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D O C U M E N TA Z I O N E

T E C N I C A

USERS MANUAL

138.11.A01_00
PISTON PUMPS FOR CERAMIC SLIP

PPB 308 - PPB 313

TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION

TECNICA

DOCUMENTAAO

TCNICA

ISH

L
ENG

138.11.A01
INDICE OF CONTENTS
TABLE

0-2

Revision 00 Date 04.10.1999

Revision 00 Date 04.10.1999

138.11.A01
TABLE OF CONTENTS

USERS MANUAL

PISTON PUMPS FOR CERAMIC SLIP

PPB 308 - PPB 313

MANUFACTURER
SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA

SERIAL NUMBER

YEAR OF MANUFACTURE

PUBLISHED ON
November 9, 1999

REVISION
00

VERSIONS
PPB308A - PPB308B - PPB313B

0-3

138.11.A01
INDICE OF CONTENTS
TABLE

0-4

Revision 00 Date 04.10.1999

Revision 00 Date 04.10.1999

138.11.A01
TABLE OF CONTENTS

Page
GENERAL INFORMATION ........................................................................................................................1 - 1
1.1
INTRODUCTION ......................................................................................................................... 1 - 1
1.2
HOW TO KEEP THE MANUAL ....................................................................................................1 - 1
1.3
HOW TO USE THE MANUAL ......................................................................................................1 - 1
1.4
USERS OF THE MANUAL .......................................................................................................... 1 - 1
1.5
WARRANTY ................................................................................................................................ 1 - 2
1.6
SUPPLEMENTS ...........................................................................................................................1 - 2
1.7
LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN
THE MANUAL ............................................................................................................................. 1 - 2
1.8
MACHINE IDENTIFICATION PLATE .......................................................................................... 1 - 3

MAIN FEATURES ......................................................................................................................................2 - 1


2.1
DESCRIPTION OF THE EQUIPMENT ........................................................................................2 - 1
2.1.1
MAIN ASSEMBLIES .................................................................................................................... 2 - 2
2.1.2
INTENDED, PROHIBITED AND MISUSE OF THE MACHINE ...................................................2 - 5
2.2
OVERALL DIMENSIONS .............................................................................................................2 - 6
2.3
TECHNICAL DATA ......................................................................................................................2 - 7
2.3.1
SPECIFICATIONS ...................................................................................................................... 2 - 7
2.3.2
NOISE LEVELS ........................................................................................................................... 2 - 8
2.3.3
LUBRICANT SPECIFICATIONS ................................................................................................. 2 - 9
2.4
DIAGRAMS ............................................................................................................................... 2 - 10
2.4.1
SPRAY DRYER SLIP SUPPLY SYSTEM ................................................................................. 2 - 10
2.4.2
HYDRAULIC SCHEMATIC ....................................................................................................... 2 - 11
2.4.3
POINTS OF USE (INSTALLATION DIAGRAM) ...................................................................... 2 - 12
2.4.4
WIRING BOX 1, HYDRAULIC POWER UNIT .......................................................................... 2 - 13
2.4.5
WIRING BOX 2, PUMP ............................................................................................................. 2 - 13

SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 1


3.1
PROTECTION AND SAFETY DEVICES INSTALLED ............................................................... 3 - 1
3.2
GENERAL SAFETY RULES ........................................................................................................3 - 3
3.3
HANDLING PROCEDURES ........................................................................................................3 - 4
3.4
OPERATOR TRAINING ...............................................................................................................3 - 5
SAFETY RULES TO BE OBSERVED WHEN OPERATING AND SERVICING THE MACHINE ....... 3 - 6
3.5
3.5.1
HAZARDS DERIVING FROM MECHANICAL PARTS ............................................................... 3 - 7
3.5.2
HAZARDS THAT MAY BE ENCOUNTERED IN THE ELECTRICAL SYSTEM ........................ 3 - 7
3.5.3
MAINTENANCE ...........................................................................................................................3 - 8
3.6
MAKING THE MACHINE INOPERATIVE ................................................................................... 3 - 9

INSTALLATION ........................................................................................................................................ 4 - 1
4.1
LIFTING AND HANDLING .......................................................................................................... 4 - 1
4.2
POSITIONING AND CONNECTING THE PUMP ........................................................................4 - 3

START UP ..................................................................................................................................................5 - 1
5.1
GENERAL INFORMATION ......................................................................................................... 5 - 1
5.2
PRELIMINARY CHECKS .............................................................................................................5 - 1

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INDICE OF CONTENTS
TABLE

OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1


6.1
CONTROL DEVICES .................................................................................................................. 6 - 1
6.2
STARTING AND STOPPING THE EQUIPMENT ........................................................................6 - 1
6.2.1
START UP PROCEDURE ........................................................................................................... 6 - 1
6.2.2
STOPPING THE MACHINE ........................................................................................................ 6 - 2
6.3
OPERATION ............................................................................................................................... 6 - 2
6.4
TIMING ........................................................................................................................................ 6 - 4
6.5
FIRST-TIME START UP ............................................................................................................. 6 - 6

ADJUSTMENTS ........................................................................................................................................ 7 - 1
7.1
MACHINE ADJUSTMENTS DURING OPERATION ...................................................................7 - 1

MAINTENANCE OPERATIONS ............................................................................................................... 8 - 1


8.1
SCHEDULED MAINTENANCE ....................................................................................................8 - 2
8.2
SPECIAL MAINTENANCE .......................................................................................................... 8 - 8
8.3
CHECKING THE NUTS AND BOLTS FOR TIGHTNESS ........................................................ 8 - 10

DECOMMISSIONING ................................................................................................................................ 9 - 1

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GENERAL INFORMATION
1

GENERAL INFORMATION

1.1

INTRODUCTION

E0004P

WARNING!

Carefully read the entire Users Manual before working on the machine and/or the packaging of the various parts.
This manual contains important information for safeguarding the operators, the maintenance staff as well as the
machine itself.
Sacmi reserves the right to make changes to the machine and in the manual without giving prior notice.
Copyright. Unauthorized reproduction can result in civil damages and criminal prosecution on the part of SACMI.
The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,
reproduced, disclosed or transferred.
Additional copies of this manual can be obtained by contacting SACMIs Customer Service Department.

1.2

E0004P

HOW TO KEEP THE MANUAL

WARNING!

This manual is supplied with the machine and must be kept along with it even if it is resold. Always keep the manual
near the machine where it can be easily consulted. The manual must always be close at hand so that the operator and
maintenance staff are able to consult it rapidly at any time.

1.3

HOW TO USE THE MANUAL

The lay-out of this manual allows it to be easily consulted as all the information and instructions provided are grouped
together and divided into chapters and paragraphs. The user has to simply refer to the table of contents.
The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to the
operators safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and
are written in italics, as shown below.

E0004P

WARNING!

Chapter 3, SAFETY EQUIPMENT AND PRECAUTIONS, must be carefully read in its entirety as it contains
important information and warnings regarding safety.

1.4

USERS OF THE MANUAL

In this manual the machine operators are categorized as follows:


- Operator: this is the person responsible for supervising and operating the machine.
- Routine maintenance men.
For a more detailed description, see paragraph 3.4 - OPERATOR TRAINING in chapter 3 - SAFETY EQUIPMENT
AND PRECAUTIONS.
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1.5

Revision 00 Date 04.10.1999

GENERAL INFORMATION
WARRANTY

SACMI shall be held responsible only for the machine as it was at the time of delivery.
Any modifications to the machine or work cycle must be carried out by SACMI personnel or duly authorized by SACMIs
Engineering Dept.
SACMI shall not be held responsible for damage deriving from the use of non-original spare parts.

E0004P

WARNING!

The operators or maintenance staff should not carry out any operations, special maintenance or repairs when the
machine is under warranty. These procedures are to be performed only by the manufacturers specially trained
personnel. For this reason, these types of operations are not dealt with in this manual.

1.6

SUPPLEMENTS

- None

1.7

LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE


MANUAL

DANGER SYMBOLS

General hazard
E0004P

E0003P

Danger of hands being injured

High voltage, risk of electric shock


E0007P

ALERT SYMBOLS

Machine must be connected to efficient ground electrodes.


E0006O

1-2

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Revision 00 Date 04.10.1999

GENERAL INFORMATION
1.8

MACHINE IDENTIFICATION PLATE

TIPO
TYPE
MATRICOLA No.
SE R I A L N U M B E R
ANNO
YE A R

VIA

SELICE

PROVINCIALE

17/A

IMOLA

I TA L I A

E0020
C1632

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GENERAL INFORMATION

Revision 00 Date 04.10.1999

138.11.A01
MAIN FEATURES

MAIN FEATURES

2.1

DESCRIPTION OF THE EQUIPMENT

The piston pump is engineered and constructed to deliver ceramic slip to spray dryers. It basically consists of two parts:
a piston pump assembly and hydraulic power unit. The function of the pump assembly is to create a flow of liquid and
maintain it at the preset delivery rate and pressure required for the system in which the pump is installed.
The hydraulic power unit delivers oil at a constant pressure. Thanks to the hoses used, the oil is sent alternately to
the cylinders of the piston pump.

Figure 2.1 - OVERALL VIEW


1 Pump assembly
2 Hydraulic power unit

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2.1.1

Revision 00 Date 04.10.1999

MAIN FEATURES
MAIN ASSEMBLIES

2.1.1.1 Piston pump assembly


(references given in figure 2.1.1.1)
The pump assembly basically consists of two alumina pistons (1), which are driven by the hydraulic cylinders (2) and
alternately immersed in the pump casings (3), thus creating a consistent flow of liquid. The intake valves (4) and
delivery valves (5) control the flow rate. In addition, the accumulator (7), located on the manifold (6), reduces any
changes in pressure which may take place when the pistons reverse.
The seals (8), pre-loaded by the device (9), are located between the pistons and the pump casing. A small slide (11),
provided with lubricated bushes which move along chrome-plated steel guides, ensure the piston moves properly
during pump operation. Two lines (10) are connected to hydraulic cylinders. They ensure the alumina pistons perform
their reciprocating motion in a synchronised manner.
Alumina, which is particularly wear resistant, was opted for as dense fluids (especially ceramic slip) are highly abrasive
on the moving parts. In order to reduce wear, clean water should be put in the top of the pump casing near the ring
nut (9). Creating a flow over the seals, the water lubricates them, thereby reducing friction while at the same time
washing the piston and eliminating any abrasive liquid which may have leaked out.
Guards (12) are provided for protection against the moving parts, thus safeguarding the operating personnel. The
reverse sensors (14) and timing sensors (15) are found on the guard mounts (13). The sensors are protected by the
removable covers (16).
This particular set up allows the position of the sensors to be changed without having to take off the guards (12). In
this way, the operator can safely adjust the piston stroke while the machine is running.

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Revision 00 Date 04.10.1999

MAIN FEATURES

Figure 2.1.1.1 - PISTON PUMP


1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Alumina pistons
Hydraulic cylinders
Pump casing
Intake valve (plate-type)
Delivery valve (plate-type)
Manifold
Accumulator
Seals
STD tie-rod system
Hydraulic lines (upstroke and timing)
Piston slide
Guards
Mounts
Reverse sensors
Timing sensors
Removable covers

7
10

11
15

13
12

14

9
8
3
4

16
15
6

5
1
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MAIN FEATURES

2.1.1.2 Hydraulic power unit


(references given in figure 2.1.1.2)
The hydraulic power unit comes with a sheet metal reservoir (1). Along with the oil required for proper system operation,
a tube-bundle heat exchanger (2) is found inside the reservoir. The exchanger is connected to the water supply
system. The motor-and-pump unit (3), oil thermostat (4), filler (5), suction filter (6), drain filter (8) and a hydraulic
assembly (7) for controlling the pressure and cylinder reverse motion are found on the reservoir.

Figure 2.1.1.2 - HYDRAULIC POWER UNIT


1
2
3
4
5
6
7
8

Reservoir
Heat exchanger
Motor-and-pump unit
Oil thermostat
Filler
Suction filter
Hydraulic control assembly
Drain filter

3
7

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138.11.A01
MAIN FEATURES

2.1.2

INTENDED, PROHIBITED AND MISUSE OF THE MACHINE

INTENDED USE OF THE MACHINE


The machine is specially engineered and constructed to produce products that have the characteristics indicated in
the specifications (see paragraph 2.3.1 - SPECIFICATIONS).
Safe machine operation is ensured only if the following conditions are satisfied:
- the machine is used under the required conditions and within the preset limits;
- maintenance is regularly carried out as specified in chapter 8 - MAINTENANCE;
- the machine is used correctly as directed in chapter 6 - OPERATING INSTRUCTIONS

E0004P

WARNING!

The pump is part of a spray drying plant and is therefore operated remotely from the spray dryers control panel.
It cycles together with the spray dryer.

UNINTENDED AND PROHIBITED OPERATIONS


No other tasks except those specified by the Manufacturer are to be performed. For this reason, the Manufacturer shall
not be held responsible for the consequences deriving from failure to observe the instructions contained herein.
MISUSE OF ERRONEOUS USE
The Manufacturer shall not be held responsible for the consequences deriving from improper use of the equipment.
These consequences may be the result of:
- use of the pump by unqualified personnel;
- fatigue (in particular during night shifts) or carelessness;
- negligence caused by superficiality or wrong habits
The equipment must be operated by well trained personnel capable of:
- using it correctly in normal working conditions;
- and, above all, facing emergencies.

2-5

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2.2

Revision 00 Date 04.10.1999

MAIN FEATURES
OVERALL DIMENSIONS

207

577

1672

1107 PPB308 - 1214 PPB313

Figure 2.2 - OVERALL DIMENSIONS

950
1840

659

659
1363

750

560

= =

600

= =

1000

= =

1050

= =

700

520
= =

585
= =

2-6

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MAIN FEATURES
2.3

TECHNICAL DATA

2.3.1

SPECIFICATIONS

Maximum head with material having a specific weight of 1.7 kg/dm

Maximum flow rate of fluid to be transferred


Maximum pressure of fluid to be transferred
Operating pressure range
Power requirements (at 50 Hz)
Cooling water at 20 C
flow rate
Oil in hydraulic power unit
Hydraulic unit reservoir
(capacity)
Hydraulic unit pump
(delivery rate)
(maximum pressure)
(operating pressure)
Weight
hydraulic power unit (no oil)
pump
Oil accumulator
inflating pressure
Slip accumulator
inflating pressure (pre-charge)*
Minimum pressure for cooling water

m
l/h
bar
bar
kW
l/1'
l
l
l/min
bar
bar
kg
kg
bar
bar
atm

PPB308

PPB313

3.5
8000
30
5 - 30
15
20
150
160
75
80
75
350
1000
50
13 - 15
2

3.5
13000
30
5 - 30
22
20
150
160
85
115
110
350
1000
70
13 - 15
2

* Only for precharged accumulators (OPT)

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Revision 00 Date 04.10.1999

MAIN FEATURES

2.3.2

NOISE LEVELS

Test conditions
- Operating conditions (refer to ISO/DIS 11202 standard, point 9.5)
- Type of operation:
- fluid pumping
- Work cycle:
- pumping (refer to ISO/DIS 11202 standard, point 3.11)
- Test conditions:
- hydraulic unit pressure (bar) 100
- operating pressure (bar)
30
- flow rate
11 m3/h
- Test environment
in a factory
Instruments employed
Class 1 instruments (IEC 804)
Acoustic radiation pressure (ISO/DIS 11202)
Noise emission level (ISO 3746)
Measurements
LbA Background noise level (dB A)
LpA Acoustic radiation pressure emitted, corrected, weighed A, average over time (dB A)
LwA Noise emission level in dB, weighed A (dBA)

P1
P1

41.3
81
92

Figure 2.3.2 - PLACE WHERE NOISE LEVEL WAS RECORDED


P1
.
d

Noisiest point of the area where measurements were taken


Area where noise level was measured
Datum zone
P1
=1m

C1639

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MAIN FEATURES

2.3.3

LUBRICANT SPECIFICATIONS

HYDRAULIC POWER UNIT

SLIDE BUSHES

OIL

HYDRAULIC OIL ISO VG46

GREASE

Dropping point 180 C


Penetration 350/370 dmm

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Revision 00 Date 04.10.1999

MAIN FEATURES

2.4

DIAGRAMS

2.4.1

SPRAY DRYER SLIP SUPPLY SYSTEM

Figure 2.4.1 - SLIP SUPPLY SYSTEM


1
2
3
4
5
6
7
8

Suction line
Pump
Delivery line
Slip filters
Spray dryer supply line
Nozzle holder
Drying unit
Hydraulic unit pump

6
3
8

5
7

2
1

C1389

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MAIN FEATURES
2.4.2

HYDRAULIC SCHEMATIC

Figure 2.4.2 - HYDRAULIC SCHEMATIC


1
2
3
5
6
7
8
9
10
11
12
13
14
15
16

Check valve
Cock and pressure gauge
Pressure gauge
Accumulator
Reversing valve
Reversing throttles
Pilot solenoid valve YV3 - YV4
Filter element
Pressure control valve
Pressure relief valve
Electric motor
Coupling
Vane pump
Check valve
Suction filter

17
18
19
20
21
22
23
24

Drain filter
Reservoir
Cooler
Level indicator
Thermometer and switch
Hydraulic cylinders
Timing valve YV1
Solenoid valve YV2, Upstroke chamber
loading
SQ Sensors
Hydraulic circuit
Pilot circuits

23
YV1
A

YV2

22

22
24

SQ1

SQ4

SQ2

SQ3

7
A

YV4 P

5
3

YV3

2
1
P
T

12

13

14

21
10

11

20
19

15
16

17

H2O

18
C0867

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Revision 00 Date 04.10.1999

MAIN FEATURES

2.4.3

POINTS OF USE (INSTALLATION DIAGRAM)

Figure 2.4.3 - POINTS OF USE (INSTALLATION DIAGRAM)


1
Electrical box, Hydraulic power unit
2
Electrical box, Pump
3
Hydraulic unit control assy
4
Pump cylinders
5
Delivery line
6
Intake line
A-B Connecting hoses
HD30 Inlet and outlet fittings, hydraulic unit cooling water
HD31 Piston washing water connection
3

A
5
HD31

HD31

2
B
4

1
HD30

6
2 - 12

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MAIN FEATURES
2.4.4

WIRING BOX 1, HYDRAULIC POWER UNIT

M
ST3

YV4

YV3

SC.2

XT1
XT2

901

303

900

2
2
2
303
304
305
306

1
24
24
101
102
103
104

SC.2

24 24 101 102 103 104 2

2x1,5 (2 - 1)
2x1 (900 - 901)

24
2
101
102
103
104
303
304
R1

304

ST3
N.C
900 - 901

305
306

PPB 130 - 85 - 900

YV4
2 - 306

2
1
1

YV3
2 - 305

C1641

WIRING BOX 2, PUMP

YV1

YV2

SQ1

SQ4

SQ2

SQ3

YV1
2 - 303

SQ1

303
304

YV2
2 - 304

2
2
24
24
101
102
103
104

2.4.5

24
101

24
104

SQ2

24
102
2

SQ4

2
24
103
K21

SQ3

C0870

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2 - 14

MAIN FEATURES

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138.11.A01

SAFETY EQUIPMENT AND PRECAUTIONS


3

SAFETY EQUIPMENT AND PRECAUTIONS

3.1

PROTECTION AND SAFETY DEVICES INSTALLED

(See figure 3.1)


The machine is provided with a number of protection and safety devices which safeguard the operator and the
machine.
Shutdown devices
These devices (oil thermostat in hydraulic power unit) detect malfunctioning and prevent the machine from being
started or stop it if running.
Stoppage
The operator is informed by the spray dryer control system whenever a stoppage occurs.
Equipment which safeguards the operator
EMERGENCY STOP BUTTON
An emergency stop button is located on the spray dryer control panel. When pressed, the spray dryer, ventilation and
fuel supply systems are immediately shut off. Reset from the control panel.
FIXED PISTON GUARDS
The operator may be injured or caught in the zone where the alumina pistons operate. To prevent access to these
potentially hazardous zones, the pump (1) is provided with fixed guards that cannot be removed without using specific
tools and do not stay in place if fasteners are not provided. Slots are found at the bottom of the guards, they are used
to pass the wrenches through when seals need to be removed and are provided with covers. The latter are to be pulled
off when adjustments are to be made by well-trained personnel.

E0004P

WARNING!

Only the wrenches supplied with the machine can be pushed through the slots in the fixed guards. Keep your hands
or any objects away from the slots.

INTAKE VALVE COVERS


The covers (2) that protect the intake and delivery valves prevent the closure plates from coming out if they are not
in place.
SENSOR COVERS
The removable covers (3) are installed on the sides of the machine. These covers protect the reverse and timing
sensors from being banged or accidentally moved.
PRESSURE RELIEF VALVE
The hydraulic system comes with a pressure relief valve (4). This valve is found in the hydraulic control assembly and
is set to the maximum allowable pressure. This is done to guarantee top machine performance and prevent the system
from exceeding the set value, thus avoiding malfunctions.

3-1

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Revision 00 Date 04.10.1999

SAFETY EQUIPMENT AND PRECAUTIONS

Figure 3.1 - PROTECTION AND SAFETY DEVICES INSTALLED


1
2
3
4
5

Pump guard
Valve cover
Sensor cover
Pressure relief valve
Oil thermostat

3
2

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138.11.A01

SAFETY EQUIPMENT AND PRECAUTIONS


3.2

E0004P

GENERAL SAFETY RULES

WARNING!

INSTALLATION
Install the machine by following the instructions provided by the Manufacturer and observing the safety regulations
in force in your country.
It is extremely important that the machine is properly connected to adequate earth electrodes. SACMI shall not be held
responsible for any damage to the machine or injury to personnel resulting from improper installation.
SAFETY DEVICES & GUARDS
The machine comes equipped with electrical and/or mechanical safety devices which safeguard the machine and the
operator. The safety devices and guards provided MUST NOT be removed or inactivated under any circumstances.
SACMI shall not be liable for any damage or injury if the machine operator fails to observe these precautions.
The machine cannot be started up if the safety devices are not operative. Periodically check all the safety devices
(emergency stop button, interlocks, limit switches, barrier guards, etc..) installed to see that they are efficient.
CHECKS, REPAIRS & MAINTENANCE
Do not perform any checks, repairs or maintenance operations on moving parts. Use clearly visible signs to warn all
personnel of possible danger. Before carrying out these operations, shut off the electricity supply by using the main
switch. The main switch is to be padlocked in the power off position so that the machine cannot be started up
accidentally.
To ensure overall machine efficiency and trouble-free operation, it is essential that the directions supplied by SACMI
are followed and that the required maintenance is carried out.
It is advisable to periodically check all of the safety devices for proper functioning and the insulation of the electrical
cables. The latter must be replaced if damaged.
LIVE ELECTRICAL PARTS
It is severely forbidden to work on or near live electrical parts.
The electrical cabinet doors must be kept locked and warning signs signalling potential danger must be placed on them
Before opening the electrical cabinets or switchboards, shut off the electricity supply with the main switch. Periodically
check that the ground is effective.
QUALIFIED PERSONNEL
The assembling, disassembling and servicing of the machine must be performed by qualified personnel. When
carrying out these operations, always use adequate equipment and follow the instructions provided.
MACHINE NO LONGER USED
If the machine is no longer going to be used, make it inoperative by unplugging the power cable from the supply mains.
Install any required safety devices.

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3
3.3

E0004P

Revision 00 Date 04.10.1999

SAFETY EQUIPMENT AND PRECAUTIONS


HANDLING PROCEDURES

WARNING!

SLINGING THE LOAD


To safely lift the machine, always follow the directions below :
- Use adequate lifting equipment. (Note that the weight is indicated on the crates and packing containers as well as
printed in the relevant form written in the customers own language).
- Cover all sharp edges.
- Check the safety device the hook is provided with.
Before lifting:
- Make sure all personnel are away from the machine.
- Make sure the load does not sway.
- Make sure all parts which may fall are secured in position.
- Lift the machine vertically in order to prevent collision with anything placed nearby
HANDLING
The load should always be lifted and handled with the aid of sticks, levers and grapples. Never use your hands!
The person in charge of handling and lifting must always:
- Know where the machine is to be carried.
- Instruct the crane operator from a visible position.
- Stop the operations if hazardous situations occur.
- Keep bystanders away from overhead loads.
PLACING THE LOAD
Before the load is placed in position, make sure the floor is level and strong enough. Never place loads near exits, fire
fighting equipment, passageways, control panels or power lines .
The load is to be placed on suitable supports in order to keep it stable and help the personnel remove the sling. Never
place containers in bad condition with protruding parts on top of each other. Never stack parts to a height which may
affect stability.
INSTALLATION
If the machine is installed by the customers personnel, the instructions provided by the manufacturer and current
safety regulations are to be followed. Always connect the machine to adequate ground electrodes. Improper
installation may result in severe injury to personnel and damage to equipment. The manufacturer declines all
responsibility. The manufacturer shall not be held responsible for unsafe machine operation if some parts are provided
and installed by the customer.

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3.4

E0004P

OPERATOR TRAINING

WARNING!

The factory supervisor should see that the machine operators:


- meet the requirements listed below;
- have fully understood the instructions contained in the manual;
- are well trained on how to safely carry out their tasks;
- have received specific instructions on how to operate the machine correctly.
The machine operators should:
- understand the instructions provided and have specific experience in operating this type of machine
- be sufficiently educated so as to be able to read and fully understand the contents of this manual as well as the
drawings provided
- have a good technical background (in the electric, mechanical and pneumatic fields) so that they are able to safely
carry out the jobs they are responsible for as specified in the manual
- know all the safety rules and regulations in force in the country where the machine is installed i.e.:
- general rules (regarding hygiene and on-the-job safety as well as work accident prevention)
- specific rules (for the type of product being manufactured)
The maintenance staff should be employed on the basis of the same criteria.
In addition, they must be qualified in specific technical fields (mechanical, electric, and pneumatic) so that they can
safely carry out the operations they are responsible for (as specified in the manual).
Tasks the operator and maintenance staff are and are not responsible for
The jobs the personnel are responsible for are dealt with in various parts of this manual (i.e. machine operation, routine
maintenance, special maintenance, etc...).
It is fundamental that the personnel only carry out the tasks they are specifically responsible for (mechanical, electric,
and pneumatic).

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SAFETY EQUIPMENT AND PRECAUTIONS


SAFETY RULES TO BE OBSERVED WHEN OPERATING AND SERVICING THE
MACHINE

The aim of this chapter is to inform the operators and maintenance staff:
- about some potentially hazardous and/or dangerous situations that may be encountered while operating or
performing maintenance on the machine
- about the safety measures and devices employed and how to use them correctly
- about any additional risks
- on the measures to be taken (general and specific precautions to eliminate potentially harmful situations).
Detailed information is given in this chapter. Your attention is called to the instructions in this manual, at the points
where the situations are encountered.

E0004P

WARNING!

For added clarity, some illustrations in the manual show the machine or parts of it without guards or with the guards
removed.
Do not operate the machine if the safety guards and devices have been removed or inactivated.
In addition to satisfying the requirements stated above the operator and maintenance staff must attend a training
course and receive on-the-job instructions before working on the machine. Along with receiving information on
machine operation and maintenance under normal conditions, they should know:
- the safety precautions and how to use the various devices,
- how to identify, control and face dangerous situations described in this manual and in particular in this chapter.

When operating this machine, the potential hazards more likely to be encountered are in the mechanical, hydraulic
and electrical systems. Where possible, hazardous situations have been eliminated:
- directly, during the design stage
- indirectly, by using barriers, guards and safety devices.

E0004P

WARNING!

Do not operate the machine if the barriers, safety guards and devices have been removed or altered in any way.
Before performing any type of operation on the machine, always consult the manual for information on how to
correctly carry out the procedures. In addition, the manual contains important information concerning safety. If any
doubts arise, contact SACMIs After-Sales Service Department.

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3.5.1

HAZARDS DERIVING FROM MECHANICAL PARTS

HAZARDS THAT MAY BE ENCOUNTERED IN THE WORK AREA


Personnel may risk slipping or falling in the work area or in the surrounding zone during machine operation and
maintenance. When installing the machine, make sure sufficient space has been left around the machine to reduce
these risks.
The passageways and areas around the machine must always be:
- free of obstacles (such as step ladders, tools, containers, boxes of material)
- clean and dry (immediately remove any drops of oil )
- well lit
The operator may be seriously injured, as stated in paragraph 3.1.
LIGHTING
It is fundamental that the areas surrounding the machine and in particular the work zone are always well lit. Replace
any defective elements without delay. Minimum value 300 lux.

3.5.2

HAZARDS THAT MAY BE ENCOUNTERED IN THE ELECTRICAL SYSTEM

The slip pump is controlled from the spray dryer switchboard.


SWITCHBOARD: DANGER OF COMING INTO CONTACT WITH LIVE PARTS.
The switchboard can be accessed even if power is being supplied to the system. As called for by the EN 60204-1
standard, it can be accessed only with a key or other specific tools. These tools must be given exclusively to authorized
personnel who are highly qualified and specially trained to access live parts.
WHEN POWER IS BEING SUPPLIED TO THE SWITCHBOARD THE QUALIFIED PERSONNEL WHO HAVE BEEN
AUTHORIZED CAN ONLY RESET THE SAFETY EQUIPMENT.

E0004P

WARNING!

Whenever a component either inside or outside the switchboard has to be replaced, the maintenance man must
shut off the system with the main switch and padlock it in its open position to prevent it from being started up
accidentally.

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SAFETY EQUIPMENT AND PRECAUTIONS


MAINTENANCE

The safety measures to be observed while performing maintenance are given in this paragraph. The procedures and
any additional safety precautions are given in chapter 8, MAINTENANCE OPERATIONS for each individual job.
Make sure the machine is in a safe condition before carrying out any maintenance operations. Once the operations
have been completed make sure the machine is able to work safely. In particular make sure all the safety devices and
guard interlocks operate properly.

E0004P

WARNING!

Failure to observe these precautions may cause severe personal injury.

E0004P

WARNING!

Do not carry out any repairs or maintenance while the machine is running.
Signs must be put up to inform the operators.
Before carrying out any operations, disconnect the machine from the power supply by using the main switch. The main
switch can also be padlocked in the power off position to prevent the machine from being started up accidentally.
To ensure top machine performance and proper operation closely follow the instructions provided by the manufacturer
and carry out maintenance at the stated intervals. Periodically check all the safety devices for proper operation and
the insulation of the power cables. Replace them if damaged.
Once maintenance has been completed, check the machine for proper functioning. Most of all make sure all the safety
devices are efficient and the guards are in place.

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3.6

MAKING THE MACHINE INOPERATIVE

When the machine is no longer to be used, it should be made inoperative by following the instructions given below:
- Shut off the electrical power to the machine by using the main switch
- Unplug the power cable attached to the terminal block in the electrical cabinet
- Unplug the cables between the electrical cabinet and the machine
- Disconnect the cooling system from the water supply and factory drain system
- Thoroughly clean the entire machine, especially the moving parts, lubricate the parts to protect them
- Close the doors of the electrical cabinet and the machine guards to prevent damage, build-ups of dust, etc...
- Use any safety devices provided.
For information on how to dismantle the machine see chapter 9 DECOMMISSIONING.

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Revision 00 Date 04.10.1999

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INSTALLATION

INSTALLATION

4.1

LIFTING AND HANDLING

SUBDIVISION OF THE MACHINE


The machine is divided into two parts: the casing and the hydraulic power unit.
DIMENSIONS AND WEIGHTS
The weights and measurements refer to each single parts: see paragraph 2.3.1 SPECIFICATIONS.
LIFTING EQUIPMENT
The points for lifting and transporting the parts are shown in figure 4.1.
To lift the packed parts, use suitable equipment and observe all safety precautions.
Use maximum care when handling the crates both indoors and outdoors. Always use equipment adequate for the
weight of the crate.
On arrival, it is fundamental that the all the parts are precisely weighed.

E0004P

WARNING!

The manufacturer shall not be held responsible for injury to persons or damage to equipment that are caused by
failure to observe current safety precautions regarding lifting and handling material inside the factory.

SAFETY MEASURES TO BE OBSERVED WHEN LIFTING


- Sling the machine as shown in figure 4.1. Use slings that are long enough and adequate for weight of the load.
- Protect the points where the sling comes into contact with the machine with cardboard or rags.
- Gradually move the load until it is stable.
- Carefully lift the load and avoid swaying it.

E0004P

WARNING!

The machine can be lifted and handled only by qualified and authorised personnel.
It is extremely important that no one is near the load and/or within the range of action of the overhead traveling
crane while the machine is being lifted and moved.
- closely follow the instructions given in the SAFETY EQUIPMENT AND PRECAUTIONS chapter.
- While being handled the load must always be kept perfectly horizontal regardless or the type of equipment used.

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INSTALLATION

Figure 4.1 - LIFTING AND HANDLING


1 Pump casing
2 Hydraulic power unit

C1634

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INSTALLATION

4.2

POSITIONING AND CONNECTING THE PUMP

When installing the equipment, which is to be done according to the plant requirements, keep in mind the pumps
cannot take in a fluid that has the indicated specific weight from a depth greater than that indicated in paragraph
2.3.1 - SPECIFICATIONS, even when working at their max. capacity.
(see figure 4.2/A)
- Place the pump and hydraulic power unit on the foundations prepared beforehand.
- Level and secure with the anchor bolts provided.
- Install the suction and delivery lines. Make sure the joints and welds are not cracked as air may leak out during
operation and the required vacuum may not be created.
- Join the ball valve at the suction end (6) to the water supply. Avoid sharp bends as air pockets may be created and
as a result the pump may not be able to take in the fluid.
- Connect the HD30 power unit cooler to the water supply. This is also used to flush HD31 porcelain pistons.
- Connect the cables to the electrical boxes (1 and 2).
- Install the hoses between the assembly (3) of the hydraulic power unit and the pump cylinders (4). Join points A and
B of the pump to points A and B of the power unit respectively.
- Wire up the electrical box of the hydraulic power unit (1) as well as the electrical box (2) for the pump as shown in
diagrams 2.4.4 and 2.4.5.
- Ground the machine (see figure 4.2/C).
- Remove the paint from the points of contact on the machine for the ground conductors before tightening the related
screws so as to ensure good electrical continuity.

E0004P

WARNING!

The equipment is to be connected to the ground electrodes provided.

The points of connection on the equipment are marked with the international ground symbol:
E0006

Failure to ground the equipment may cause serious personal injury and property damage.

E0004P

WARNING!

The equipment is to be connected by qualified personnel as indicated by SACMI.

E0004P

WARNING!

The RST cable is not supplied with the machine. Its characteristics and dimensions are given in paragraph 2.3.1
SPECIFICATIONS.

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INSTALLATION

Figure 4.2/A - POINTS OF USE AND INSTALLATION DIAGRAM


1
2
3
4
5
6
A-B
HD30
HD31

Electrical box, Hydraulic power unit


Electrical box, Pump
Control assembly, Hydraulic power unit
Pump cylinders
Delivery line
Suction line
Connecting hoses
Inlet and outlet fittings, Cooling water for hydraulic power unit
Connection, Piston flushing water

A
5
HD31

HD31

2
B
4

1
HD30

4-4

C1640

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Revision 00 Date 04.10.1999

INSTALLATION

(See figure 4.2/B)


Ball valves should be fitted to both the delivery (13) and suction lines (12) of the machine so that the latter can be shut
off without affecting the rest of the system, thereby allowing maintenance to be carried out without stopping the spray
drying plant.

Figure 4.2/B - DELIVERY AND INTAKE VALVES

1
2
3
4
5
6
7

Delivery valve
Cover
Clamp
Plate
Intake valve
Disk
Pin bush

8 Valve seat
9 Guide pin
10 Spring
11 Protective frame
12 Valve on suction line
13 Valve on delivery line
14 Ball valve on suction line
15 Ball valve on delivery line

2
11
10
4
7

14

13

12
1

15

C1642

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INSTALLATION

Figure 4.2/C - GROUND CONNECTIONS

E0006

C1633

E0006

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START UP

START UP

5.1

GENERAL INFORMATION

E0004P

WARNING!

These operations are to be carried out only by the manufacturers personnel who are responsible for starting up
the equipment as specified in chapter 1 GENERAL INFORMATION. Hazardous situations may be created causing
serious injury to persons and/or damage to equipment if these operations are performed by anyone other than the
manufacturers staff.
For information regarding the control keys, see chapter 6 OPERATING INSTRUCTIONS.
First time start up requires specialized mechanics and electricians. The customers operator and maintenance staff
only have to see how the machine is started up (as it is useful to understand the operating principle of the machine,
how to adjust the auxiliary equipment and accessories as well as the safety guards and devices employed) and the
trials run to see if the parts have been properly set.

5.2

PRELIMINARY CHECKS

CONDITIONS
The machine has already been tested when delivered therefore the machine only needs to be checked for any damage
that might have occurred during shipment or installation.
- Make sure the max. pressure in the relief valve 115 bar for the PPB 313 or 80 bar for the PPB 308.

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START UP

PREPARATION
(for the references see figure 5.2)
- Circulate the cooling water for the hydraulic power unit as well as the water for flushing the porcelain pistons.

WARNING!

E0004P

Never start the pumps without water for washing the pistons as the seals will be prematurely worn and irreparably
damaged.
- Fill the pump with water to facilitate priming.
- After shutting the valves (12 and 13), open the ball valves (14 and 15) located on the fittings of the suction and delivery
lines respectively. As a result, the water will flow through the pump casing.
- Close the ball valve (15) on the delivery side and the ball valve (14) at the suction end in the order given. As a result,
the pump casing will remain full of water.
- Open the valves (12 and 13).
Figure 5.2 - DELIVERY AND INTAKE VALVES

1
2
3
4
5
6
7

Delivery valve
Cover
Clamp
Plate
Intake valve
Disk
Pin bush

8 Valve seat
9 Guide pin
10 Spring
11 Protective frames
12 Valve on suction line
13 Valve on delivery line
14 Ball valve on suction line
15 Ball valve on delivery line

2
11

10
4
7

14

13

12
1

15

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OPERATING INSTRUCTIONS
6

OPERATING INSTRUCTIONS

E0004P

WARNING!

The directions given in this manual must be closely followed and all safety precautions fully observed.

6.1

CONTROL DEVICES

These devices are located on the spray dryer control panel.

6.2

STARTING AND STOPPING THE EQUIPMENT

6.2.1

START UP PROCEDURE

Before starting the machine make sure all the safety devices (which may have been removed during maintenance)
are correctly installed.
Check the inflating pressure in the slip accumulator ( the values are indicated in paragraph 2.3.1 SPECIFICATIONS)
and make sure the pressure control valve is completely open.
Make sure the reverse and timing sensors are placed in such a way as to fully exploit the stroke of the pistons (the
reversals are reduced and therefore system performance is improved).
When the equipment is started up for the first time or after maintenance has been performed on the hydraulic pump,
fill the suction hose of the pump with oil before starting the electric motor. Once the motor has been started up, bleed
any air from the delivery hose of the pump.
The electric motor can now be started. The entire flow is delivered by the hydraulic pump but the cylinders do not
operate as there is hardly any pressure in the circuit. Gradually adjust the control valve. In fact, as a result of slight
increases in the oil pressure the alumina pistons accelerate significantly as the duct that joins the pump to the point
of use is still empty. Once the line is full, the pressure of the fluid will start to increase and the pump will slow down.
The pressure can now be gradually increased until the required value is reached.
In versions equipped with a proportional pressure control the start-up ramp and operating pressure control are
controlled from the ATMs electrical cabinet.
The operating pressure of the hydraulic circuit is strictly related to the pressure of the slip circuit. For this reason, if the
pressure in the hydraulic circuit does not rise neither will the pressure in the slip circuit.
The pressure ratio in the PPB 313 is 3.5:1. For example, in order to obtain a pressure of 30 bar in the slip lines,
the oil pressure must be about 105 bar. The pressure ratio in the PPB 308 is 2.5:1. or example, in order to obtain
a pressure of 30 bar in the slip lines, the oil pressure must be about 75 bar. This ratio is however approximate as
it is strictly related to the friction created by the working parts of the machine, in particular between the seals and
alumina pistons.
Reverse motion should be optimised during this stage. To do this, adjust the relative throttles (7) (see figure 6.3).
Increasing braking will extend the stroke of the pump pistons, therefore timing sensors SQ1 and SQ2 need to be reset.
In addition, be careful not to full extend or retract the hydraulic cylinders.
At this point, the machine will run at normal speed. Check the pressures in the two lines. The pressure gauge (3) should
be shut off by using the cock (2).
This prevents malfunctioning due to changes in pressure during operation. If the speed of the equipment varies
notably due to increased ATM output or one of the pumps has stopped, etc., repeat the adjustments described above
in order to suit the new conditions.

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6.2.2

Revision 00 Date 04.10.1999

OPERATING INSTRUCTIONS
STOPPING THE MACHINE

First of all, gradually relieve the pressure until the equipment stops by using the control valve. Once this has been done,
shut off the electric motor with the main controls.
At this point, check the pressure gauge located on the slip accumulator to see whether the pressure has dropped. This
will ensure that the lines located after the pump are no longer under pressure, thus preventing problems from arising
during flushing.
The water for flushing the alumina pistons should be shut off after approximately ten minutes. This will ensure that any
slip residues are flushed from the washing chambers.
The same should be done with the hydraulic unit cooling water. In addition, it is good practice to flush the delivery
and intake valves of the pump. To do this, use the valves located on the inlet and outlet fittings of the machine. If good
results are not obtained, take off the protective frame and covers of the valves and wash by spraying water.

6.3

OPERATION

(references given in figure 6.3)


The gear pump (14), which is driven by the electric motor (12), provides a constant flow of oil which passes through
the hydraulic control assembly and is alternately delivered to the upper chambers of the hydraulic cylinders (22). As
a result, the cylinders move down.
One of the cylinders will move up while one of the pistons goes down, as the two lower chamber are connected to each
other.
The operating pressure is obtained by setting the control valve (10), which gives the element (9) the pressure at which
it has to drain the excess oil. A second pressure level, which is slightly higher than the first one, is obtained through
the pressure relief valve (11). The latter comes into operation if the control valve (10) fails to work.
The order of operation of the cylinders is defined by the reversing valve (6). The latter is operated by the solenoid valve
(8) which receives the pulses for reversing from sensors SQ3 and SQ4. The position of the sensors determines the
extent of the stroke.
The speed at which the spool of valve (6) reverses motion can be varied by adjusting the throttles (7). As a result, any
pressure variations created during this stage will be kept to a minimum.
The accumulator (5) can also reduce pressure peaks. The oil pressure is controlled by the pressure gauge (3), which
is turned on by opening the cock (2).
The check valve (1) is installed in the hydraulic control assembly which protects the pump (14) from abrupt changes
in pressure.
The equipment also includes a tube bundle heat exchanger (19), suction and drain filters (16 & 17) and a thermometer
with switch (21) which reads the oil temperature. When the temperature is too high the electric motor stops running.
Note that a level indicator (20) is located outside the reservoir (18).

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OPERATING INSTRUCTIONS

Figure 6.3 - OPERATION


1
2
3
5
6
7
8
9
10
11
12
13
14
15
16

Check valve
Cock and pressure gauge
Pressure gauge
Accumulator
Reversing valve
Reversing throttles
Pilot solenoid valve YV3 - YV4
Filter element
Pressure control valve
Pressure relief valve
Electric motor
Coupling
Gear pump
Check valve
Suction filter

17
18
19
20
21
22
23
24

Drain filter
Tank
Cooler
Level indicator with thermometer
Thermometer
Hydraulic cylinders
Timing solenoid valve YV1
Solenoid valve YV2, Upstroke chamber
loading
SQ Sensors
Hydraulic circuit
Pilot circuit

23
YV1
A

YV2

22

22
24

SQ1

SQ4

SQ2

SQ3

7
A

YV4 P

5
3

YV3

2
1
P
T

12

13

14

21
10

11

20
19

15
16

17

H2O

18
C0867

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6.4

Revision 00 Date 04.10.1999

OPERATING INSTRUCTIONS
TIMING

(references given in figure 6.4)


During machine operation oil leaks are present in the upper chamber of the cylinders (22) (at high pressure) which tend
to increase the volume of oil in the lower chambers (at low pressure).
These leaks would cause the machine to stop running as the left-hand cylinder (22) would reach its upper most position
before the right-hand one reaches sensor SQ3. As a result the valve (6) would not receive the pulse for reversal. To
solve this problem, the timing valve (23) is installed between the reservoir and the upstroke circuit. This valve is piloted
by sensor SQ1 which drains the oil from the lower chambers while the left-hand piston keeps SQ1 activated. During
this stage the left-hand piston stays in its upper most position while the right-hand one continues to move down until
the relative piston activates sensor SQ3 and reversal starts.
Under normal operating conditions, the right-hand piston has to reach SQ3 before the left-hand one activates SQ1 so
that the latter comes into action only if oil leaks are really present and not during each reversal.

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OPERATING INSTRUCTIONS

Figure 6.4 - TIMING


1
2
3
5
6
7
8
9
10
11
12
13
14

Check valve
Cock and pressure gauge
Pressure gauge
Accumulator
Reversing valve
Reversing throttles
Pilot solenoid valve YV3 - YV4
Filter element
Pressure control valve
Pressure relief valve
Electric motor
Coupling
Gear pump

15 Check valve
16 Suction filter
17 Drain filter
18 Reservoir
19 Cooler
20 Level indicator
21 Thermometer with switch
22 Hydraulic cylinders
23 Timing solenoid valve YV1
24 Solenoid valve YV2, Upstroke chamber loading
SQ Sensors
Hydraulic circuit
Sections of circuit under pressure
Pilot circuit

23
YV1
A

YV2

22

22
24

SQ1

SQ4

SQ2

SQ3

7
A

YV4 P

5
3

YV3

2
1
P
T

12

13

14

21
10

11

20
19

15
16

17

H2O

18
C1011

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6.5

Revision 00 Date 04.10.1999

OPERATING INSTRUCTIONS
FIRST TIME START UP

(references given in figure 6.5)


When the machine is started up for the first time, i.e. when the lower chambers of the cylinders (22) are either empty
or almost empty (see figure 6.5), a problem opposite to that described in paragraph 6.4 will arise. The left-hand piston
moves fully down before the right-hand slide reaches SQ4 and therefore the valve (6) does not reverse the flow of fluid.
The problem can be solved through the use of the charge valve (24). In fact the latter, which is piloted by sensor SQ2,
provides a link between the upper chamber of the left-hand cylinder (under pressure during this stage) and the lower
chambers. At this point, the left-hand piston remains fully down as both chambers are under pressure while the righthand one moves up until SQ4 is activated causing reverse motion.
The valve (24) must not come into action and SQ4 should be activated slightly before SQ2. In addition, keep in mind
that the delay time for timing sensors SQ1 and SQ2 in relation to the reversing sensors SQ3 and SQ4 varies depending
on the speed of the machine and on how the reversing throttles (7) are set .

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OPERATING INSTRUCTIONS

Figure 6.5 - FIRST-TIME START UP


1
2
3
5
6
7
8
9
10
11
12
13
14
15

16
17
18
19
20
21
22
23
24

Suction filter
Drain filter
Reservoir
Cooler
Level indicator
Thermometer with switch
Hydraulic cylinders
Timing valve YV1
Solenoid valve YV2, Upstroke chamber
loading
SQ Sensors

Check valve
Cock and pressure gauge
Pressure gauge
Accumulator
Reversing valve
Reversing throttles
Pilot solenoid valve YV3 - YV4
Filter element
Pressure control valve
Pressure relief valve
Electric motor
Coupling
Gear pump
Check valve

Hydraulic circuit
Sections of circuit under pressure
Pilot circuit

23
YV1
A

YV2

22

22
24

SQ1

SQ4

SQ2

SQ3

7
A

YV4 P

5
3

YV3

2
1
P
T

12

13

14

21
10

11

20
19

15
16

17

H2O

18
C1012

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OPERATING INSTRUCTIONS

Revision 00 Date 04.10.1999

138.11.A01
ADJUSTMENTS

ADJUSTMENTS

E0004P

WARNING!

The operations are to be carried out with the machine off and following all the safety precautions dealt with at the
beginning of the manual.
Always shut off the electrical power to the machine before accessing the electrical cabinet, electrical boxes and
wherever danger-of-electrocution signs are located.
The adjustments described below are to be carried out when necessary in the presence of malfunctioning or after
maintenance has been performed, parts replaced, etc.. Carefully observe all the safety precautions when carrying out
these operations.
Figure 7.1/A

7.1

MACHINE ADJUSTMENTS
DURING OPERATION

ADJUSTING THE SLIP PRESSURE (references given


in figure 7.1/A)
The slip spray nozzles are subject to wear. As a result,
the output and operating speed of the pumps which
supply a spray dryer that has run for several consecutive days may increase (even slightly). This will cause
the slip pressure to decrease; to correct , adjust the
control valve (1).

C1635

Figure 7.1/B
ADJUSTING THE SEALS (references given in figure
7.1/B)
The seals (2) may need to be adjusted during operation.
Every day, check for slip leakage and, when required,
adjust the preload device (1).

1
2

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7

7-2

ADJUSTMENTS

Revision 00 Date 04.10.1999

Revision 00 Date 04.10.1999

138.11.A01

MAINTENANCE OPERATIONS
8

MAINTENANCE OPERATIONS

GENERAL INFORMATION AND SAFETY PRECAUTIONS

E0004P

WARNING!

Only expert personnel who know how the machine and plant operate should carry out maintenance, as indicated
in chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS.
Take all the precautions required in order to prevent accidental machine start-up.
- turn the main switch on the board to OFF
- remove the safety key
- post a maintenance in progress sign on the electrical cabinet.
- press the emergency stop buttons
Always keep in mind that risks may arise and follow the safety rules given in chapter 3 - SAFETY EQUIPMENT
AND PRECAUTIONS.

Maintenance operations are divided as follows:


- routine maintenance (to be carried out by the customers maintenance staff)
- special maintenance (to be carried out either by the manufacturers or customers specially trained personnel).
Routine maintenance includes:
- mechanical jobs: lubricating and cleaning mechanical parts, replacing and tensioning the belts, replacing and
cleaning the valves, etc..
- electric jobs: replacing fuses in the electrical cabinet.
All the maintenance operations must be carried out with the machine stopped and cooled down. Maintenance
operations must be carried out at the stated intervals. The operations are divided as follows:
- SCHEDULED OPERATIONS;
- SPECIAL MAINTENANCE.

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MAINTENANCE OPERATIONS

8.1

SCHEDULED MAINTENANCE
OPERATION
OPERAZIONI

8
CONTROLLO
TENUTA SEALS
GUARNIZIONI IN GOMMA
1 -- CHECK
THE RUBBER
PULIZIATHE
POMPA
E CENTRALINA
2 -- CLEAN
PUMP
AND HYDRAULIC POWER UNIT
LAVAGGIO
E TUBAZIONI
3 -- WASH
THE VALVOLE
VALVES AND
PIPING
VERIFICA
PRESSIONE
ACCUMULATORE
4 -- CHECK
SLIP
ACCUMULATOR
PRESSUREBARBOTTINA
LUBRIFICAZIONE
COLONNE
DI GUIDA
5 -- LUBRICATE
THE GUIDE
COLUMNS
SOSTITUZIONE
FILTRO
ASPIRAZIONE
6 -- CLEAN
THE SUCTION
FILTER
PULIZIATHE
SCAMBIATORE
DI CALORE
7 -- CLEAN
HEAT EXCHANGER
VERIFICA
PRESSIONE
ACCUMULATORE
OLEODINAMICO
8 -- CHECK
THE HYDRAULIC ACCUMULATOR
PRESSURE
SOSTITUZIONE
OLIO
IMPIANTO
OLEODINAMICO
9 -- CHANGE
THE OIL
IN THE
HYDRAULIC
SYSTEM
SOSTITUZIONE
FILTRO
SCARICO
10 -- CHANGE
THE DRAIN FILTER

IN
THEREAFTER
SEGUITO
EVERY
OGNI:
(HOURS)
2500

TO BE PERFORMED
DA ESEGUIRE DOPO ORE:
HOURS

40

200

8 hours
ore
8 hours
ore
40 hours
ore
ore
40 hours
ore
200 hours
2500 hours
ore
2500
2500 hours
ore
2500
2500 hours
ore
2500
2500 hours
ore
2500
2500 hours
ore
2500

C1644

Checking the rubber seals

(references given in figures 8.1/A and 8.1/A2)


Check the water flowing out of the pump washing chambers at the start of every work shift. When under normal working
conditions a small amount of slip should come out as it acts as a natural lubricant for the seals. If the amount of slip
flowing out increases, adjust the device (1) to increase the pre-load on the seals (3). Carry this out gradually. The seals
should be tightened as little as possible. This is extremely important in order not to increase friction and energy
dissipation as well as to notably extend the service life of the seals.
Ring-nut adjustment (fig. 8.1/A1)
The adjustment is to be made gradually. Move the device (1) by half a turn and wait a few minutes to see the results
obtained.
Use the pin wrenches provided to turn the ring nut (1). Insert the wrenches through the slots in the front and rear boards.
The ring nut should be washed with a jet of water before being turned to avoid seizure due to solid particles that may
deposit between the threads. If a ring nut (1) is blocked and cannot be turned with the wrench, stop the machine, take
off the protective boards and loosen the four screws that secure the ring (2) to the pump casing. After doing this, turn
the ring nut (1) counter-clockwise until it can move freely again.
Put the parts back in place, pre-load the seals as required and then start the machine again.
Stay bolt adjustment (fig. 8.1/A2)
In this case, the seals (3) are pre-loaded by turning the nuts (9) which push the plate (1) against the seals.
It is essential to tighten the nuts to the same degree so as to pre-load the seals in a uniform manner. The service life
of the seals is strictly related to the way this operation is carried out.

E0004P

WARNING!

Only the pin wrenches provided with the machine can be put through the slots in the boards. Never put your hands
through them. This is of vital importance.

8-2

138.11.A01

Revision 00 Date 04.10.1999

MAINTENANCE OPERATIONS

1
2
1
2

4
5

C
7
A

6
7
6
Figure 8.1/A1 - INSTALLING THE SEALS AND
PUMP CASING
1
2
3
4
5
6
7
8

Ring nut
Ring
Seal pack
Piston
Pump casing
Spacer
Seal
Device for installing seals

C1013

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Revision 00 Date 04.10.1999

MAINTENANCE OPERATIONS

1
2

9
1
2
3

4
5

7
Figure 8.1/A2 - INSTALLING THE SEALS AND PUMP
CASING
1
2
3
4
5
6
7
8
9

Pressure plate
Stay bolt
Seal pack
Piston
Pump casing
Ring spacer
Seal
Device for installing seals
Nut

7
6

C1341

Cleaning the pump and hydraulic power unit

The hydraulic power unit can be cleaned by blowing compressed air and using rags. This should be done to ensure
that the electric motor cools down well and to prevent matter from building up on the cover of the unit, which if parts
are removed, may get inside the reservoir and dirty the oil. Running water can be used for the pump to remove any
dust or slip build ups that tend to block the ring nut and reduce the sensitivity of the reversal and timing sensors.

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Revision 00 Date 04.10.1999

MAINTENANCE OPERATIONS

3 Washing the valves and piping


(references given in figure 8.1/B)
This operation is normally carried out at the end of each work shift or when the material being handled is changed.
Shut the pump off from the rest of the system by using the main ball valves located before and after the machine. This
should be done after the machine has been stopped and any remaining pressure has been eliminated (check there
is no pressure by observing the relevant gauge). Once this has been done, open the ball valves on the delivery and
suction lines so that water can flow through the pump, thereby flushing the casing and the plate-type valves.
From time to time, thoroughly clean the entire system in the following way. Take off the protective frame, covers and
plates of the valves and wash the valve seats and the inside of the pump with jets of water coming from the delivery
valve. As a result, the fluid flows through the pumping chamber and out of the intake valve.
After checking the seals and seats for condition, wash the bodies of the valve, prime the pump and put everything back
in place.

Figure 8.1/B - DELIVERY AND INTAKE VALVES

1
2
3
4
5
6
7

Delivery valve
Cover
Clamp
Plate
Intake valve
Disk
Pin bush

8 Valve seat
9 Guide pin
10 Spring
11 Protective frames
12 Valve on suction line
13 Valve on delivery line
14 Ball valve on suction line
15 Ball valve on delivery line

2
11

10
4
7

14

13

12
1

15

C1642

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8
4

Revision 00 Date 04.10.1999

MAINTENANCE OPERATIONS
Checking the slip accumulator pressure (OPT)

At the end of each work shift, make sure the pre-charge pressure has not decreased (the value is indicated in paragraph
2.3.1 - SPECIFICATIONS). If the pressure has dropped, find out what is causing the nitrogen to leak.
5

Lubricating the guide columns

A certain amount of fresh grease (see paragraph 2.3.3, LUBRICANT SPECIFICATIONS) should be injected through
the fittings on the guide columns to remove the fine abrasive powders captured by the grease during operation. Take
off the front protective board to carry out this operation.
6

Cleaning the suction filter

(references given in figure 8.1/C)


The filter in question is installed on the hydraulic pumps intake line inside the reservoir.

Figure 8.1/C - HYDRAULIC POWER UNIT


1
2
3
4
5
6
7
8

Reservoir
Heat exchanger
Motor-pump unit
Oil thermostat
Reservoir filler
Suction filter
Hydraulic control assembly
Drain filter

C1637

2
8-6

Revision 00 Date 04.10.1999

138.11.A01

MAINTENANCE OPERATIONS
7

Cleaning the heat exchanger

Clean the heat exchanger inside using de-scaling products.


8

Checking the hydraulic accumulator pressure

Install the inflator- tester to check the nitrogen pressure. It should be about 60-70% of the flow pressure. If the value
read is lower, inflate the bag with a full nitrogen cylinder.
9

Changing the oil in the hydraulic system

(references given in figure 8.1/C)


This operation is extremely delicate as, if it is not correctly carried out, the oil will be highly contaminated shortening
the service life of all the hydraulic components, above all the filters and solenoid valves. Thoroughly clean the hydraulic
power unit, completely empty the reservoir by using the drain plug located on the bottom, wash the reservoir inside
with oil and then fill it up. Use hydraulic oil that meets the specifications indicated in paragraph 2.3.3, Lubricants. Add
oil through the filler (5), if required.
10 Changing the drain filter
(references given in figure 8.1/C)
The filter (8) in question is located outside the reservoir of hydraulic power unit. When the indicator located on the filter
constantly reads 2 bar, replace the filter cartridge even if the time interval indicated in the scheduled maintenance chart
has not elapsed.

8-7

138.11.A01
8
8.2

Revision 00 Date 04.10.1999

MAINTENANCE OPERATIONS
SPECIAL MAINTENANCE

The special maintenance operations that usually regard only the machine in question are described below.
8.2.1
REPLACING THE RUBBER SEALS
(references given in figure 8.1/A)
IMPORTANT!
When the ring nut or plate (1) is almost all the way down the whole seal pack (3) has to be replaced. The alumina
piston will wear down much more quickly if overworn seals are used. For this reason, the ring nut should be replaced
when the piston only completes 2/3 of its total stroke.
-

Move the piston (4) fully up


Completely loosen the pressing system
Raise the ring nut or plate as far up as possible
Remove the seal pack (3) (seals 7 and spacers 6)
Thoroughly clean the chamber
Install the new seal pack moistening it with a silicone based lubricant which eases the operation and decreases
friction between the seals and the mechanical parts (piston and cylinder).

IMPORTANT!
The seals (7), when supplied, have the correct length and adequate contact surfaces.
The spacers (6) have to be cut in slices. Insertion is made easier if the clamp (8) provided with the machine is used.
Do not overlap points (A) of the seals over those of the clamp (B) to avoid oil leaks.
- Put a spacer (6) (cut so that it fits around the piston 4) in the seat of the cylinder (5). Push it all the way down.
- Put a seal (7) around the piston (4), being very careful to accurately join the ends together and fit it into the seat of
the cylinder (5).
- Fit the clamp (8) over the piston (4) and push it downwards to lower the seal. Make sure that the seal is in place
before pushing the clamp down. Also ensure the joints of the clamp do not match those of the seals.
- Remove the clamp (8) and take it apart.
- Put on another cut ring spacer (6).
- Install another seal (7) by performing the procedure described above and continue until the entire pack (3) has been
installed.
RING-NUT ADJUSTMENT
- Hold the ring (2) in place by slightly tightening the respective screws.
- Tighten the ring nut (1) until it rests on the seal pack
- Secure the ring (2).
STAY-BOLT ADJUSTMENT
- Turn the nuts (9) of the stay bolts (2) to bring the plate (1) into contact with the seal pack.
- Slightly pre-load with the nuts (approx. half a turn).
WARNING!
To further preload the seal pack (3), turn the ring nut (1, figure 8.1/A1) or the stay bolts of the plate (1, figure 8.1/A2).
This operation is to be performed with the pump running only if required.

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MAINTENANCE OPERATIONS

8.2.2
OVERHAULING THE DELIVERY AND INTAKE VALVES
(references given in figure 8.1/B)
The disk (6) and valve seat (8) get worn when slip under pressure flows in the intake valves. These parts therefore
need to be replaced.
- Take off the protective frames (11)
- Replace the parts (6 and 8)
- Put the parts back in their correct position and tighten the clamp (3)
- Put the protective frames (11) back on.

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Revision 00 Date 04.10.1999

MAINTENANCE OPERATIONS

8.3

CHECKING THE NUTS AND BOLTS FOR TIGHTNESS

Sr = Resisting section (mm2)


M = Tightening torque (N.m)
P = Pre-load (corresponding to the tightening torque) (N).

NOTE: Class 12.9 screws must be tightened with a torque wrench as if they were class 10.9.

Example: a 12 mm diameter screw, 1.75 thread, 12.9 must be tightened to 12.28 Kg instead of 14.74 Kg.

COARSE THREAD SCREWS

DIAMETER

mm.

10

12

14

16

18

20

22

24

27

30

36

PITCH

mm

0.70

0.80

1.00

1.25

1.50

1.75

2.00

2.00

2.50

2.50

2.50

3,5

Sr

mm2

8.78

14,2

20,1

36,6

58

84,3

115

157

192

245

303

353

459

561

817

M (Nm)

1,9

3,8

6,5

15,4

31,3

53

84,3

128

177

250

332

432

631

857

1500

2500

4000

5600

10250

16200

23600

32200

68600

84800

98800

3,1

10,4

24,6

50,1

84,8

135

400

532

691

3930

6360

9000

16400

26000

37800

51500

4,3

8,5

14,6

34,7

70,5

119

190

5530

8950

12700

23100

36500

53000

72500

5,2

10,1

17,5

41,6

84,6

143

228

6640

10700

15200

27740

43900

63700

86900

5.8

P (N)

CLASS

8.8

M (Nm)
P (N)

10.9

M (Nm)
P (N)

12.9

M (Nm)
P (N)

44000 53800
205

283

70300 86000
288

1010

110000 136000 158000

398

562

98900 121000
346

129000 157000 228800

748

971

20600
1420

1370

251000 366000
1930

478

674

119000 145000

897

1170

1700

2310

mm

10

12

14

16

18

20

22

24

27

30

36

PITCH

mm

1,00

1,25

1,25

1,50

1,50

1,50

1,50

1,50

S.R.

mm2

39,2

61,2

92,1

125

167

216

272

333

384

496

621

865

M (Nm)

16,3

32,7

56,6

89,6

134

193

270

357

457

667

923

1587

11000

17100

25800

35000

46800

60500

76200

93200

108000

139000

174000

242200

26

52,4

90,6

143

214

308

431

571

731

1070

1480

2539

17600

27400

41300

56000

74800

96800

122000

149000

172000

222000

278000

387500

36,6

73,6

127

202

302

434

607

803

1030

1500

2028

3570

24700

38500

58000

78800

105000

136000

171000

210000

242000

312000

391000

544900

43,9

88,4

153

242

362

520

728

964

1230

1800

2490

4284

29600

46300

69600

94500

126000

163000

206000

252000

290000

375000

469000

653900

CLASS

8.8

M (Nm)
P (N)

10.9

M (Nm)
P (N)

12.9

M (Nm)
P (N)

8 - 10

4046

185000 229000 267000 347000 424000 617600

DIAMETER

P (N)

3372

154000 191000 222000 289000 353000 514700

FINE THREAD SCREWS

5.8

2398

Revision 00 Date 04.10.1999

138.11.A01
DECOMMISSIONING

DECOMMISSIONING

Proceed as follows to dismantle the machine:


- disconnect the machine from the electricity supply.
- disassemble the various parts observing all safety precautions and following the instructions given in chapter 4 INSTALLATION.

9-1

138.11.A01
9

9-2

DECOMMISSIONING

Revision 00 Date 04.10.1999