Operation and Maintenance Manual

MI15E
SELFCLEANING SCREEN FOR SMALL TREATMENT PLANTS
Rev. 01 dated 21/1/08

M.A.IND. srl Sede Legale - Head Office: Via Calcinaro, 2131 - 47521 CESENA (FC) - Italy Tel: +39 0547 385043 Fax: +39 0547 638182 E-mail: maind@maindsrl.it Unit Produttiva - Factory: Via Pitagora, 30 - 41010 LIMIDI DI SOLIERA (MO) - Italy Tel: +39 059 525720 Fax: +39 059 525443 Web: www.maindsrl.it C.F. & P.IVA: 03147280402 - R.I. Forl-Cesena n. 03147280402 - R.E.A. Forl-Cesena n.288130

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INDEX
1
1.1 1.2 1.3 1.4 1.5 1.6 1.7

GENERAL INFORMATION ............................................................................. 4

INTRODUCTION ................................................................................................... 4 HOW TO READ THE MANUAL ............................................................................. 4 IDENTIFY THE UNIT ............................................................................................. 4 WARRANTY .......................................................................................................... 5 MANUFACTURER DECLARATION (TYPE B) MACHINE ..................................... 6 MANUFACTURER DECLARATION (TYPE B) ELECTRIC MOTOR ..................... 6 TECHNICAL SERVICE .......................................................................................... 6

2
2.1 2.2 2.3 2.4 2.5

TRANSPORT AND INSTALLATION ............................................................... 7

CHECKING AFTER RECEPTION ......................................................................... 7 PACKING............................................................................................................... 7 LIFTING AND POSITIONING ................................................................................ 7 INSTALLATION AREA........................................................................................... 8 INSTALLATION ..................................................................................................... 9 ELECTRICAL CONNECTION ........................................................................ 9 EFFLUENT INLET CONNECTION SCREENINGS OUTLET CONNCETION ..................................................................................................................... 11

2.5.1 2.5.2

3
3.1 3.2 3.3

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

NOT PERMISSIBLE USE .................................................................................... 12 SAFE USE ........................................................................................................... 13 SAFETY DEVICES OF THE PLANT.................................................................... 14

4
4.1 4.2 4.3 4.4

DESCRIPTION AND SPECIFICATIONS ....................................................... 15

SAFE AND CORRECT USE ................................................................................ 15 COMMANDS ....................................................................................................... 15 WORKING PRINCIPLE, NOT PERMISSIBLE USE ............................................. 15 TECHNICAL CHARACTERISTICS ...................................................................... 16 BUILDING FEATURES STANDARD DIMENSIONS ................................. 16 Flow rates (m3/h) .......................................................................................... 17 Weight .......................................................................................................... 17

4.4.1 4.4.2 4.4.3

5 6
6.1 6.2

USE FO THE MACHINE ................................................................................ 18 MAINTENANCE ............................................................................................. 19

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

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MI15E 6.3 EXTRAORDINARY MAINTENANCE ................................................................... 20 CLEANING BRUSHES REPLACEMENT ..................................................... 20 GEARMOTOR REPLACEMENT .................................................................. 21

6.3.1 6.3.2

7
7.1 7.2

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

SPARE PARTS .................................................................................................... 22 HOW TO ORDER SPARE PARTS ...................................................................... 22

8
8.1 8.2

OTHER INFORMATION ................................................................................ 25

LONG TERM STORAGE ..................................................................................... 25 DISMANTLING OF THE MACHINE ..................................................................... 25

9 10
10.1 10.2

FAULT RESEARCH ...................................................................................... 26 ATTACCHEMENTS ....................................................................................... 27

DECLARATION OF THE MANUFACTURER ....................................... 27

OPERATION AND MANINTENANCE MANUAL MANUFACTURER DECLARATION OF ELECTRIC MOTOR ............................................................ 27

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MI15E

1 GENERAL INFORMATION
1.1 INTRODUCTION
Before starting with every operation, it is necessary to read very carefully the manual to avoid every problem and/or dangerous use of the machine. Operation and instruction manual is part of the technical leaflets supplied with the machine and the scope is to give all the information necessary for a safe and correct use of the machine. Manual is addressed to the persons in charged for the installation of the machine and to the persons in charged for the use and for the maintenance who have to read this manual very carefully.

1.2 HOW TO READ THE MANUAL

During the consultation of this manual it is possible to see some symbols and the meaning of these symbols is explained in the following table: This type of notice advises the personnel about the dangers during the operation of the machine. In case this notice will not be followed, the machine could cause damages with danger for the personnel. This type of notice advises about the NOTICE OF DANGER BECAUSE PRESENCE presence of electric tension. Before starting with every maintenance on the machine it is OF ELECTRIC necessary to stop the electric tension TENSION ON THE switching off the general switch. After that it MACHINE is necessary to be sure that the electric tension is not more present on the machine. WARNING This type of notice advise about the necessity to give particular attention. GENERAL WARNING

Warning !

1.3 IDENTIFY THE UNIT

The machine can by identified by the descriptions punched on the metallic Plate here following represented and explained. The Plate is easily recognizable on the metallic frame of the unit.

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On the Name plate it is possible to find the following details: 1) 2) 3) 4) 5) 6) Name and address of the manufacturer Machine type Serial number Years of manufacturing Power Weight

Name plate data cannot be modified. In case of necessity to contact our after sales service, please advise us about the serial number of the machine.

1.4 WARRANTY
MA.IND. give the warranty that the machine supplied was tested concerning the safety and the functionality. Warranty period of time is always present with our order confirmation. Warranty is referred to the mechanical components and in case of defect, the manufacturer will replace the components without any extra cost for the customer. Warranty doesnt include the electric motor, electric components and every problem caused from external reasons, wrong maintenance or not permissible use. Every alteration of the machine, in particular on the safety devices, will cause the termination of the warranty and the manufacturer will be free from every responsibility.

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1.5 MANUFACTURER DECLARATION (TYPE B) MACHINE

The machine is manufactured according to the directive 2006/42/CE and its following modifications. The machine is destined to be part of a plant that will be executed from the installer.
Warning !

In attached to the present manual is reported the Manufacturer Declaration provided for the directive 2006/42/CE.

1.6 MANUFACTURER DECLARATION (TYPE B) ELECTRIC MOTOR

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

1.7 TECHNICAL SERVICE

To obtain the best performance from the machine and to avoid every possible problem that could cause the termination of the warranty it is necessary to follow all the indications of the present operation and maintenance manual. This operation and maintenance manual is part of the machine and it must be easily reachable by all the personnel in charge. In case of need to contact , even after reading the instruction, it is necessary to have this manual close at hand, to have a better understanding of all the explanations. Please always remember to inform our Service about the serial number of the machine. The serial number is always reported on the Plate of the machine.

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MI15E

2 TRANSPORT AND INSTALLATION

2.1 CHECKING AFTER RECEPTION

Before proceeding with the unloading of the unit, please check that the machine was not damaged during the transport. In case of damages, it is necessary to make a short description on the transport document.

2.2

PACKING

The machine can be delivered on request in a wood cage packing of the weight of about 30 Kg.

2.3

LIFTING AND POSITIONING

Lifting and positioning of the machine can be done by means of lifting system suitable for the weight and dimension (for the weight of the machine, please check the weight on the Name plate and on the weight table, paragraph 4.4). In case the unit is provided with the wood cage packing take also that weight into consideration (ref. paragraph 2.2) The lifting of the machine must always be done by means of the suitable eyebolt fixed on the unit. Only hooks provided of a safety fastener device can be connected to the eyebolt. In case of wood cage packing move the structure connecting the hooks to two suitable lifting belts positioned in correspondence of the bars. Always lift and move the machine using exclusively the eyebolt positioned on the machine.

Picture 1: Lifting eyebolt of the unit

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MI15E It is forbidden to use clamps, rings, open hooks or other system that do not guarantee the safety in lifting operation.

Lifting and positioning operation must be executed only by competent persons. It is forbidden to displace in the action range of the means of lifting.
Warning !

WARNING: Personnel in charge for the lifting and positioning of the machine must operate with maximum attention to avoid any damage to the goods or to the people. Nobody can remain under the area where the machine is hanging. Check the efficiency of the lifting system to avoid damage to the operator or other. It is forbidden to use lifting chain that can damage the surface of the machine. If chain will damage the surface of the steel, it is necessary to make again the surface treatment of passivation. Transport packing must be removed only when the machine is positioned close to the installation area (machine is supplied without packing in the standard version).

2.4

INSTALLATION AREA

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

It is responsibility of the user to preview the positioning area with the safety devices as per the present manual.

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2.5

INSTALLATION

It is recommended to foresee, in phase of installation, adequate spaces all around the machine to let the movements and facilitate the operations of maintenance in full safety. The machine is fixed to the inlet pipes through the scheduled flanges. The unit must be collocated inside a container which grant a level of the effluent lower than the screening zone.

Fixing of the unit through the connection of the flange to the inlet pipe and direct laying on the base of the container

An unsuitable fixing may cause damages to people or things; it is so recommended to follow the present instructions and verify the tightening of all bolts and screws and the whole stability of the structure.

2.5.1

ELECTRICAL CONNECTION

Machine is supplied with standard electric components for the normal operation of the machine: the electric motor. It is responsibility of the user to provide the electric panel, installation and connection to the machine following international laws and local rules.

Electric work must be executed only by specialized worker. Project and execution of the electric panel is under the responsibility of the installer. We recommend to provide appropriate protection against excessive adsorption of the electric motor.

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MI15E Besides, it is necessary to foresee the impossibility of the automatic startup of the machine in case of stop and restart of the electric power. WARNING: Electric work must be executed only by specialized worker. Check that voltage is the same as per the Name plate present on the electric motor. Electric cables must have the correct dimensions and safety as requested from the electric motor.

It is forbidden to work on the electric motor when it is in tension. During electrical connection, the principal electric power line must be disconnected and the work must be executed only from specialized workers following international and local laws and rules. Electric cables must be protected considering the installation area and places to avoid to obstruct the working of the machine, following specific applicable rules.

It is forbidden to introduce the hands inside the screw in operation. Concerning the technical characteristics of the motor make reference to the fabricants documentation attached to the present manual. Particularly, what required by the fabricant about environmental characteristics and electric connections must be respected. 2.5.1.1 Working principle Electric panel must be designed and supplied by the end-user in conformity with the rules and the laws regulating the safety of the workers. For a correct work it is necessary to follow this working principle: 1) Electric motor startup in case of: - Manual startup - Automatic startup (through timer or level indicator) 2) Electric motor stop in case of: - Manual stop - Automatic stop (through timer or level indicator) - Emergency manual stop (red button)

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MI15E 2.5.2 EFFLUENT INLET CONNECTION SCREENINGS OUTLET CONNCETION

Picture 2: inlet and outlet connections

POS. 1 2 3

DESCRIPTION Effluent inlet Screenings outlet Screen

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3 SAFETY RULES
3.1 NOT PERMISSIBLE USE
The machine is provided of all necessary protections, however due to its conformation and functionality there is a part of the unit which can be protected only on the installation place (see picture here under). This indispensible protection is responsibility of the installer.

INLET ZONE

OUTLET ZONE

Picture 3: Dangerous zones depending from installation unit MI15E

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WARNING: Never put hands, objects etc inside the solids outlet. A notice must be fixed near the outlet to inform the personnel. Screen zone inside the channel must be closet with a cover. If this operation is not possible, it is necessary to round the area with a proper enclosure and with notices to prohibit the access. Where it is possible, to provide with automatic device to switch off the machine in case of access.

3.2 SAFE USE

Warning !

To avoid every accident, it is necessary to read carefully the following information: The machine can be used only by qualified and expert personnel. All the connections must be executed from qualified and expert personnel. Execute a correct fixing among the different components and a correct fixing to the floor. When the machine is running, all the personnel must remain at the safety distance. Before starting the machine it is necessary that all the safety devices are connected and working and that the machine is in perfect conditions. In case of defects, in particular on the safety devices, the operator must inform immediately his superiors, the safety manager and the operator of the next shift. If the defect prevents the machine from a safe use, the machine must be immediately stopped. If during the working more people are in charged, before to make any operation it is necessary to inform also the other people. The machine can be used only for the correct use (see . 4.1) Every modification regarding the use or the safety conditions can be executed only from personnel , and following this, refuse every responsibility for not authorized modifications or damages caused from these modifications. It is forbidden to remove safety devices present in the machine. All checks, maintenance etc, can be executed only by qualified and expert personnel. Personnel in charged must use a proper workwear. It is necessary to ask for this workwear (gloves, shoes, ) at the safety manager. Disconnect electric power before making every operation and/or maintenance at the machine. To avoid every accidental startup of the machine during inspection, cleaning and maintenance, it is necessary to turn the general switch on the position OFF and push the emergency button to block the machine. Operation and Maintenance Manual Page 13 of 27

MI15E Before starting the machine it is necessary to be sure that all the safety devices are active. refuses every responsibility for damages to people and objects caused form the absence and/or tampering of the safety devices (notices and protections). It is necessary to make inspection of the plant minimum once per day, or once each working shift to check possible damages or defects that can be seen from outside. In case of any anomaly, stop immediately the plant, in particular if there are risks for your safety or for the safety of the plant. Be sure that safety devices, safety notices and the identifying plate of the plant are always clearly readable. It is compulsory the connection to the floor of the external metallic part of the machine. It is forbidden to remove safety and warning notices. It is forbidden to start the work with safety devices opened or to open them during the working. Touching the rotating part of the machine could cause serious injuries. Never introduce hands inside the outlet of the machine.

3.3 SAFETY DEVICES OF THE PLANT

Every plant must be provided, by the installer, with an emergency button (red colour) to stop the plant. Pushing this button in particular dangerous conditions the plant must stop immediately. Emergency button must be present near the machine and it must be easily approachable. Safety devices include: Protection covers of electric motor fan Enclosure, covers or automatic protection of the screen zone Warning notices

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

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4 DESCRIPTION AND SPECIFICATIONS

4.1 SAFE AND CORRECT USE
The unit MI15E has three principal functions:

Screening Lifting Compacting

The machine is connected directly to the inlet pipe of the incoming effluent, inside the specific collecting container. The effluent is immediately screened in the inlet zone where a suitable screen is placed. The solid retrained by the screen is removed through brushes positioned on the screw and it is transported to the compacting zone before the outlet zone. For a correct functioning of the unit it is necessary to ensure that the level of the effluent inside the container does not exceed the screening zone of the machine. Every other use of the machine will cause the finish of the warranty and will avoid to every responsibility.

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

4.3 WORKING PRINCIPLE, NOT PERMISSIBLE USE

Functioning of the plant or functioning of each machine can be prejudiced if the transported solids: Solids cannot be mechanically separated from the liquid flow Solids form an agglomerate (between each other or on the machine) Solids cause incrustations (between each other or on the machine) Solids contain an excessive quantity of grease Solids react between each other mechanically (polymerize, coagulate..etc)
Warning !

In case of a screening which tends to agglomerate or encrust, the solid accumulated must be capable to be taken off from the machine with a vacuum water machine without mechanical tools! The percentage of solid in the inlet waste water must not overcome the value on which the capability of the machine was dimensioned. If into the water to screen exists a high quantity of fibrous solid and solid which tends to tangle and/or a particularly high percentage of paper some working problems can happen; so it is not advised the use of the machine under this conditions. Operation and Maintenance Manual Page 15 of 27

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4.4 TECHNICAL CHARACTERISTICS

4.4.1 BUILDING FEATURES STANDARD DIMENSIONS

Picture 4: Standard dimensions of the machine

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

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MI15E 4.4.2
Type
MI 15 E MI 15 E MI 15 E

FLOW RATES (M3/H)

Filtration/screening meshes
2 mm 3 mm 5 mm

Maximum capability
8 mc/h 13 mc/h 20 mc/h

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

4.4.3

WEIGHT

The machine weights about 35 kg.

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5 USE FO THE MACHINE

Warning: Before proceeding with start/stop of the machine, please check that all the blocking conditions are removed. Before proceeding with start/stop of the machine, please check that all safety devices are present and perfectly efficient. CHECKS AND STARTUP. Before starting the machine, please provide as per the following: Read carefully all the OPERATION and MAINTENANCE MANUAL Check the positioning and the fixing of the machine. Check the hydraulic connections. Check the power supply connections and the cable box: it must be perfectly sealed. Check that the direction of rotation of the screw is as per the arrow installed on the machine (see picture here under). Check that all the safety protection at the inlet and at the outlet are present. Check that all the warning notices are present on the machine. Warning: During first startup, it is necessary to check very carefully regarding every single thing that could appear like a working defect, for example: vibrations, high noise level, wrong rotation direction, etc. Startup procedure must be executed every time that the machine remained stopped for a long period of time (more than one week). To grant personnel safety and machine safety, it is necessary to read very carefully section SAFETY RULES.

Picture 5: Correct sense of rotation of the gearmotor

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6
6.1

MAINTENANCE
PRELIMINARY OPERATION FOR SAFETY

CAUTIONS: Before making any maintenance, please stop the machine and switch off the electric power. SAFETY CONDITIONS IN CASE OF MAINTENANCE In case of particular dangerous condition, a second person must be present together with the technician in charge for maintenance. Maintenance of the unit must be executed only from expert, trained and qualified personnel. Before proceeding with the maintenance, it is necessary to inform all the other personnel in charged in the work. Any maintenance, when the machine is operating. Every time, before restarting the machine, be sure that all the protections and safety guards are efficient; be sure that all the tools are removed; be sure that other personnel is not working on the machine. Warning: To grant the full efficiency of the machine only original spare parts must be used.

6.2

PERIODICAL CHECKS

It is possible to divide all the checks in two parts : CHECKS TO DO AFTER 10 WORKING HOURS DESCRIPTION Check bolts and screws fixing wearing bars Electric motor and gearbox: check noise level and temperature PERIODICAL CHECKS DESCRIPTION Cleaning brushes (screen basket) Screen basket efficiency No clogging in the Screening outlet Gearbox Electric motor TIMING 100 hours 100 hours Daily Monthly Monthly

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MI15E For gearbox lubrication please refer to the gearbox manufacturer use and maintenance manual here attached.

6.3

EXTRAORDINARY MAINTENANCE

Here-under you can find information about how to replace some components mostly subject to wearing. To make all the replacements it is necessary to remove the machine from the working area, wash it and put it in safe conditions. (ref. chapter 6.1) 6.3.1 CLEANING BRUSHES REPLACEMENT

1. Dismount the screen basket unscrewing the fixing bolts A. Remove the screen basket from the pipe. 2. Unscrew the bolts B fixing the brushes to the spiral. 3. Fix new brushes to the spiral with new bolts. 4. Reassembly the screen.

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MI15E 6.3.2 GEARMOTOR REPLACEMENT

1. Dismount the protection. 2. Unscrew bolt A fixing the motor shaft. 3. Unscrew bolts B fixing the gearmotor to the screen screw frame. 4. Put the new gearmotor following the previous operation on

the opposite.

INTERNAL SIDE

EXTERNAL SIDE

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7
7.1

ACCESSORIES AND SPARE PARTS

SPARE PARTS
is in the condition to replace

Please find hereunder a list with the principal parts. every single component of the machine. Description Kit of brushes with fixing bolts

Picture

Gearmotor

7.2

HOW TO ORDER SPARE PARTS

To order spare parts it is necessary to check the label present on the unit: Machine model and serial number Manufacturing year Part code (if specified on the part)

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8 OTHER INFORMATION

8.1

LONG TERM STORAGE

In case of long term storage: Clean the machine in the screen zone, transport and compaction. Fix the machine in a wood cage and to stock it inside a covered area. Gearmotor: follow the instruction present in the manufacturer manual. Before restartin the machine proceed as per first startup.

8.2

DISMANTLING OF THE MACHINE

In case of dismantling of the machine, it is necessary to separate different materials composing the machine: Plastic, brushes and seal, must be separated and stocked in a proper area. Metallic part must be recycled as steel material. Gearmotor oil must be stocked in a proper area. For the dismantling of the machine it is advised to contact a specialized company for the recycle of the materials. PRECAUTIONS: Dismantling of the machine must be executed following general and local environmental rules.

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9 FAULT RESEARCH
Problem
MACHINE DOESNT START AND ELECTRIC MOTOR DOESNT WORK. VIBRATIONS WITH MACHINE EMPTY. HIGH ADSORBED POWER WITH MACHINE EMPTY. VIBRATIONS AT THE INLET DURANG THE WORK. MACHINE IS RUNNING, BUT AFTER A FEW SECOND, ELECTRIC MOTOR LIMIT SWITCH STOP THE MACHINE. MACHINE DOES NOT SCREEN, TRANSPORT AND DISCHARGE.

Cause z z z z z z z z z z z z z z z z z z z z z z z z z
There is not electric power. Wrong electric connections. Bad regulation of electric motor limit switch. Very low tension, very high frequency. Overload for screw conveyor blocked. A foreign solid or cloth can block the screw.

Solution
Switch on electric power. Make the electric connections. Regulate it. Check wire conditions. Check the reason of the block and to start the screw again. Remove the foreign solid, inverting the screw rotation direction. Check that electric motor is well connected. Voltage and phases must be as per electric motor manufacturer label. Invert electric motor poles. Remove the foreign solid, inverting the screw rotation direction. Replace it. Clean it. Check the situation at the inlet of the plant. Reduce the flow rate. Check the reason because the level of the effluent after the screen remain high. Replace the drum if necessary. Invert the screw rotation direction to remove the clogging solid.

Gearmotor can be damaged. Screw conveyor rotation direction can be in the wrong sense. A coarse or voluminous solid can clog the screw. Brushes not efficient. Screen clogged. Very high % of solids in the effluent. Very high flow rate. High level after the screen. Filtration meshes of the drum are not correct to treat the effluent typology. Outlet clogged.

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10 ATTACCHEMENTS
10.1 10.2 DECLARATION OF THE MANUFACTURER OPERATION AND MANINTENANCE MANUAL MANUFACTURER DECLARATION OF ELECTRIC MOTOR

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