humidity and rain coming
into direct contact with the machine, and cover it with a waterproof tarpaulin.
Take special care with the electrical enclosures and electronic equipment, which are sensitive to low
temperature and humidity.
If packaged separately, we recommend storing the latter indoors, and in any case use humidity
absorbers.
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4.3.2 Storage for longer than 6 months
If the machine must be stored prior to installation for more than 6 months, keep it indoors, away from
atmospheric agents, dust and corrosive vapours, as indicted above, with special attention to the
electrical equipment.
If the machine is to be stored without being used for any longer than 6 months, contact GEA Niro
Soavi customer service for the operations of checking, restoration and special maintenance prior to
starting.
FIG. 4.5
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4.4 Setting up the installation site
The client must provide a suitable installation site in accordance with European Directives related to
safety in the workplace.
The site must be:
- equipped with emergency exits;
- easy to clean to assure good hygiene;
- well aerated (good circulation of air);
- equipped with natural and articial lighting sufcient to assure the safety, health and wellbeing of
the operators, in compliance with EN 60204-1
- equipped with a regulatory grounding system.
FIG. 4.6
WARNING:
During installation and scrapping, the client must provide the technical equipment and individual
safety equipment required to ensure the safety of his staff, property and the environment.
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The user must be sure that the installation site (rooms) comply with established safety requirements.
They must be adequately ventilated.
The installation must be done in an area clear of obstacles so as to permit normal operation (insertion
of parts, on-board adjustments) and maintenance of the machine in complete safety, and with easily
accessible entrances and emergency exits.
CAUTION:
Theinstallationsitemustbeclearofammablesubstancesincludingpetrolandsolventsand
slippery substances including oil and grease.
WARNING:
Theworkdescribedinthisparagraphmustbedonebyqualiedstaff.
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4.5 Hookup and cabling
4.5.1 Hookup
The machine is normally connected to the product line with ttings of the type, size and position
specied on the drawing of the enclosed Technical Specications Dossier.
There are also:
- water connection for lubrication of packings and cooling (max hardness 8 °dH / 15 °fH;
recommended chlorides < 25 mg/litre, max 200 mg/litre);
- water drain;
- compressed air connection (when needed);
- steam connection (when needed);
- condensate drain from lubrication circuit (inside the machine – lubrication circuit);
- cooling air outlet/grille.
For the needs of each machine, the type of connections and the characteristics of the mediums
please refer to the technical information sheet and the installation drawing in the enclosed Technical
Specications Dossier.
As regards the service ttings, we recommend providing upstream solenoid valves for the user
machine (if not already provided on the machine itself) which open at startup.
In particular, the manual water circuit cocks must always be open, at a setting which provides
sufcient water ow for lubrication or condensation production (aseptic version).
Note that excessive lubrication water ow will ood the machine's water sump, which risks water
entering the transmission section and contaminating the lubrication oil; the condensation or water in
the lubrication circuit must therefore be drained regularly, as described in Chapter 7 “MAINTENANCE”.
CAUTION:
Comply with local legislation in relation to the treatment of waste and cooling water. The
waste water may contain traces of lubrication oil and product.
The cooling air is discharged through grilles located on the side of the machine.
CAUTION:
Do not install anything that can close the delivery pipe partly or wholly, as this can lead to
dangerous overpressure.
The machine is rated for outlet backpressures no greater than those given in Chapter 2 of this manual,
but since it is a volumetric pump, it can create hazardous overpressures due to backpressure in the
downstream lines when they are closed.
CAUTION:
For reasons of safety, it is ALWAYS best to install a safety valve downstream of the machine
to protect the line and user equipment. It is also essential that all downstream valves are of
the NORMALLY OPEN type, to prevent them closing when the machine stops unintentionally
or in case of power failure. The machine has a certain operational inertia, so that it continues
pumping even when the main motor has been shut down.
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FIG. 4.7
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4.5.2 Electrical hookup
The enclosure's power line must be sized according to the length, type of installation, ambient
temperature, nature of the load and in any case in compliance with the regulations in force in the
country of installation.
Unless otherwise agreed in writing with GEA Niro Soavi, the user is responsible for rating the power
line and earthing system to the electrical enclosure's terminal block, as well as selecting the short
circuit and contact voltage protection equipment.
If GEA Niro Soavi supplies the electrical enclosure, we also supply a list of cables rated for a length
of 50 metres, routed in closed ducting with three-pole cable and ambient temperature 40 °C.
With regard to the machine's power supply rating and connection diagrams, refer to the electrical
specications and wiring diagrams given in the enclosed Technical Specications Dossier.
CAUTION:
Thespecicationsforthecablesassumestandardroutingandenvironmentalconditions;they
are only illustrative and must ALWAYS be checked by the user against the actual operating
conditions.
The electrical connections between the machine and electrical enclosure and electrical enclosure
and main power line are to be done by the Client, who is also responsible for ensuring that they are
made properly and in compliance with the diagrams before the machine is started up.
GEA Niro Soavi is not liable for damage or injury resulting from incorrect connection of electrical
equipment; the electrical connections must always be checked over by qualied electricians.
In case of doubt, contact GEA Niro Soavi Service Department.
WARNING:
The power supply must be rated for the machine's maximum draw, as given in the Wiring
DiagramsintheenclosedTechnicalSpecicationsDossier.
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4.5.3 Grounding system (provided by client)
The machine's metal components and structures must be grounded by the client.
The exact characteristics are dened by the CEI 1713/1 and CEI 44/5 standards.
The standards require that in every user system, the grounding system for the entire system and all
circuit and user equipment grounding systems must be grounded by a single circuit.
Make sure that the materials used in the grounding system are robust and mechanically protected.
The connection to the main grounding system must be as short as possible, and the cables may not
be mechanically stressed or subject to corrosion.
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4.6 Installation and assembly
4.6.1 Installation instructions
The following instructions regard the installation and proper use of the machine and its parts for a
long and efcient service life, as well as preventing operator hazards.
• A high pressure volumetric pump or homogenizer ALWAYS require a minimum operating
pressure to work properly without cavitation, which may damage the machine itself. Scrupulously
enforce the minimum values given in the enclosed Technical Specications Dossier; in any case,
depending on the process temperature and viscosity, you must always ensure a constant supply
pressure sufcient to prevent cavitation or under-feeding the machine.
For explanations and special requirements, ALWAYS contact GEA Niro Soavi
• To feed the machine use a supply pump, provided by the Client, sized for a ow rate of 1.2 times
the rated ow rate for a machine with 3 or more pistons, and at least 1.5 times. The pump's ow
must be calculated at least at the minimum supply pressure
• If a volumetric or positive displacement pump (lobes, single-screw, etc.) or a diaphragm pump
is used, it is necessary to have a suitable by-pass pipe regulated with a modulating valve on the
feed pump and/or a suitable system for changing the speed of the feed pump, in order to allow
feeding the machine correctly
• If the treated products have very different viscosities or it is necessary to use a volumetric pump
for viscous products and for the wash water, it is necessary to use a system for regulating the
pump speed regulated by the feed pressure so as to be able to supply the machine correctly
under all conditions, even in the transitory phases of production
• A supply pump must be used for each machine; do not install two or more machine in parallel on
a single supply pump, as this can cause hazardous pulsation
• The supply line between the supply pump and homogenizer must be direct, preferably without
bends, of section greater than or equal to that of the homogenizer/piston pump itself, of constant
section, to limit pressure drops; the radius of any bends must be as wide a possible to prevent
pressure drops (especially in supply) or noise (in delivery)
• It is always advisable to install a pressure gauge near the product infeed to the homogenizing
unit to control the feed pressure; this pressure gauge can be supplied as an option by GEA Niro
Soavi and be the simple type, with a minimum contact or with a continuous analogue signal for
remote control
• Should it be necessary to install lters on the feed line, it is necessary to have a clear ow area
of at least 3 times that of the pipe used; in addition, it is necessary to install a pressure gauge
downstream from the lter to control the actual feed pressure and prevent any clogging of the
lters and hazards of cavitation of the machine. For cleaning, it is advised to install lters in
parallel to be used alternately
• Each homogenizing unit features pulsating operation: for this reason, depending on the type of
system and the ow rate of the machine, it is advisable to install a pulsation damper on both the
inow and outow (up to at most 20 bar of backpressure on the line)
• The pulsation damper on the suction side must be installed as close as possible to the machine's
intake, and on the delivery side on a horizontal section of pipe at a minimum distance of around
1 metre away from any bends. For the technical rating and installation information, contact GEA
Niro Soavi
• The pulsation damper must be installed in a vertical position; do not install the pulsation damper
with the ow entering it directly, to prevent it rapidly lling with uid and this losing its efciency
due to the lack of air trapped inside it
• If the supply pump is connected to a tank, make sure the suction port cannot suck in air due to
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vortex formation by using internal ow deviation barriers; the suction port must always be under
head
• It is always recommended to install a suitable pressure relief valve, downstream from the
homogenizing unit, to protect the system from any overpressure caused by incompetence or
incorrect operations on the system downstream from the machine; the pressure relief valve
installed on the machine is used to protect the machine and not the system to which it is connected
from any dangerous overpressure
• Never use the machine to drain a supply tank completely, in order to prevent a sudden lack of
product during pressure mode, but have at least a level sensor to cut off the pressure (in the case
of a homogenizing unit) and stop the machine before product stops being supplied
• The treated product must contain no air or gas, as this can lead to cavitation. If the product
contains air due its elevated viscosity or upstream processes, it must be de-aerated with special
equipment before entering the machine
• If the process temperature is greater than 90°C, the supply must be increased due to the increased
steam pressure, which can result in cavitation.
The supply pressure must therefore be increased by 1 bar every 5°C of temperature in excess of
90°C over the minimum supply pressure specied in the enclosed Technical Specications Dossier.
This value must be doubled if the product's viscosity is in excess of 500 cP.
For special products and process temperatures, contact GEA Niro Soavi.
The machine is equipped with automatic spring-loaded pumping valves, whose load is set in relation
to the product type. This means that if the machine is stopped or stops, and the supply line is open
and under pressure, the product may continue to ow through the machine. To be sure that no
product ows through the machine when its is stopped, the user must provide a check valve on the
supply line upstream of the machine
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4.6.2 Positioning
Positioning the machine properly on the client's production line allows it operate optimally as well as
ensuring good access for routine maintenance.
For this reason, in relation to its size, you must maintain a free area around the machine for
maintenance, as shown in the gure given below.
In particular, we recommend keeping enough space for replacing the main motor using lifting
equipment (bridge crane or lift truck).
The front end and head need routine maintenance; keep enough free space for completely removing
the head.
It is also good to keep any sources of heat which may affect its cooling away from the machine, and
make sure there are no obstacles to the free ow of air.
You must also provide drainage for the waste water to avoid ooding which may affect the machine,
and make sure no jets of water can enter the machine via its ventilation openings.
CAUTION:
Theoormustberatedtosupportatleast150%ofthemachine'sweight.
The weight is shown onthe installationdrawing in the enclosed Technical Specications
Dossier.
FIG. 4.8
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4.6.3 Levelling the machine
To allow the machine to operate properly without excess vibration, it must be levelled and all feet
must be in good contact with the oor.
The machine features height-adjustable feet.
To level the machine, proceed as follows:
- raise the machine
- adjust its height off the ground by screwing the adjustable feet in/out, using the machined surface
of the head as a level reference;
- make sure that the machine's weight is resting on all the feet;
- lock the feet with the nut (1).
If you wish to prevent vibrations moving the machine and thus stressing the pipes, you can mount
steel rings to the oor to restrain the feet.
FIG. 4.9
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4.6.4 Positioning the electrical equipment
The machines are supplied in a standard execution without electrical enclosure, which is designed
and fabricated in relation to the machine's specications as an optional accessory; however the
machine is equipped with a terminal block which connects the on-board electrical equipment,
excluding the motors.
If an electrical enclosure is supplied, and in any case as a general suggestion, the cabinet containing
the electrical control and power equipment, if separate from the machine, must be located in a room
that is as clean and dry as possible, ventilated, far away from steam, dust in suspension, corrosive
fumes, and in any case its characteristics of protection against external factors must be adequate
for the installation room, whose specications must be evaluated by the Customer before ordering.
In addition, it is necessary to keep away from sources of heat so as to cause no local overheating
and to permit appropriate cooling of the electrical equipment.
With regard to the type, overall dimensions, weight and installation requirements of the electrical
enclosure, if supplied by GEA Niro Soavi, refer to the wiring diagrams and Technical Specications
enclosed with Chapter 11 of this manual.
WARNING:
If the electrical enclosure is provided by the client, it will be the client's responsibility to include the
lockable disconnecting device between the machine and the power line.
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5.Commissioningandrststartup
Contents
5.1 Procedure
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5.1 Procedure
Before starting up the machine, run the following checks and controls.
CAUTION:
Any work requiring removal of the protective panels must be done with the MACHINE
STOPPED, with power cut off with the circuit breaker (1) padlocked so as to prevent anyone
powering up the system unexpectedly.
FIG. 5.2
The machine develops very high pressure; we recommend running careful checks to avoid damage
and injury.
The controls described below table refer to rst startup or to situations where the machine is not in
continuous use.
• Check the connections with the ancillary services and product line referring to the Technical
Specications Dossier.
• Check that the pipes upstream and downstream from the machine are clean and free from scaling
or welding residues which may seriously damage the machine.
CAUTION:
Do not use the machine to drain impurities from the up/downstream pipes!
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a) Check the belt transmission (2). For the belt alignment and tension checks, refer to Chapter 7 -
MAINTENANCE.
FIG. 5.3
b) Check the lubrication oil level via the sight glass, which must be covered up to 3/4, or on the
visual indicator. This should be done only with the machine stopped, since starting the machine
lowers the level as the circuits ll. For topping up the level, use only the type of oil indicated in
Chapter 7 - MAINTENANCE.
CAUTION:
For reasons of safety during shipping, the machine is shipped WITHOUT LUBRICATION OIL
in the transmission casing. Before anything else, ll the machine with oil as indicated in
Chapter 7 “MAINTENANCE”, Sheet F “Lubrication circuit”.
FIG. 5.4
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c) Check that the high pressure anges, ttings and all nuts of the compression head (3) are torqued
to the values given in the "Tightening torques" table in Chapter 7 in this manual (sheet 00[C]).
FIG. 5.5
d) Check the tightness of the pumping pistons (4) and that the seal packs are present, if they were
removed because the machine was stopped or stored for more than 3 months.
FIG. 5.6
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e) Check the rotation of the motor (5) as follows:
CAUTION:
Check the direction of rotation by running the motor IN JOG MODE ONLY.
Observe all safety regulations, and do not come close to the moving parts inside the machine.
Remove ONLY the LH side panels.
ALWAYSttheguardsontheright(transmissionside)beforestartingthemachine.
The direction of rotation is indicated by adhesive arrows on the motor and pulleys.
FIG. 5.7
f) Check that all housing panels (6) are in place and securely xed.
FIG. 5.8
CAUTION:
failure to observe this latter instruction may result in serious injury for persons in the vicinity
of moving and rotating parts when the machine is started up.
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Instructions for use and maintenance
g) Check that the homogenizing pressure control devices on the panel on the machine (pneumatic
switch A and reducer B STAGE 1 and switch C and reducer D STAGE 2) are completely slackened
or turned OFF.
FIG. 5.9
h) Check that all safety and protection equipment is present and operational.
i) Make sure that any valves and parts of the system downstream from the homogenizer are open
to prevent overpressure in pipes when the homogenizer is started.
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Instructions for use and maintenance
6. Operation and use
Contents
6.1 Operator's responsibilities
6.2 Electrical enclosure and control panel
6.2.1 Control Panel on the machine
6.3 Startup procedure
6.3.1 Position of operator
6.3.2 Startup
6.3.3 Operation and adjustment
6.3.3.1 Regulating the homogenizing pressure - 1 stage
6.3.3.2 Regulating the homogenizing pressure - 2 stages
6.4 Stopping the machine
6.4.1 Normal stop
6.4.2 Emergency stop
6.5 Washing
6.6 Checks after starting up the machine
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Instructions for use and maintenance
6.1 Operator's responsibilities
While the machine is working, the operator must:
A) Operate the machine in compliance with the provided safety equipment. Checking:
• the position of the safety equipment;
• observance of individual safety regulations.
B) Check that the work cycle is perfectly efcient, for maximum productivity. Checking:
• the condition and operation of the machine's major assemblies;
• that the work parameters are optimal;
• that all material prepared for the work is uniform.
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Instructions for use and maintenance
6.2 Electrical enclosure and control panel
The machine may be tted with an electrical enclosure supplied by GEA Niro Soavi S.p.A. or
provided by the Client.
To know the real structure of the machine please refer to the TECHNICAL INFO SHEETS attached
to Chapter 11 of this manual.
If the electrical enclosure is supplied by GEA Niro Soavi S.p.A. it will be shown in the wiring diagrams,
which are also enclosed with chapter 11.
In either case, the electrical enclosure is equipped with two important devices which enable the
operator to run the Startup or set the machine in Maintenance mode.
These devices are represented in the example gure shown below.
CONTROL ELECTRICAL ENCLOSURE (EXAMPLE)
FIG. 6.1
Pos. Description Function
1 (QF) Master power switch Turns on power to the machine
2 (HL-L) Indicator lamp Indicates that the electrical enclosure is live
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Instructions for use and maintenance
6.2.1 Control Panel on the machine
The control panel is on the front of the machine.
There is just one panel for the various languages and it bears the symbols and instruments for
controlling the machine (see g. 6-2), specically:
• Emergency Stop button (1) to stop the machine immediately in an emergency
• Start (2) and Stop (3) buttons.
• Pneumatic controls for adjusting the stage 1 and 2 homogenization pressure (pos. (5) in the rst
case, pos. (6) in the second case), comprising a pneumatic switch for turning the pressure on or
off (7) and an associated pneumatic regulator (8) with the function of increasing or decreasing
the pressure.
• Pressure gauges to control the pressure of the air (9) sent to the pneumatic head to reach the
homogenizing pressure.
CONTROL PANEL
FIG. 6.2
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Instructions for use and maintenance
6.3 Startup procedure
6.3.1 Position of operator
To operate the machine safely, the operator must stay in the position shown below when starting up
and adjusting the machine.
The control panel (1) is on the front of the machine and is congured to the client's specications; the
EMERGENCY STOP BUTTON is always present.
CAUTION:
Scrupulously stay in the area in front of the machine to permit immediate access to the
emergency stop button and any start/stop/adjustment controls.
Before starting the startup procedure, run the following checks:
1. Check that all guards on moving parts are closed
2. Check that the emergency stop button is released
FIG. 6.3
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Instructions for use and maintenance
This manual is owned by GEA Niro Soavi Any reproduction, even partial, is prohibited.
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GEA Niro Soavi93
Instructions for use and maintenance
6.3.2 Startup
CAUTION:
Thelubricationoilindicatedinthespecicationsissuitedtooperatingtemperaturesinthe
range +5°C to +40°C: DO NOT START THE MACHINE UP if the ambient temperature is lower
than +5°C, as this can lead to failure of the lubrication system.
Contact the GEA Niro Soavi S.p.A. Service Department who will provide the correct lubricant
for your operating conditions.
CAUTION:
Do not start the machine up if the ambient temperature is less than +5°C before checking the
condition of the piston lubrication water circuit and the water heat exchangers (if present).
Once all preliminary checks have been completed, the machine can be started as follows:
1) Open all auxiliary service check valves (water, air, steam) and adjust the ow rates if necessary
(such adjustments are normally done at the factory when testing the machine)
CAUTION:
NEVER start the machine with no pumping piston lubrication water or the seal packs and the
pistons will be seriously damaged.
CAUTION:
Excesscoolingwatercanoodthesumporspurtontotheguidepistons,thusallowingwater
toenterthetransmissioncasing.Itisthereforeimportanttokeepthewaterowundercontrol
afteradjustingittoanapproximateowrateofatleast30l/hperpiston.Regularlydrainthe
lubrication circuit to drain out any water in the oil.
2) Feed the machine with product observing the ow rate and pressure stated in the TECHNICAL
SPECIFICATIONS enclosed with chapter 11 of this manual.
CAUTION:
FeedingproductatapressurelowerthanthatspeciedcancauseCAVITATIONwhichmakes
an unmistakable noise in the compression head and can seriously damage the entire machine.
GEA Niro Soavi S.p.A. shall not be liable for any breakage, malfunction or damage to the
machine caused by CAVITATION even if this occurs during the 12 month warranty period.
3) Power up using the main switch on the electrical enclosure.
4) Press the start button. If the electrical enclosure is supplied by GEA Niro Soavi S.p.A., this starts
the machine in the right sequence for the machine in question and optional equipment present:
- open service solenoid valves (optional);
- start main motor.
If the electrical enclosure is provided by the client, the correct starting sequence is specied (see
TECHNICAL DATASHEETS enclosed with Chapter 11 of this manual) and must be scrupulously
followed.
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6.3.3 Operation and adjustment
Once the machine has been started, without increasing the homogenizing pressure, check that the
machine itself is operating normally, with particular attention paid to the feed pressure, establishing
it is stable and within the limits as prescribed in the TECHNICAL SPECIFICATIONS enclosed with
chapter 11 of this manual.
It is now possible to use the adjustment controls to obtain the desired homogenizing pressure via
the control system.
Check there is the second homogenization stage, consulting the TECHNICAL SPECIFICATIONS
attached to Chapter 11 of this manual.
6.3.3.1 Regulating the homogenizing pressure - 1 stage
This type of adjustment uses a servo-system that, via a pneumatic cylinder, acts on the position of
the homogenizing valve to determine the homogenizing pressure.
On the front panel of the machine (see gure 6-4 below) there is a pneumatic switch (A) and a
pressure reducer (B).
The adjustment operations are as follows:
• check that the pressure reducer (B) is completely slackened
• pull the pneumatic switch onto ON;
• turn the reducer knob to obtain the desired homogenizing pressure that can be detected with the
pressure gauge located on the head.
CAUTION:
Slowly turn the pressure regulator checking the homogenizing pressure actually increases
up to the working value.
CAUTION:
Check the increase in air pressure on the pneumatic head with the pressure gauge installed
on the control panel; this enables verifying the slow increase in the homogenizing pressure.
In addition, it is possible to use the air pressure gauge as a reference should the pressure
gauge of the head not work correctly.
Once the homogenizing pressure has been set on the desired value it is possible to lock the reducer
knob (B) by pressing it.
If the set pressure is normally used in production, it is possible to cut homogenizing pressure in and
out using ONLY the pneumatic selector switch (A), leaving the reducer locked in the adjustment
position.
CAUTION:
This procedure is permitted ONLY for machines with an operating pressure of up to 250 bar,
to avoid over-straining the machine and increasing the pressure too quickly, which can cause
the pressure relief valve to open.
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Instructions for use and maintenance
FIG. 6.4
FIG. 6.5
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GEA Niro Soavi96
Instructions for use and maintenance
6.3.3.2 Regulating the homogenizing pressure - 2 stages
Nevertheless, for the adjustment procedure you must read paragraph 6.3.3.1, especially the warnings.
The pressure to be applied via the second stage corresponds to 1/10 of the maximum homogenization
pressure.
CAUTION:
The intended homogenizing pressure value must be set FIRST on stage 2, THEN on stage 1
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.
The adjustment operations are as follows:
• check that the pressure reducer (B, D) is completely slackened
• pull the pneumatic switch of the second stage (C) onto ON;
• turn the reducer knob of the second stage (D) to obtain the desired homogenizing pressure that
can be detected with the pressure gauge.
• pull the pneumatic switch of the rst stage (A) onto ON;
• turn the reducer knob of the rst stage (B) to obtain the desired homogenizing pressure that can
be detected with the pressure gauge.
CAUTION:
The pneumatic adjustment system on purpose has a certain inertia in order to allow increasing
the pressure slowly and gradually.
Slowly turn the pressure regulator checking the homogenizing pressure actually increases
up to the working value.
Once the homogenizing pressure has been set on the desired value it is possible to lock the reducer
knob (B) by pressing it.
If the set pressure is normally used in production, it is possible to cut homogenizing pressure in and
out using ONLY the pneumatic selector switch (A), leaving the reducer locked in the adjustment
position.
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Instructions for use and maintenance
FIG. 6.5
CAUTION:
This procedure is permitted ONLY for machines with an operating pressure of up to 250 bar,
to avoid over-straining the machine and increasing the pressure too quickly.
CAUTION:
To release homogenizing pressure in a two-stage system you need to reverse the procedure
used to add pressure.
Thereforerstreleasepressurefromthe1ststageandthenfromthe2ndstage.
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