Y. Evaporator TC 15000 PDF

TC 15000
USE AND MAINTENANCE

MANUAL
Written by Elena Mussio (VWS Italia)

Approved by Giuseppe Girolami (VVWS Italia)
Code number TC 15000 MAN GB 05_R
Release 24/03/2010
Translation from original instruction done by VWS Italia
2 TC 15000
Index
Index
1 General information _______________________________________ 9
1.1 Identification of the machine _________________________________________________________ 9
1.2 Graphic symbols used _____________________________________________________________ 10
1.2.1 General symbols __________________________________________________________________ 10
1.2.2 Danger signals ___________________________________________________________________ 11
1.2.3 Prohibition signs __________________________________________________________________ 11
1.2.4 Obligation state __________________________________________________________________ 11
1.3 Generality about the manual ________________________________________________________ 11
1.3.1 Terminology and definitions_________________________________________________________ 11
1.3.2 Instructions on using the manual ____________________________________________________ 12
1.4 Measure units ____________________________________________________________________ 13
1.4.1 International System base units _____________________________________________________ 13
1.4.2 International System derived units ___________________________________________________ 13
1.4.3 Conversion factors from units not of the international system ______________________________ 14
1.5 Personal protection devices _________________________________________________________ 14
1.6 Qualification of operators___________________________________________________________ 15
1.6.1 Suitable operators for running the machine ____________________________________________ 15
1.6.2 Operators types __________________________________________________________________ 15
1.6.3 Handling personnel _______________________________________________________________ 16
1.6.4 Mechanical assembler _____________________________________________________________ 16
1.6.5 Electrician _______________________________________________________________________ 16
1.6.6 Plumber ________________________________________________________________________ 16
1.6.7 Installation technician _____________________________________________________________ 17
1.6.8 Machine operator _________________________________________________________________ 17
1.6.9 Maintenance technician ____________________________________________________________ 17
1.6.10 Electrical maintenance personnel __________________________________________________ 18
1.6.11 Devices and solutions for the operators protection ____________________________________ 18
1.6.12 Signals related to residual risks and their location _____________________________________ 19
1.6.13 Other signals __________________________________________________________________ 20
1.6.14 Expendable chemical products ____________________________________________________ 20
1.6.15 Warning on residual risks and signals_______________________________________________ 21
1.6.16 Warnings and rules on behaviour __________________________________________________ 21
2 Functional description _____________________________________ 23

2.1 Process diagram __________________________________________________________________ 23
2.2 Description of units and functional descriptions _________________________________________ 27
2.2.1 Unit identification _________________________________________________________________ 27
2.2.2 Feed and washing unit _____________________________________________________________ 27
2.2.3 Boiling chamber unit ______________________________________________________________ 27
2.2.4 Antifoam metering unit ____________________________________________________________ 28
2.2.5 Concentrate circulation unit _________________________________________________________ 28
2.2.6 Concentrate unit discharge _________________________________________________________ 28
2.2.7 Circulation pump flushing unit _______________________________________________________ 29
2.2.8 Vapour line unit __________________________________________________________________ 29
2.2.9 Distillate accumulation, transfer and discharge unit ______________________________________ 29
2.2.10 Air compressed unit_____________________________________________________________ 30
2.3 Predispositions and optional accessories _______________________________________________ 30
2.3.1 Concentrate density measurement system (I) __________________________________________ 30
2.3.2 Additive metering system (II) _______________________________________________________ 30
2.3.3 Automatic system to check for foaming in boiler (III) ____________________________________ 31
2.3.4 Set up for levels control system in the process liquids storage tanks (V)______________________ 31
2.3.5 System for measurement of the amount of distilled product (IX) ___________________________ 31
2.3.6 Thermal recovery system of concentrate (X) ___________________________________________ 32
2.3.7 Remote control system ____________________________________________________________ 32
2.3.8 Setup for remote control via GSM modem on PLC _______________________________________ 32
TC 15000 3
Index
3 Technical characteristics and data____________________________ 33
3.1 Applicable fields __________________________________________________________________ 33
3.1.1 Correct and incorrect use __________________________________________________________ 33
3.1.2 Notes on the correct use of the evaporator ____________________________________________ 34
3.2 Description of the machine _________________________________________________________ 36
3.2.1 Available models _________________________________________________________________ 36
3.2.2 Technical characteristics and nominal performance ______________________________________ 36
3.2.3 Materials _______________________________________________________________________ 36
3.2.4 Noise emission ___________________________________________________________________ 37
4 Pre-installation requirements _______________________________ 39

4.1 Requirements in the site of installation________________________________________________ 39
4.1.1 Dimensions and clear spaces _______________________________________________________ 39
4.1.2 Masses, supports and foundations ___________________________________________________ 41
4.1.3 Ventilation of room and vents _______________________________________________________ 41
4.1.4 Catching spills ___________________________________________________________________ 42
4.1.5 Operating pressure and temperatures ________________________________________________ 42
5 Packing, handling and storage ______________________________ 43

5.1 Packaging and transport modules ____________________________________________________ 43
5.1.1 Transport and movement __________________________________________________________ 44
5.1.2 Storage and conservation __________________________________________________________ 46
6 Assembly and positioning of the machine ______________________ 49

6.1 Positioning of modules ____________________________________________________________ 50
6.1.1 Positioning of condenser module ____________________________________________________ 50
6.2 Connections to the plumbing, electrical and pneumatic lines inside the module________________ 51
6.2.1 Plumbing connections _____________________________________________________________ 51
7 Connection to external and service networks ___________________ 53

7.1 Connection of electrical power ______________________________________________________ 53
7.2 Connection to the electrical signals for management of automation _________________________ 54
7.3 Connection to the pneumatic network ________________________________________________ 55
7.4 Plumbing connections _____________________________________________________________ 56
7.5 Arrangement of ventilation and vents_________________________________________________ 58
7.6 Connection of optional devices ______________________________________________________ 58
8 Start-up and commissioning ________________________________ 59

8.1 References to the machine _________________________________________________________ 59
8.1.1 External cleaning _________________________________________________________________ 59
8.1.2 Preliminary checks ________________________________________________________________ 60
8.1.3 Start-up in stand by mode__________________________________________________________ 61
8.1.4 Pre-start checks __________________________________________________________________ 62
8.1.5 Test with tap water _______________________________________________________________ 62
8.1.6 Stopping procedure in stand-by mode ________________________________________________ 63
8.1.7 Shutdown procedure ______________________________________________________________ 63
8.1.8 Start up with the processed liquid____________________________________________________ 64
9 Control and signal devices __________________________________ 65

9.1 Main electrical panel cabinet ________________________________________________________ 66
9.2 Control terminal __________________________________________________________________ 67
9.3 Using the control terminal __________________________________________________________ 67
9.3.1 Modifying numeric or alphanumeric data ______________________________________________ 67
9.3.2 Modifying a selection field __________________________________________________________ 67
9.4 Video pages _____________________________________________________________________ 67
9.5 Opening video page_______________________________________________________________ 68
9.6 Video pages of the main menu ______________________________________________________ 69
9.6.1 Display pages tree ________________________________________________________________ 69
9.7 Main menu ______________________________________________________________________ 70
4 TC 15000
Index
9.7.1 Events__________________________________________________________________________ 72
9.7.2 Machine info _____________________________________________________________________ 73
9.7.3 Recipes _________________________________________________________________________ 74
9.7.4 Maintenances ____________________________________________________________________ 75
9.7.5 Tele-maintenance_________________________________________________________________ 79
9.7.6 Password _______________________________________________________________________ 80
9.7.7 ADV settings _____________________________________________________________________ 81
9.7.8 Alarms__________________________________________________________________________ 83
9.8 Cycle control_____________________________________________________________________ 84
9.9 Machine synoptic _________________________________________________________________ 88
9.9.1 Boiler D01 _______________________________________________________________________ 89
9.9.2 Blower K01 ______________________________________________________________________ 94
9.9.3 Circulation G01 __________________________________________________________________ 101
9.9.4 Feed G02 ______________________________________________________________________ 103
9.9.5 Distillate D02 ___________________________________________________________________ 107
9.9.6 Exchanger E02 __________________________________________________________________ 113
9.9.7 Concentrate discharge ____________________________________________________________ 114
9.9.8 Antifoam _______________________________________________________________________ 115
Here it’s possible to insert the following data: _________________________________________________ 116
9.9.9 Washing _______________________________________________________________________ 117
9.9.10 Conductivity meter ____________________________________________________________ 118
9.9.11 Additive _____________________________________________________________________ 121
9.9.12 Densimeter __________________________________________________________________ 122
9.10 Operating data __________________________________________________________________ 124
9.11 User setup _____________________________________________________________________ 126
9.11.1 Utility _______________________________________________________________________ 126
9.11.2 Setup HMI ___________________________________________________________________ 127
9.12 Alarm and information pages_______________________________________________________ 127
9.12.1 Alarm pages and information messages ____________________________________________ 127
9.12.2 Alarm log pages_______________________________________________________________ 128
10 Diagnostics ____________________________________________ 131

10.1 Alarm signals and information ______________________________________________________ 131
10.1.1 Alarm signals _________________________________________________________________ 131
10.1.2 Information message signals ____________________________________________________ 131
10.2 Alarm situations: troubleshooting ___________________________________________________ 131
10.2.1 Alarm code 00 ________________________________________________________________ 132
10.2.2 Alarm code 01 ________________________________________________________________ 132
10.2.3 Alarm code 02 ________________________________________________________________ 133
10.2.4 Alarm code 03 ________________________________________________________________ 134
10.2.5 Alarm code 04 ________________________________________________________________ 134
10.2.6 Alarm code 05 ________________________________________________________________ 135
10.2.7 Alarm code 06 ________________________________________________________________ 135
10.2.8 Alarm code 07 ________________________________________________________________ 135
10.2.9 Alarm code 08 ________________________________________________________________ 135
10.2.10 Alarm code 09 ________________________________________________________________ 136
10.2.11 Alarm code 10 ________________________________________________________________ 136
10.2.12 Alarm code 11 ________________________________________________________________ 137
10.2.13 Alarm code 12 ________________________________________________________________ 137
10.2.14 Alarm code 13 ________________________________________________________________ 137
10.2.15 Alarm code 14 ________________________________________________________________ 138
10.2.16 Alarm code 15 ________________________________________________________________ 138
10.2.17 Alarm code 16 ________________________________________________________________ 139
10.2.18 Alarm code 17 ________________________________________________________________ 139
10.2.19 Alarm code 18 ________________________________________________________________ 140
10.2.20 Alarm code 19 ________________________________________________________________ 140
10.2.21 Alarm code 20 ________________________________________________________________ 140
Index
10.2.22 Alarm code 21________________________________________________________________ 141
10.2.23 Alarm code 22________________________________________________________________ 141
10.2.24 Alarm code 23________________________________________________________________ 142
10.2.25 Alarm code 24________________________________________________________________ 142
10.2.26 Alarm code 25________________________________________________________________ 142
10.2.27 Alarm code 26________________________________________________________________ 143
10.2.28 Alarm code 27________________________________________________________________ 143
10.2.29 Alarm code 28________________________________________________________________ 144
10.2.30 Alarm code 29________________________________________________________________ 144
10.2.31 Alarm code 30________________________________________________________________ 144
10.2.32 Alarm code 31________________________________________________________________ 145
10.2.33 Alarm code 32________________________________________________________________ 145
10.2.34 Alarm code 33________________________________________________________________ 146
10.2.35 Alarm code 34________________________________________________________________ 146
10.2.36 Alarm code 35________________________________________________________________ 147
10.2.37 Alarm code 36________________________________________________________________ 147
10.2.38 Alarm code 37________________________________________________________________ 147
10.2.39 Alarm code 38________________________________________________________________ 148
10.2.40 Alarm code 39________________________________________________________________ 149
10.2.41 Alarm code 40________________________________________________________________ 149
10.2.42 Alarm code 41________________________________________________________________ 149
10.2.43 Alarm code 42________________________________________________________________ 150
10.2.44 Alarm code 43________________________________________________________________ 150
10.2.45 Alarm code 44________________________________________________________________ 151
10.3 Information messages ____________________________________________________________ 151
10.3.1 Message code 64 _____________________________________________________________ 151
10.3.2 Message code 65 _____________________________________________________________ 151
10.3.3 Message code 66 _____________________________________________________________ 152
10.3.4 Message code 67 _____________________________________________________________ 152
10.3.5 Message code 68 _____________________________________________________________ 152
10.3.6 Message code 70 _____________________________________________________________ 153
11 Control, adjustment, maintenance __________________________ 155

11.1 Generality and safety_____________________________________________________________ 155
11.2 Daily maintenance _______________________________________________________________ 156
11.2.1 Monitoring of data ____________________________________________________________ 156
11.2.2 Adjustments of the treatment process _____________________________________________ 157
11.2.3 Checking for formation of foam in the evaporator____________________________________ 158
11.2.4 Anti-foam level check __________________________________________________________ 158
11.2.5 Anti-foam level check __________________________________________________________ 158
11.3 Monthly maintenance ____________________________________________________________ 158
11.3.1 Measurement of the flow rate of the produced distillate _______________________________ 158
11.3.2 Concentrate discharged volume measurement ______________________________________ 159
11.3.3 Control of the density of discharged concentrate ____________________________________ 160
11.3.4 Cleaning of the separator filters of the condensation of the compressed air _______________ 161
11.3.5 Check of anti-foam metering units ________________________________________________ 161
11.3.6 Check and cleaning of the conductivity measurement probes (CE01) ____________________ 161
11.3.7 Cleaning of the filter in water spray line in blower delivery (F01)________________________ 162
11.3.8 Changing the oil of blower K01 __________________________________________________ 162
11.4 Semi-annual maintenance _________________________________________________________ 162
11.4.1 Electrical terminals check _______________________________________________________ 162
11.4.2 Cleaning of electric board ventilators ______________________________________________ 163
11.4.3 Cleaning of the liquid to be treated storage tank ____________________________________ 163
11.5 Yearly maintenance ______________________________________________________________ 163
11.5.1 Check of hydraulic interconnection parts (and check of the vacuum)_____________________ 163
11.6 Special maintenance _____________________________________________________________ 164
11.6.1 Measurement of non-standard data _______________________________________________ 164
6 TC 15000
Index
11.6.2 Inspection and cleaning of tube side of heat exchanger E01 ___________________________ 165
11.6.3 Inspection and cleaning of heat exchanger E02 _____________________________________ 166
11.6.4 Inspection and cleaning of the thermal recovery exchanger (E03) (if optional X is present) ___ 167
11.6.5 Inspection and cleaning of the distillate tank (D02)___________________________________ 168
11.6.6 Cleaning of the pumps for circulation (G01) and feed (G02) ____________________________ 169
11.6.7 Cleaning the blower (K01) ______________________________________________________ 170
11.6.8 Cleaning of the condensate flow sensors (FT01) (if optional IX is present) ________________ 171
11.6.9 Replacement of the mechanical seal of the pumps for circulation, discharge or feeding ______ 171
11.6.10 Maintenance of the distillate discharge pump G03, liquid injection pump G05 and fluxing pump
G04 171
11.6.11 Cleaning the boiler and replacing the filling bodies ___________________________________ 172
11.6.12 Maintenance of level sensor LT04 of the distillate tank ________________________________ 173
11.6.13 Cleaning of concentrate and distillate discharge tubes ________________________________ 174
11.6.14 Maintenance of metering pumps G06 and G07 ______________________________________ 174
11.6.15 Cleaning and maintenance of diaphragm valves with pneumatic actuator _________________ 175
11.6.16 Cleaning and maintenance of butterfly valves with pneumatic actuator ___________________ 176
11.6.17 Check of the solenoid valves of the pneumatic circuit _________________________________ 176
11.6.18 Manual concentrate discharge procedure ___________________________________________ 177
11.6.19 Inspection and cleaning of shell of heat exchanger E01 _______________________________ 177
11.6.20 Check of hot air extraction fan and electrical panel filter_______________________________ 178
11.6.21 Calibration of electrical conductivity transducer (CT01) ________________________________ 178
11.6.22 Check of fuses ________________________________________________________________ 178
11.6.23 Resetting the motor protections __________________________________________________ 178
11.6.24 Procedure for drainage of liquids in the machine _____________________________________ 179
11.6.25 Prolonged machine shutdown ____________________________________________________ 180
12 Disassembly and demolition _______________________________ 185

12.1 Disassembly ____________________________________________________________________ 185
12.2 Demolition _____________________________________________________________________ 185
13 Attachments ___________________________________________ 187

Index
8 TC 15000
1 General information
CHAPTER 1
This chapter gives generic indications about:
• the machine itself and its components,
• the manual itself and the whole documentation attached to the machine,
• the operators qualification,
• safety and residual risks.
The manual contains continual references to the concepts expressed in this

chapter. Therefore, the user should read it very carefully.
1.1 Identification of the machine

TC 15000 mechanical recompression evaporator
Constructor: Veolia Water Solutions & Technologies Italia (VWS) S.r.l.
Unipersonale
Via Pra’ di Risi, 3
33080 Zoppola (PN) Italia
tel. (int. ++39) 0434 - 5163.11
telefax (int. ++39) 0434 – 5163.10
internet: www.veoliawaterst.it
e-mail address: solutions@veoliawaterst.it
VAT no. 01983841204
A copy of the plates identifying the machine and being related to CE mark and to electrical
specifications is shown in the following figure.
Figure 1.1-1 - Identification plates and CE mark
TC 15000 9
General information 1
The identification plates are located on the left side of the main switchboard (see the following
figure).
Figure 1.1-2 – Position of the identification labels on the electrical panel
If the user makes modifications without asking the manufacturer for assistance,
the certifications of the machine referred to by the aforementioned tags will no
longer be valid. The manufacturer shall not be held liable for the machine in
any way if the aforementioned identification tag is missing.
1.2 Graphic symbols used

To make the manual reading clearer, appropriate symbols to underline the meaning or the
importance of information given have been used.
There are four types of symbols, as it is described in the next section.
1.2.1 General symbols

The general symbols used in this manual are:
It points out warnings, notes, suggestions and important operating methods to

which the attention of the reader has to be drawn to avoid any damage.
It indicates manual paragraphs which are related to other sections of the

document.
It indicates manual paragraphs which advise the reader to carry out visual
checks.
The different operator icons point out the types of operator which have to
follow the instruction included in highlighted sections.
10 TC 15000
1.2.2 Danger signals

Danger signals have a triangular shape and they emphasize the paragraphs referred to possible
dangerous conditions. For instance:
General danger warning:

Indications of this paragraph alert the operator of dangerous situations which it
is possible to come into during the maintenance procedure. They may also be
used to communicate that dangerous conditions could happen if the indications
are not properly followed.
1.2.3 Prohibition signs

These signals have a circular shape and they are characterized by a typical diagonal bar. The
internal area may include particular symbols related to the different type of warning. They
emphasize the paragraphs referred to forbidden actions or to actions which it is possible to avoid.
For instance:
General forbidden state warning:

This sign points out an action or a behaviour to absolutely avoid.
Do not stand in the manoeuvre and lifting areas
Do not climb on the system structures
1.2.4 Obligation state

These signals have a circular shape and they are characterized by a filled circle. The inner area
includes particular symbols related to the type of message. They emphasize the paragraphs
referred to fundamental prescriptions which have to be followed. For instance:
General obligation signal:

The knowledge and the respect of these signals are fundamental for operators.
1.3 Generality about the manual

1.3.1 Terminology and definitions
Term Description
Machine In this manual the word is referred to “TC 15000 mechanical vapour
recompression”.
Operator It generically defines the person who interacts with the machine to do
control operations, handling and maintenance.
Constructor It is the juridical person which has built the machine and who is indicated
in par. 1.1.
Vendor It is the third person who buys the machine from the constructor to sell it
to the user.
TC 15000 11
User It is the juridical person who buys the machine to use it in its own
activity.
Peripheral assistance It is the unit which is better located on the territory; it enters into a
centre contract with the constructor or the vender to carry out maintenance
operations.
Clearance zone It is an area which has to be kept clean to allow the machine to run and
to carry out maintenance operations.
PLC Programmable Logic Controller, which supervises the machine running.
Main switchboard It is the electrical box which includes the PLC and on which the command
terminal is installed.
Command terminal It is the command panel board of the machine; it interacts with the PLC
and it is located on the main switchboard.
The initials used in this manual to identify the machine components are defined
in the process diagrams and in the units description referred in chap. 2.
1.3.2 Instructions on using the manual

This manual is intended for operators and technicians in charge of use and maintenance of the
machine. It has been prepared with the aim of providing the above mentioned personnel with all
the information and instructions necessary for safe operations.
This documentation presumes that the place in which the machine is installed is in compliance with
current local laws and regulations concerning work safety and health. Furthermore, operating or
maintenance personnel should have a level of education that allows them to correctly understand
the information provided in it.
This manual MUST be used to train the staff which is going to work on the
machine in order to maintain it well operating.
The knowledge of the directions of this manual does not free the operators
from the comprehension and the knowledge of the whole documentation
attached to the machine.
Any unauthorized copying, total or partial, of this manual is strictly

FORBIDDEN.
If there is a real need, further copies or editing of this manual may be

requested from the constructor or the vendor of this machine.
If operations which lead to significant modifications are carried out, the user
may ask the constructor or the vender for an updated copy of the present
manual.
The user MUST take care of this instruction manual in a known, easily
accessible place to allow the operators a quick and easy consultation of the
manual itself.
The constructor has no responsibility and can not be liable for incorrect work
carried out after possible non-compliance with the instructions given in the
manual.
Drawings, plans and technical data of this document are updated and they are exclusively referred
to the machine described in this manual.
The manual and the whole enclosed documentation have been checked before issuing the
material. If eventual errors come out, the user is asked to inform the constructor or the vender.
12 TC 15000
1.4 Measure units

The measure units used in this manual are related to the International System following the norm
ISO 1000 (see following tables).
1.4.1 International System base units

Quantity Symbol Unit Notes
Length M meter When it is convenient, its submultiples are used
(centimetres [cm] and millimetres [mm]).
Time s second When it is convenient, its multiples are used (minutes
[min] and hours [h]).
Mass kg kilogram When it is convenient, its sub multiples is used [g].
Electric current A ampere When it is convenient, its sub multiple is used [mA].
Electromotive V volt Vac: alternate current; Vdc: direct current.
force
Thermodynamic °K kelvin The temperature unit used in this manual is generally
temperature the Celsius degree [°C].
Plane angle rad radian In this manual the angles are expressed as sexagesimal
degrees, based on the relation: 360°=2 π[rad]
Table 1.4.1 – Base units
1.4.2 International System derived units

Relation with
Quantity Symbol Unit
other SI units
Frequency Hz hertz s-1
Velocity m/s meter per second
2
Acceleration m/s meter per second squared
3
Density kg/dm kilogram per cubic meter kg/(m3*10-3)
Conductance S Siemens A/V
Conductivity μS/cm micro Siemens per centimetre (S*106)/(m*10-2)
Force N Newton kg*m/s2
Pressure Pa Pascal N/m2
Viscosity Pa*s Pascal per second Pa*s
Work, energy, quantity of heat J joule N*m
Work, energy, quantity of heat erg erg J*10-7
Power W watt J/s
Capacity l/h litre per hour (m3*103)/(s * 3600)
Mass flow (air) m3/h cubic meter per hour m3/(s * 3600)
Mass flow (normalized air) Nm3/h normal cubic meter per hour m3/(s * 3600) (a)
decibel with A type weighting

Acoustic pressure level dB(A)
filter
Liquid head mcw meters column water M
Spinning velocity rpm revolutions per minute 2π * rad/(s * 60)
(a): mass flow measured in normal conditions of pressure and temperature (1 atm and 0°C).
Table 1.4.2 – Derived units
TC 15000 13
1.4.3 Conversion factors from units not of the
international system
Conversion
Quantity Symbol Unit
factor
ft foot 0.3048 m
Length
in inch 0.0254 m
Mass lb pound 0.453 kg
°C Celsius degree °K – 273.15
Temperature 1.8*(°K-
°F Fahrenheit degree
273.15)+32
Work, energy, quantity of kWh kilowatt 3.6*106 J
heat kcal kilocalories 4186.8 J
bar bar 100 kPa
Pressure atm atmosphere 101325 Pa
psi pound per squared inch 6894.8 Pa
Power kcal/h kilocalories per hour 1.163 W
Viscosity cP centipoise Pa*s*10-3
Table 1.4.3 – Conversion factors
1.5 Personal protection devices

The user has to provide the operators of individual protection devices, in order to avoid risks which
may be caused by the machine itself or by the working area where the machine is installed.
The symbols which specify the use of different types of protection device are:
It is compulsory to wear suitable clothing, avoiding loose clothing parts which

may get caught in the various system components; furthermore, it is
compulsory to wear clothing which protect the skin, when chemical substances
or process liquids are handled.
It is compulsory to use acoustic protection devices (headset) when working

conditions require them.
It is compulsory to use of protection devices (mask) to protect the respiratory

system when there is any presence of steam or noxious substances.
It is obligatory to use gloves to protect against contact with metallic parts, with
chemical substances, or from electrocution.
It is obligatory to use type S1 safety shoes
It is compulsory to use head protection devices (helmet) when it is necessary to

carry out maintenance operations inside the machine perimeter.
It is compulsory to use protection devices (slinging) to safeguard the personnel

by accidental falls during the setting up, the installation and the maintenance
phases.
14 TC 15000
It is compulsory to use protection devices (goggles) to protect the eyes when
there is any chance to be in touch with chemical substances or process liquids
splashes.
1.6 Qualification of operators

1.6.1 Suitable operators for running the machine
The machine use is allowed to trained (theoretically and practically) personnel only.
The use of the machine is strictly FORBIDDEN to operators which take

substances that bring down their attention and reaction times.
The operators can NOT “train themselves” on the base of similar working
experience.
Access to the machine is absolutely PROHIBITED to persons who are not

authorized by the manufacturer and/or by the user of the machine
The knowledge of the information included in this manual is COMPULSORY,

but it does not replace the maturated specific experience required to the
operator.
Use of the machine is reserved to professional operators, trained on current
legislation in the country where the machine is used. In particular, all operators
are required to be familiar with current standards concerning labour health and
safety, as well as the state of the art in the operational sector
The user, who has bought the machine, should ask the constructor or the
vender for an adequate training of his own personnel.
1.6.2 Operators types

There are two main operators categories which may interact with the machine:
• unskilled operators;
• skilled operators.
Inside these two categories it is possible to have different professional figures, named below:
PERSONNEL REQUIRED DURING MOVEMENT/INSTALLATION/DISASSEMBLY OF THE

MACHINE
• handling personnel (skilled);
• mechanical installer (qualified)
• electrician (qualified)
• plumber (qualified)
PERSONNEL REQUIRED DURING START-UP/OPERATION OF THE MACHINE
• installation technician (qualified)
• machine operator (unskilled)
• mechanical maintenance personnel (skilled);
• electrical maintenance personnel (skilled);
The machine, during its whole working life, needs qualified and/or trained personnel.
Operation made by untrained personnel may lead to dangerous situations.
TC 15000 15
Qualified operators can NOT ask other operators with different skills for help,
because the latter inadequate experience may lead to unsafe situations.
Operators with specific qualifications have NOT to carry out procedures beyond
their competence.
Qualified operators HAVE to have an overall knowledge of required safety

prescriptions, considering the particular conditions in which the machine may be
when some kind of maintenance is required.
Operators assigned to the machine maintenance and/or control HAVE to have a
technical knowledge that allows them to adequately interact with the machine
itself and to interpret both the instructions and the diagrams included in this
manual.
1.6.3 Handling personnel

QUALIFIED operator able to load, unload and handle the machine and its
components when the operation requires the use of lifting devices.
Persons assigned to handling must have all qualifications or certifications

required by legal standards for the use of handling equipment such as cranes,
forklifts, baskets, etc.
The handling personnel HAVE not to interact with other unknown operations.
1.6.4 Mechanical assembler

Highly qualified personnel capable of mechanically assembling the machine
(screws, bolts, etc.) and the parts adjacent to it (gangways and so forth).
The electrician must perform assembly work on the machine (fastening of foundations, assembly
of stairs and gangways, etc.) in strict compliance with the provisions of this manual, in accordance
with good construction practice and according to current laws in the country where the work is
carried out.
1.6.5 Electrician
Highly qualified personnel capable of electrically connecting the modules that
make up the machine and inside of them. He must also connect the electrical
power supply to the main panel of the machine
The electrician must electrically connect the modules of the machine, and the power supply of its
main panel, in strict compliance with the provisions of this manual, in accordance with good
construction practice and according to current laws in the country where the work is carried out.
1.6.6 Plumber
Highly qualified personnel capable of hydraulically connecting the modules that
make up the machine and inside of them.
The plumber must hydraulically connect the modules of the machine in strict compliance with the
provisions of this manual, in accordance with good construction practice and according to current
laws in the country where the work is carried out. He must also make the hydraulic connections
between the lines that are the responsibility of the user/retailer and those of the machine (supply,
distillate discharge, concentrate discharge, and so on). The plumber is also responsible for making
the pneumatic connections of the machine.
16 TC 15000
1.6.7 Installation technician
QUALIFIED operators provided by the manufacturer, by the vender or by a
assistance centre authorized by the manufacturer to perform complex
operations in special situations as arranged with the user.
It is the responsibility of the technical installation personnel to perform the operations of assembly
and installation of the machine (see chapters 6 and 7).
The technical installation personnel (provided by the manufacturer, by the

vender or by the assistance centre authorized by the manufacturer) is directly
trained at the manufacturer’s branch.
1.6.8 Machine operator

Personnel without specific abilities, able to perform simple tasks ONLY, i.e.
running the machine with all the protections installed and activated. It may also
carries out manual operations to do simple control, start-up and reset functions
following an alarm condition.
The need to manually interact with the machine requires specific competence of
the operators.
The machine operator is able to:

• interact with the machine and work in its perimeter without any personal risk;
• turn on/turn off the machine;
• work in normal running conditions and in stand-by;
• interact with the machine manual commands;
• carry out washing operations;
• know and describe alarm situations to the mechanical operator;
• set the machine running mode and carry out main regulations related to the process
treatment;
• verify the levels of the process liquids and of the chemical reactants necessary to start or
to stop the treatment;
• work in safety conditions using personal protection devices when it is required to handle
chemical products necessary to help the process treatment;
• directly solve the conditions which have generated an alarm, no less than a serious
problem occurs;
• clean the external parts of the machine when it is required.
1.6.9 Maintenance technician

QUALIFIED personnel able to run the machine under normal conditions, to
operate in manual mode, to work on mechanical, hydraulic and pneumatic parts
to carry out adjustment, maintenance and repair operations required.
It is NOT able to work on electrical running plants, on the blower and on PLC
programming.
This type of operator, besides having the machine operator competence, is able to:
• make a diagnosis of the machine efficiency;
• find out eventual failures;
• directly solve the conditions which have generated an alarm, no less than a programming
problem occurs (in this case it is necessary to advert the technical assistance of the
constructor or the vender);
TC 15000 17
• keep the machine efficiency through the correct carrying out of the periodic maintenance
operations;
The mechanical operator keeps all the tools which allow the regulation or the assembly of the
machine parts.
These operators may be separated based upon their specific role, their skills, competence and
matured experience.
If the intervention leads to particular risks (for example on the electrical plant),
the mechanical operator HAS to be qualified to work also in these particular
conditions.
1.6.10 Electrical maintenance personnel

QUALIFIED operator able to run the machine under normal conditions and to
operate in manual mode. He has to deal with all the electrical operations
required (adjustments, maintenance and repairs) and he is able to work in live
electric cabinets and junction boxes.
This type of operator, if adequately trained, may also carries out operations assigned to the
machine operator and to the mechanical maintenance operator.
1.6.11 Devices and solutions for the operators protection

In order to grant the operators safety, the following solutions have been adopted:
• The machine is protected by sound-absorbent devices and/or by thermal insulation
material that protect the operators from noise or from contact with hot parts of the
machine. The panels are composed of (refer to Figure 1.6-1):
A- Doors which can be opened using keys that allow access to the machine only by
authorized users
B- Panels removable with keys
C- Fixed panels
Figure 1.6-1 – Protective panelling of the machine
18 TC 15000
Before closing the access doors of the machine, the users MUST check that
there is no-one in the machine
• Total absence of accessible moving or dangerous parts: all the pumps impellers and the
moving parts of the blower K01 are integrated into the casings of those units or protected
from the accidental touch.
• The K01 blower is equipped with safety systems (pressure and temperature sensors) in
suction and delivery.
• The piping, fittings, heat exchangers, storage tanks and valves of the various circuits which
convey fluids are suitably sized and made of suitable material. The presence of manually
operated shut-off valves allows the isolation of different sections of the various circuits to
simplify work on the equipment.
• The boiling chambers, which are suitably sized and made of suitable material, are
equipped with special doors with a suitable locking system. These doors allow access to
the chamber for maintenance operations. It is not possible to open the doors during
machine operation because of the vacuum in the evaporation chamber. This ensures that
operators do not come into contact with the treated liquid during the boiling phase.
• The terminal boards on the machine having dangerous voltages are suitably protected by
junction boxes with a cover fixed by screws. The door of the main cabinet is fitted with a
key lock and an isolator, which operates as a door lock and does not allow opening of the
electric cabinet when live.
• The machine can operate in completely automatic mode, without requiring the constant
presence of personnel.
• The PLC provides independent management of the entire distillation process and the timely
warning of personnel in the event of malfunctioning through acoustic and luminous signals.
In case of a serious anomaly, the PLC stops the machine.
• All necessary functions may be activated or programmed by means of the special control
terminal. This is also equipped with a series of commands that allow the machine to be
started/stopped and some procedures to be manually activated.
For further details on use and configuration of the control terminal, refer to
chap.9
• The machine configuration has been optimized in order to reduce the overall dimensions
and to facilitate access to the various components for adjustment/maintenance.
1.6.12 Signals related to residual risks and their location

The following table shows the signals for residual risks.
Message Location Precautions taken
- it is compulsory to put on protective gloves
Warning: Non-insulated surfaces of the before any work that requires approaching the
Heated components and line devices containing flanges
surface. the process fluid -unauthorized personnel are prohibited from
accessing the machine
Table 1.6.1 – Signals related to residual risks
TC 15000 19
1.6.13 Other signals
Message Location
Electric panel and junction
Warning: boxes, pumps, blowers, fans,
Disconnect from power supply before opening. doors of the boiling chamber
D01.
Warning:
Heat exchanger E01 and tank
Before removing the flange, put on goggles and gloves and drain
D02.
the liquid by means of the valve provided.
Warning:
Doors of the boiling chamber
Before removing the flange, put on goggles and gloves.
D01.
Immediately after having removed the flange, ventilate the room.
Vents from distillate collection
Warning – dangerous vents: stay far from the action area of the tanks D02 and venting in
vents during the machine functioning condensables from the heat
exchanger E01
WARNING –Overflowing dangerous liquid: before opening the
cover, disconnect Doors of the boiling chambers
from power supply and check if the level in the evaporation D01.
chamber is below the door bottom edge
Table 1.6.2 – Labels concerning signals on the machine
1.6.14 Expendable chemical products

Expendable chemical products used by the machine are of two types:
• Antifoam
• Generic chemical additives (if optional II is installed and enabled)
In the course of normal operation of the system, these products will need to be restored in the
storage tanks
Before adding chemical products, carefully read the safety information on the
product.
When adding the products, the operators MUST wear suitable individual
protection gear. The safety devices to be adopted must be chosen according to
the physical-chemical characteristics of the fluid used or being treated.
In order to operate, the machine also required lubricant oils. The types of oil recommended by
VWS are the following, whose characteristics are indicated in Table 1.6.3:
Type of oil Use Requirement for each change
Total Carter SH320 Blower K01 5 litres
Table 1.6.3 – Lubricant oils required for correct operation of the evaporator
For information on changing the oil, see chapter11
Before adding chemical products, carefully read the safety information on the
product.
When adding the products, the operators MUST wear suitable individual
protection gear. The safety devices to be adopted must be chosen according to
the physical-chemical characteristics of the fluid used or being treated.
20 TC 15000
1.6.15 Warning on residual risks and signals
In order to avoid any dangerous situation for individuals or damage to the equipment caused by
residual risks and signals, i.e. those situations of potential risk which remain in spite of all the
observed prescriptions, or by non-evident potential risks, it is recommended to strictly observe the
following warnings:
The operators MUST comply with signals and indications on the tags on the
machine. They must work only in compliance with the instructions contained in
this manual.
The operators MUST always wear personal safety clothing and accessories
during assembly and maintenance operations.
The operators MUST always wear suitable personal safety clothing and
accessories in case of operations on equipment where there is the possibility of
coming into contact with the fluid treated or with chemical products used during
the process. The safety devices to be adopted must be chosen according to the
physical-chemical characteristics of the fluid used or being treated.
When opening the doors of the evaporation chamber to carry out maintenance
work, it is recommended to ventilate the room before carrying out the required
operation.
During normal operation of the evaporator, some sections of the different

circuits could be at a moderately high temperature.
The whole working area beside to the machine is defined as dangerous area;
the operator who works in it is considered “at risk” in compliance with the
norms in force.
1.6.16 Warnings and rules on behaviour

To avoid any hazardous situation for operators or damage to the equipment, it is recommended
that the following warnings rules and behaviour be scrupulously complied with.
The constructor may NOT be held liable for injuries to people or damage to
property resulting from failure to comply with these warnings.
To avoid damaging the equipment or creating dangerous situations, mechanical

maintenance operators have NOT to leave objects on the various system
components and to lean or to try to climb them.
In order not to lower the safety level of the system, NO attempt should be
made by the personnel to remove the safety measures adopted or to bypass
them.
If maintenance operations have been done by the qualified personnel, the
operators HAVE to check that the safety measures eventually removed are
correctly re-installed before running the machine.
It is strictly FORBIDDEN to non qualified operators to carry out any kind of

work on equipment with the power on.
TC 15000 21
It is strictly FORBIDDEN to non qualified operators to carry out any kind of

work on components or parts under pressure.
Qualified personnel MUST always check that the pressure of the relevant circuit
is equal to the atmospheric pressure before carrying out any work.
All materials that are polluting to the environment, coming from work on the
equipment or the distillation process, MUST be disposed of in compliance with
the norms in force. If it is necessary, a suitable organization for their disposal
has to be contacted.
The operators trained for operating in specifically areas must NOT interact with
other qualified operators’ job.
Electrical and pneumatic connections to external utilities MUST be carried out

by authorized operators in compliance with the norms in force.
The user may NOT modify the machine programming without consulting the
constructor or the vender.
The machine is supplied already programmed and tested by the constructor.

Eventual program modifications MUST be made in collaboration with the
constructor or the vender, who well know the machine limits and the
parameters variation related to the work of the machine.
The operators MUST take care both of themselves and of the other people who
are inside the working area where the machine is located.
The operators must NOT work without the personal protection devices
described in this manual.
If the operators hear weird and unusual noises coming from the machine, they
MUST turn it off and keep themselves at a safe distance until the machine is
off.
The operators HAVE to keep clean the working area and the clearance zones
around the machine.
The operators have NOT to allow anybody to work in the zones of the safety
measures which protect various system components while the machine is
running.
The operators MUST run the machine in an properly illuminated environment.
Before modifying in any possible way the machine, it is COMPULSORY to

contact the constructor or the vender to get necessary clarifications on it, in
order to avoid to compromise the safety of the machine.
In case of disagreement between the original version and translated version of

the manual, the reference will be the original Italian version.
22 TC 15000
2 Functional description
CHAPTER 2
This chapter describes in detail the operating principles of the machine through:
• a division in main parts and their description through process diagrams;

• a division in functional groups and their detailed description.
Furthermore, there is a description of all optional accessories which it is possible to install and to
supply the machine with.
2.1 Process diagram

The process diagram of the machine is attached to this manual.
Each diagram is supplied with a list of the symbols which identify the components and with a brief
description. All the components of the machine are identified by an univocal symbol.
The following table owns the necessary symbolization to identify also the functioning logic. It may
also be seen as a simplified operating diagram.
Besides the streams related to the process liquids (liquid to be treated, concentrate and distillate),
hydraulic and pneumatic lines are represented.
The optional parts are boxed with a dashed line.
Legend of essential components:
Symbol Description
CE01 Conductivity probe of the distillate
Distillate conductivity indicator (located inside the switch board, see the
CI01
electric diagrams attached)
Distillate conductivity transmitter (located inside the switch board, see the
CT01
electric diagrams attached)
D01 Boiling chamber
D02 Distillate collecting tank
D03 Fluxing liquid storage tank mechanical seal of pump G02
D04 Antifoam tank (to be provided for by client)
D05 Additive tank (to be provided for by client)
DPT01 Blower differential pressure transmitter
DT01 Concentrate density transmitter (present if optional I is installed)
E01 Primary condenser
E02 Distillate heat recovery exchanger
E03 Thermal recovery exchanger (present if optional X is installed)
ER01-ER04 Heating resistor of the distillate tank D02
Heating resistor of the distillate tank D02 (equipped with emergency
ER05
thermostatic probe TS05)
ER06 Heating element for the oil sump of the blower
EV01, EV03, Solenoid valves for compressed air with double effect
EV04, EV07,
EV08, EV09,
EV12, EV13
TC 15000 23
Functional description 2
EV02, EV05, Solenoid valve for compressed air with single effect
EV06, EV10,
EV17, EV11
F01 Filter of the blower suction liquid injection
Safety limit switches having the task to signal the opening of the door to the
FC1
electric protection systems, blocking the operation of the machine.
FI01 Field indicator of the liquid injection flow rate into the blower suction
FT01 Distillate flow rate transmitter (present if optional IX is installed)
G01 Circulation pump of the concentrate
G02 Supply pump
G03 Distillate discharge pump
G04 Fluxing pump of the mechanical seal of the circulation pump G01
G05 Injection pump of liquid in blower suction
G06 Anti-foam dispenser membrane pump
G07 Additive dispenser pump (present if optional II is installed)
H01 Calm tube of the level sensor LS01
H02 Boiling chamber sight glass
H03 Sprayer for the sight glass H02 washing
H04 Packed bed for the separation of the liquid drops entrained with the steam
H05 Calibrated neck of the concentrate recycle
H06 Calibrated neck of the feed
H07 Nebulizer of the liquid injection into the blower suction
H08 Sight glass of blower delivery
H09 Expansion joint
H10/H11 Calibrated neck of the distillate
H15 Nebulizer of the liquid injection into the blower delivery
H24 Plugs dedicated to circuit drainage
H33 Inspection flange for tank D02
K01 Steam blower
LS01 Work vibration level switch of the boiling chamber D01
LS02 Maximum vibration level switch of the boiling chamber D01
LS03 Minimum vibration level switch of the boiling chamber D01
LS05 Minimum float level switch of the fluxing liquid tank D03
LS06 Minimum float level switch of the antifoam tank D04
LS07 Minimum float level switch of the additive tank D05
LS09 Maximum float level switch of the fluxing liquid tank D03
Maximum level of external concentrate storage tank (to be provided for by
LS10
client)
LS11 Minimum level switch of the external feed storage tank.
LS12 Maximum level of external distillate storage tank (to be provided for by client)
LS13 Minimum float level switch of the blower lubricating oil K01 (drive side)
LS14 Minimum float level switch of the blower K01 lubricating oil (gear side)
LT04 Pressure level sensor of the distillate storage tank D02
Valve for the pressure control in the compressed air circuit for the process
PCV12
control
24 TC 15000
Valve for the pressure control in the compressed air circuit for the anti-foam
PCV13
metering pump G07
Valve for the pressure control in the compressed air circuit for the additive
PCV14
metering pump G08
PI12 Compressed air pressure indicator at the process side
PI13 Compressed air pressure indicator at the anti-foam metering pump G07 side
PI14 Compressed air pressure indicator at the additive metering pump G08 side
PS14 Pressure switch of the compressed air
SS1 Foam sensor in the boiler
TS05 Protection thermostat of the resistor ER01
TT01 Transmitter of the boiling chamber D01 temperature
TT02 Transmitter of the distillate collecting tank D02 temperature
TT03 Transmitter of the blower suction temperature
TT04 Transmitter of the blower delivery temperature
TT07 Transmitter of the blower lubricating oil temperature (gear side)
V01-V46 Globe and butterfly manual sectioning valves
VP01-VP17 Pneumatic sectioning valves
VR01-03 Check valve
Table 2.1.1 – Process diagrams legend
TC 15000 25
The machine has different optional, which can be current or installed on request; if an optional is
not arranged, it is possible to use the corresponding accessory (unit independent from the
machine). The available kits are shown in Table 2.1.2.
The choice of the tanks varies according to the customer’s requirements and to the need of
managing adequate storages, also considering expected machine stops. Table 2.1.2 shows a
possible solution.
Reference no.
Optional on
Description on process Series options Accessories
request
diagram
Concentrate I OC DN C
density control TC 15000
system
Additive metering II OM AD F
system TC 15000
Automatic system III OC AF F
to check for TC 15000
foaming in the
boiler
Bactericide AM BT D
metering system
Feeding tank AS F 15000
Distillate tank AS D 15000
Concentrate tank AS C 15000
System of IV OC CN C
measurement of TC 15000
condensate
conductivity
Predisposition for V
the system of the
external tank
levels
System for VI OW TW
washing inside of TC 15000
boiling chamber
Anti-foam VII OM AF F
metering system TC 15000
Flow rate IX OC FM D
transmitters of TC 15000
the distillate
Device for X OR HE C
thermal recovery TC 15000
of concentrate
Remote control OC RC TC 15000
via GSM modem
Table 2.1.2 – Predispositions and optional groups legend
26 TC 15000
2.2 Description of units and functional

descriptions
2.2.1 Unit identification
The machine may be split in a certain number of functional units which may be named as follows:
• feed and washing unit;

• boiling chamber unit;
• antifoam metering unit;
• concentrate circulation unit;
• concentrate discharge unit;
• circulation and feed pumps flushing unit;
• steam line unit;
• distillate accumulation, transfer and discharge unit;
• air compressed unit;
Units description and their functioning explanation are reported in the following paragraphs. The
main components which characterize each unit have been previously described.
2.2.2 Feed and washing unit

This unit encloses the following main components:
E02a/b/c/d/e/f/g/h, E03a/b, G02, H02, H03, H06, V01, V12, V19-21, V25, LS01, VP01, VP10
The liquid to be treated, drawn from the G02 pump, passes through the calibrated neck H06 and
enters recovery exchanger E02, where it receives the heat from the hot distillate from the tank
D02. Then the heated liquid enters the boiling chamber D01.
An inverter controls the speed of pump G02, which feeds the constant reflux, based on the
working level LS01, in order to maintain constant, within a certain tolerance, the amount of liquid
being treated in the machine.
The manual cut-off valve V01 is useful during maintenance of the components of the line, while
valve V25 drains the liquid in the feed line.
During the start-up phase of the machine, the valves VP03 and VP08 are open, while the valve
VP01 and VP09 are close; the liquid to be treated receives the heat necessary to warm up from the
recycled distillate. In normal stationary conditions, the valves VP01 and VP09 are open, the valve
VP07 opens with pause/work, while the valves VP03 and VP08 are close and the liquid receives the
heat necessary to boil from the concentrate and the distillate, before their discharging.
The level sensor LS01 and sight glass H02 washing is regulated at settable time ranges by the
pneumatic valve VP05. The manual valves V19-20-21 are useful for the maintenance operation.
2.2.3 Boiling chamber unit

D01, H01-02, H04, LS01-03, V24, TT01, VP12

Inside the boiling chamber D01 the liquid to be treated is subjected to a separation process, after
which the water passes into vapour phase. The sensor LS01, inserted in the calm tube H01,
generates the level control LCL01 that affects the feed flow rate. The sensor LS02 activates the
alarm LAH02, while the sensor LS03 activates the alarm LAL03: they stop the machine running
when a condition of high and, respectively, low liquid level in the boiling chamber occurs.
The temperature sensor TT01 generates the control signal TCL01 that, in the start up phase,
indicates that the liquid has reached a usable temperature for evaporation and the blower is
started. The same sensor activates the alarm TAH01 of the high boiling chamber temperature.
TC 15000 27
Inside of the boiler, over the liquid entrance, a metal plate is inserted that has the function to
prevent eventual jets during the inlet of the liquid.
The vapour generated passes through the demister for drops separation (H04). The demister is
made by a grate that holds up a layer of packing elements. The aim of the demister is to prevent
eventual jets from reaching the upper part of the evaporation chamber (dome) with a consequent
pollution of the produced distillate.
Sight glass H02 is used to check the inside of the boiling chamber D01.
The valve VP12 makes it possible to break the vacuum in the boiler by letting air into the machine.
It works automatically when the cycle starts to limit the formation of foam. it also works
automatically at the end of the cycle, in order to limit counter-rotation phenomena of the blower.
2.2.4 Antifoam metering unit

The antifoam unit controls the foam production inside the boiling chamber.
The foam production is caused both by the liquid stirring and by the low pressure boiling. The
foam can cause dragging effects of the pollutants in the distillate.
D04, G06, LS06, V22, V40, VP05

The anti-foam liquid is metered with timer.control by means of the activation of the pneumatic
valve VP05 and the membrane metering pump G06. The metering system places anti-foam in the
boiler D01.
The floating level sensor LS06 activates the low level alarm LAL06 if the liquid in the storage tank
D04 is over. This alarm leads to the machine stop.
The antifoam metering unit may be directly switch on/switch off by the control panel.
2.2.5 Concentrate circulation unit

G01, H05, V07, V32, VP03

The liquid in the boiling chamber D01 is taken by the circulation pump G01 and it is sent through
the tubes of condenser E01. The pump G01 is supplied with a flushed mechanic seal to avoid air
infiltrations caused by seal wear and tear. These air infiltrations may lead to the vacuum breaking.
The condenser provides to heat the liquid during its treatment. The steam produced and
compressed by the blower K01 goes through the shell of the condenser. After the heating, the
liquid goes back to the boiling chamber loosing part of the pressure in the calibrated nozzle H05.
During the machine start, the opening of the valve VP03 allows the recycle of the liquid to be
treated until it has reached the set boiler temperature.
2.2.6 Concentrate unit discharge

V08, VP07, V33

A secondary pipeline (derived from the delivery pipeline of pump G01) allows the concentrate
discharge. The machine automatically activates the valve VP07.
The opening of valve VP07 is influenced by the parameters set by the control panel. The
concentrate discharge may take place:
• volume: the desired concentration ratio is set

• by density (if optional system I is present and enabled): discharge occurs based on the
density reached in the boiler.
28 TC 15000
The manual butterfly shut-off valve V02 lets you close off the concentrate discharge line to
perform maintenance.
The valve V24 makes it possible to completely drain the concentrate discharge line along with
boiling chamber D01.
2.2.7 Circulation pump flushing unit

D03, G04, LS05, LS09
Pump G04 draws water from storage tank D03 and sends it to the mechanical seal of pump G01.
The sensor LS09 activates the high level alarm LAH09, while the sensor LS05 activates the low
level alarm LAL05: they stop the machine in the event of high or low level of liquid in the tank D03.
2.2.8 Vapour line unit

This unit includes the following main components:
CE01, DPT01, E01, ER04, F01, FI01, G05, H07-09, K01, LS13-14, PT01, TT03, TT04, TT07, V11,
V31, VP04, VP17
The produced vapour in the boiling chamber goes to the blower K01 that, by means of the
compression, raises the temperature allowing the heat exchange with the liquid in the boiling
chamber: in the exchanger E01 the vapour condensates releasing the latent heat to the recycled
liquid of the boiling chamber, causing it to evaporate. The blower is instrumented as follows:
• TT03, TT04 transmitters of the suction and delivery temperature

• PT01 transmitter of the suction pressure
• DPT01 transmitter of the delivery/suction differential pressure
• TT07 transmitter of lubricant oil temperature
• LS13, LS14 level switches of the lubricating oil
The blower is handled by a system that settles the machine capacity and controls its start-up at
machine starting.
The heating element ER04 is used in the start-up phase to heat the oil in the blower and to
maintain the distance between the moving parts, which may be altered due to thermal dilations.
The pump G05, with the contemporary opening of the solenoid valve VP17, sends the distillate
drawn from D02 in the sprayer H07 at the blower K01 suction to reduce the vapour temperature
The filter F01 hinders that eventual solid bodies clog the line, while with the flow meter FI01 it’s
possible to check and control the flow rate.
The sight glass H08 is used in order to control the blower delivery.
The probe CE01 measures the distillate conductivity: if this exceeds, it means that strong
entrainment occurs in the boiling chamber and an alarm is generated stopping the machine.
The pneumatic valve VP04 allows the discharge of the non-condensing gases, or the excess
vapours, that may accumulate in E01 reducing the heat exchange, together with those in the
distillate storage tank D02.
H09 is the expansion joint of the vapour pipeline.
2.2.9 Distillate accumulation, transfer and discharge unit

D02, ER01-03, FT01, G03, LT04, TT02, TS05, V13, V15-16, VP08, VP09
The distillate discharge is accomplished continuously: the pump G03, controlled by an inverter,
maintains the level measured by the sensor LT04 in the tank D02.
The distillate sensible heat is recovered in the exchanger E02 and it’s released to the feed liquid.
TC 15000 29
The flow sensor FT01, present only if optional IX is installed, measures the flow rate of the
discharged distillate, the same produced by the evaporator.
During the heating phase, the distillate is recycled in D02 by means of the pneumatic valve VP08
opening and VP09 closing; the electric heaters ER01-03 heat the distillate and the heat produced is
transferred in the exchanger E02 to the liquid in the boiling chamber recycled by the circulation
pump. The activation of the electric heaters ER01-03 is controlled on the base of the temperature
measured by the transducer TT02, while the thermostat TS05 protects the resistors generating an
alarm if the level in D02 is low, leaving the resistors uncovered.
The return valve VR01 prevents return of the distillate into tank D02 when the transfer pump G03
is off.
The flow rate of the distillate leaving the pump G03 can be controlled by changing the diameter of
the calibrated neck H10.
2.2.10 Air compressed unit

The air compressed distribution network is divided in two parts. The first issued for the control of
the pneumatic valves, while the second is for the activation of the membrane pumps G06 and G07
(if optional II is installed and enabled).
The pressure inside the three parts is regulated respectively by valves PCV12, PCV13 and PCV14.
Pressure gauges PI12, PI13 and PI14 show the pressures measured downstream by the regulation
valves.
The pressure inside the control part of the pneumatic valves has to be set at values between 600 e
650 [kPa]. The pressure in the part for the activation of the membrane pumps G06 and G07 must
be set to values between 250 e 300 [kPa].
The pressure switch PS14, located on the part that controls the pneumatic valves, activates the low
pressure alarm PAL14. This alarm, which stops the machine, is activated only when the length of
the low pressure condition is higher than a time by the constructor.
Non-return valves VR02 and VR03 does not allow a pressure drop in the part which controls the
pneumatic valves when a temporary pressure drop occurs in the pneumatic supply line.
The solenoid valves EV01-EV17 controls the activation or deactivation of the pneumatic valves
witch are connected to.
2.3 Predispositions and optional accessories

As it was previously said, the machine may be supplied with predispositions and optional
accessories listed in Table 2.1.2. Furthermore, the machine may be supplied with a remote control
system.
2.3.1 Concentrate density measurement system (I)

The concentrate density measurement system DT01 is used to run the machine in “density” mode.
Consequently the concentrate discharge occurs when the liquid reaches a value set by the user.
The optional accessory includes the following elements:
DT01
Cables, join tubes
If the concentrate density increases out of control, the concentrate high density alarm stops the
machine.
2.3.2 Additive metering system (II)

The additive metering may be necessary for special performances, function of the user
requirements or of the type of process. For instance it could be necessary to meter products to
inhibit fouling.
30 TC 15000
The optional system includes the following elements
D05, G07, EV11, PCV14, PI14, LS07, V41, V23, VP06

The additive metering occur through the opening of the valve VP06 and, at the same time by the
activation of the membrane pump G07 that draws the liquid from the tank D05: the activation of
solenoid valve EV11 gives the compressed air required. The floating level sensor LS07 activates the
minimum level alarm if the liquid in the storage tank D05 is over. This alarm leads to the machine
stop. For the remaining components, refer to the paragraph of the compressed air.
The additive metering unit may be directly switch on/switch off by the control panel.
2.3.3 Automatic system to check for foaming in boiler

(III)
This system makes it possible to monitor foaming in the boiler.
The optional accessory includes the following elements:
SS01, EV13, VP13

Sensor SS01 detects foam in the boiler. If the sensor is tripped, it automatically activates the anti-
foam product dispensing system (see paragraph 2.2.4) until the foam is eliminated and the sensor
de-activates the signal.
An automatic timed wash system (controlled by valve VP13) sends a jet of water (via the nozzles)
to the foam sensor to keep it clean.
The automatic foaming control group can be turned on or off from the control panel of the
machine.
2.3.4 Set up for levels control system in the process

liquids storage tanks (V)
This predisposition allows to automate the machine working in function of the liquid level in the
storage tanks of the process liquids.
The connection to the machine of the level switches located in the tanks is carried out using the
terminals inside the switch board (see electric diagrams attached).
LS 11 (provided with the machine) and LS10-12 (to be provided for by the client)
If the low level control LS11 is activated, the machine stops and goes to stand by mode, supposing
the process over since the liquid to be treated is over.
If the high level control L12 is activated, the machine stops and goes to stand by mode, supposing
that the user wants to accumulate a certain amount of distillate to recycle it.
if the high level alarm LS10 is activated, the machine stops and goes to alarm mode, supposing
that the user has to dispose the concentrate.
With the exclusion of the concentrate tank, the machine restarts when the levels are restored.
2.3.5 System for measurement of the amount of distilled

product (IX)
This optional system allows constant measurement of the amount of distillate produced. The data
collected by this device can be used by the PLC to determine the desired ratio of concentrate and
hence to guide the concentrate discharge, and to run the machine in "concentration ratio" mode.
FT01
TC 15000 31
The volume of discharged distillate is measured by the flow measurement device FT01, which
sends its signal to the PLC. Based on this signal, the machine automatically calculates the
discharge parameter, if the operating mode is “Volume”.
2.3.6 Thermal recovery system of concentrate (X)

E03 a/b
The liquid to be treated, drawn from pump G04, passes through thermal recovery exchanger E03
(divided into 4 modules) before it enters exchanger E02.
The machine activates with pause/work the pneumatic valve VP07 that allows the concentrated
liquid to go through the tube side of the exchanger E03. In the exchanger, the concentrate gives
its latent heat to the liquid to be treated before its discharging.
2.3.7 Remote control system

The machine is set up to be controlled also by a remote control, for example to integrate the
machine into a centralized treatment plant. The connection to the remote panel is made by a
series of contacts located on the terminal board of the electrical panel (see enclosed electrical
diagrams).
These contract make it possible to:
• turn on/turn off the machine
• connect an indicator light that shows the machine is in operation
• connect an indicator machine to show that the machine has shut down or is in an alarm
situation
• connect an indicator light that shows that the machine is in stand-by status.
For further information on how to make the electrical connections, refer to the enclosed electrical
diagrams.
2.3.8 Setup for remote control via GSM modem on PLC

The machine is set up for the installation of a device that lets you send an SMS message to a
series of enabled cell phones it the machine shuts down due to an alarm. The use of the device by
the client requires installation in the modem of a SIM card enabled for sending SMS messages and
the programming of the modem itself.
32 TC 15000
3 Technical characteristics and data
CHAPTER 3
This chapter describes the machine characteristics and gives a general description of the main
applicable fields and of the performances to the user.
It is particularly described:
• possible applicable fields supplied by information about the correct use of the machine;
• a simplified functional description to give a main idea about working principles to the
reader;
• machine characteristics;
3.1 Applicable fields

The machine is an evaporator for the treatment of water-based liquids. It makes use of the
combined effect of vapour mechanical recompression technology to make water-based liquids boil
at low temperature (<100 °C).
Construction materials, design, heat exchange system make the machine suitable to treat solutions
and/or water-based suspensions:
• intermediate (washing, rinsing, etc.) to recycle in the process itself;
• to dispose in order to reduce the volume when a reduction of the disposal expenses is
required.
However, the machine is not suitable to treat solutions and/or water-based suspensions of
alimentary nature (for instance milk, juices, concentrate juices, etc.).
Some of the possible applicable fields are:
• textile and graphic arts; treatment of rinsing water containing inks, pigments or
photopolymers;
• waste dischargers: concentration and reduction of exhausted liquids;
• chemical (leather, pharmaceutical, cosmetic industry, etc.): concentration of water used in
the manufacturing process and in the reactor washing;
• mechanical: separation of the exhausted oil-based emulsion, treatment of water used in
vibrofinishing and liquids from phosphatization and degreasing baths;
• landfills: treatment of permeated liquid;
• galvanising and goldsmith’s craft: concentration of work bath liquids and recovering of
metals from the washing water;
• food industry: concentration of vegetation waters, treatment of creamery water and
equipment washing water;
• photographic industry: treatment of exhausted liquids.
3.1.1 Correct and incorrect use

The machine may only be used for the distillation of water-based liquids. The liquids that are to
undergo evaporation (distillation) may contain organic or non-organic substances, but they must
comply with the following characteristics:
• suspended and dissolved substances content must be such that the resulting concentrate
does not have a density equal to or higher than 1.3 [kg/dm3].
• Newtonian liquids and such that the resulting concentrate does not have a viscosity equal
to or greater than 10 [cP].
TC 15000 33
Technical characteristics and data 3
The machine can not process liquids that:
• are flammable;
• form flammable and/or harmful aerosols;
• are radioactive;
• during the evaporation process, create adhesive films, encrustations or stubborn soiling
which would alter the thermal exchange;
• which contain chemical solvents or organic components that may damage the material of
the gaskets located in the machine
• which develop gases or vapours with a condensation point that is lower than that of water
vapour (“incondensables”);
• which cause corrosion of the materials that the machine is made of;
• with a temperature upon entering the machine of less than 20 [°C];
• with a density greater than 1.3 [kg/dm3];
• have a viscosity higher than 10 [cP];
The limits specified above are to be considered as approximate. The actual
decision on whether or not a waste liquid can be treated is to made on a case-
by-case basis contingent upon the defined analytical data. The final decision
on whether a waste liquid can be treated or not is up to the manufacturer.
The use of the machine for other purposes or to treat liquids having characteristics not in
compliance with those defined above can cause injuries to people or damage to the evaporator
itself and is therefore judged as incorrect use, for which the constructor and the vender will not be
held liable.
The following are examples of incorrect use:
• The use of the machine with liquids that belong to the categories of non-treatable liquids
as mentioned above
• The use of the machine in ways that are not included in the technical specifications of
machine operation (technical report and/or this use and maintenance manual)
• The use of the machine in excess of treatment parameters (concentration ratio, chemical
and physical characteristics of the liquids to be treated, and so forth) defined in the sales
agreements (offer and general sales conditions) and process agreements (chemical
analysis) established with the manufacturer.
• Modifications to the machine made without a written agreement with the manufacturer
• Routine maintenance performed using methods other than those set forth in this manual,
or special maintenance by personnel that have not been expressly authorized by the
manufacturer
• Connections to utilities (electrical, pneumatic, plumbing, etc.) that are not compliant with
the specifications set forth in this manual
• Alteration or deletion of the data contained on the tags placed on the machines
• Use of spare parts that are not authorized by the manufacturer of the machine
If the machine is required to be used for other purposes, the constructor or
the vender MUST be consulted in advance. Otherwise, neither the constructor
nor the vender may be held for any sort of damage which may occur to the
machine.
It is prohibited to re-circulate the concentrate to increase the actual yield. This
would be tantamount to feeding the machine with a fluid different from that
permitted by VWS.
3.1.2 Notes on the correct use of the evaporator

Coarse materials
The machine is not suitable to treat liquids containing coarse materials in solid shape of modest
dimensions. In fact, because of their presence, the impellers of circulation pumps may be
34 TC 15000
subjected to abrasion phenomena which make the pumps unusable. The limit dimension tolerated
for the granulometry of the particles in the incoming liquid is 800 micron.
These materials may accumulate in the lower zones producing deposits which could clog some
parts of the machine reducing the efficiency.
It is the responsibility of the user to check that the liquid fed to the machine is
free of abrasives, of any size, which may damage the parts of the machine
that come into contact with them.
It is the responsibility of the vender and/or user to check that the fed liquid
meets the aforementioned characteristics
Fouling and deposits

These kinds of developments may occur when:
• liquids with high content of suspended and dissolved substances are treated,
• the processed liquid is concentrated too much because of errors in the machine control.
These situations may occur because of a deposits accumulation, deposits which become as harder
as the time goes by. Deposits may be caused by the separation of suspended and dissolved
substances.
The problem may more often occurs if the liquids in question remain in the evaporation chamber
for a long time with the system not operating.
This may reduce the heat exchange efficiency or the efficiency of the machine itself and it may
lead to laborious specific maintenance operations.
Therefore it is recommended to leave the machine in stand-by mode when the process liquid
treatment is over to allow the circulation pumps to keep the liquid stirred, avoiding the deposits
hardening.
If the machine is not operating for more than 48-52 hours, it is recommended to totally drain it
and eventually rinse it with water. After an evaluation, to be performed based on the liquid treated
by the machine, the rinse liquid obtained may be treated the next time the machine is used along
with the process liquid.
Additives metering
The machine is preset for additives metering. These additives can be:
• pH adjustment agents,
• corrosion inhibitors,
• fouling formation inhibitors.
The use of these additives needs to be accurately studied in compliance with the process liquids.
Generally, it is the user of the machine who chooses the type of liquid additives based on specific
needs. However, it is advisable for the user to contact the machine's constructor of vender in order
to verify the compatibility of the liquid additive with the characteristics of the machine.
Unpleasant odors
Putrescible liquid waste (containing organic substances, surfactants, mineral oils and especially
those generated during processes in the food industry) must be suitably treated to prevent
proliferation of bacteria and emission of unpleasant odors in the air.
Bacteria proliferation may occur if the liquids in question remain in the storage tanks or in the
evaporation chamber for more than 24 hours with the system not operating and an ambient
temperature higher than 10ºC. It is therefore advisable to use bactericides.
For optimum results the bactericide must be mixed into the entire mass of liquid. The metering of
the bactericide product can be done automatically by using the special accessory unit for
bactericide metering (see Table 2.1.2).
TC 15000 35
3.2 Description of the machine

3.2.1 Available models
At the present moment the available model is:
Model
TC 15000 FF#
TC 15000 AA#
3.2.2 Technical characteristics and nominal performance
Model TC 15000 --3 TC 15000 --4

Frequency [Hz] 50 60
Power supply voltage [V] 400 3F 460 3F
Power [kW] (with concentrate discharge 10%) 31±10% 31±10%
Maximum production of distillate with water [l/h] 660±10% 660±10%
Maximum production of distillate with water [l/24h] 15840±10% 15840±10%
Specific consumption [kWh/l] (with concentrate discharge 0,045±10% 0,045±10%
10%)
Boiling chamber working volume [l] 800 800
Table 3.2.1 – Technical characteristics and nominal performance
3.2.3 Materials
Component
Modello TC 15000 FF# Modello TC 15000 AA#
symbol
D01 (lower Superduplex steel UNS S32750/UNS
Austenitic steel AISI 316 L (EN 1.4404).
dome) S32760 (EN 1.4410/EN 1.4501)
D01 (wall) Austenitic steel AISI 316 L (EN 1.4404). Austenitic steel AISI 316 L (EN 1.4404).
D02 Austenitic steel AISI 316 L (EN 1.4404). Austenitic steel AISI 316 L (EN 1.4404).
E01 (tubes) Superduplex steel UNS S32750/UNS
S32760 (EN 1.4410/EN 1.4501)
E01 (shell) Austenitic steel AISI 316 L (EN 1.4404). Austenitic steel AISI 316 L (EN 1.4404).
E02 (tubes) Superduplex steel UNS S32750/UNS
S32760 (EN 1.4410/EN 1.4501)
E02 (shell) Austenitic steel AISI 316 L (EN 1.4404). Austenitic steel AISI 316 L (EN 1.4404).
E03 Superduplex steel UNS S32750/UNS
S32760 (EN 1.4410/EN 1.4501)
G01 Superduplex steel UNS S32750/UNS
S32760 (EN 1.4410/EN 1.4501)
G02 High quality alloy austenitic stainless
steel UNS N08028 (EN1.4563)
G05 Austenitic steel AISI 316 (EN 1.4436) Austenitic steel AISI 316 (EN 1.4436)
G06 Polypropylene Polypropylene
G03 Austenitic steel AISI 316 (EN 1.4436) Austenitic steel AISI 316 (EN 1.4436)
36 TC 15000
K01 Gray iron (UNI-ISO 185 G 200 with Gray iron (UNI-ISO 185 G 200 with
chemical nickel-plating for the elements chemical nickel-plating for the elements
in contact with the vapour / martensitic in contact with the vapour / martensitic
steel EN 1.4313 + Austenitic steel EN steel EN 1.4313 + Austenitic steel EN
1.4408. 1.4408.
LS 01/02/03 Austenitic steel AISI 316Ti (EN 1.4581) Austenitic steel AISI 316Ti (EN 1.4581)
Structure and
Austenitic steel AISI 304 (EN 1.4301) Austenitic steel AISI 304 (EN 1.4301)
frame
Pipings and PVDF, polypropylene, austenitic steel
line parts EN 1.4436 (AISI 316), superduplex PVDF, polypropylene, austenitic steel
steel UNS S32750/UNS S32760 (EN AISI 316 L (EN 1.4404)
1.4410/EN 1.4501)
Table 3.2.2 – Construction materials of the main components
3.2.4 Noise emission

The noise emission of the machine in normal working conditions is ≤ 80 [dB(A)]. This emission has
been measured as the level of sound pressure (expressed by the weighting in curve "A") in various
points around the machine. Measurements were taken at a distance of 1000 [mm] from the
machine and at a height of 1600 [mm] from the floor.
TC 15000 37
38 TC 15000
4 Pre-installation requirements
CHAPTER 4
This chapter describes all the requirements in the site of installation relating to the use of the
machine.
4.1 Requirements in the site of installation

The characteristics of the machine allow it to be used in almost all working environments.
However, the following basic rules must be observed:
The working environment where the machine is installed MUST NOT contain
corrosive substances for metal surfaces: aerosols or fumes of acids or
aggressive substances, etc.
The machine MAY NOT BE installed in working environments where there is

the risk of explosion.
The place where the machine is to be installed must take into account the
dimensions of the machine and the clear areas needed to perform
maintenance, etc. (see paragraph4.1.1)
Prior to installation, the vender and the user shall check that the entire floor
where the machine will rest meets the following characteristics: it must have a
slope of less than 1%, it must have a regular surface (no gravel or broken
ground), and it must be such that water does not accumulate inside of it.
The place of installation MUST NOT affect the visibility of the alarm signals.
The place of installation MUST BE well illuminated so as allow the operators

to work correctly during the installation, commissioning, use and servicing of
the machine.
4.1.1 Dimensions and clear spaces

The overall dimensions of the machine are reported in the attached drawing TC 15000_LYT-NNN
(SEC. B).
Clear spaces must be left around the machine so as to allow the users and the maintenance
personnel to work without impediments. The clear spaces required are shown in Figure 4.1-1
The area around the perimeter of the machine must remain clear and free, in order to ensure
access to all the parts of the machine.
Zone (A): this is the area in front of the heat exchanger E01, which must remain clear for the
cleaning and maintenance operations.
Zone (B): this is the area to the front of the main electrical panel. This area must remain free so as
to allow easy access to the control panel.
Zone (C): this area must ensure maintenance can be performed on the blower K01. It must also be
possible to reach the area with suitable hoisting equipment for dismantling/assembling the blower
under special circumstances.
Zone (D): this zone is used for the storage of expendable chemical products (anti-foam (1) and
possibly additive(2)) which are required for proper operation of the machine.
Sufficient space (at least 2 metres) must be left above the machine for the assembly operations
using the chosen hoisting equipment.
TC 15000 39
Pre-installation requirements 4
40 TC 15000
Figure 4.1-1 – Clear spaces
4.1.2 Masses, supports and foundations

The estimated empty weight of the machine when installed is around 7700 [kg], while at full load
in normal operating conditions it may reach 9500 [kg].
The attached drawing TC15000_LYT-NN (SEC. A) shows the disposition of the supports (shown
from above) assurgi the correct installation of the machine. All the feet on the machine have a
diameter of 100 [mm]. The maximum static thrust generated by the machine on the surface is 1.8
MPa.
4.1.3 Ventilation of room and vents

To dispose of the heat dissipated inside the panelling, the machine is fitted with an internal fan
that expels the hot air, and one fresh air opening. Refer to the attached drawing TC15000_LYT-NN
(SEC. A).The generated heat amounts to about 15 kW, with a temperature of about 40-45°C and a
maximum air flow rate of about 7000 m3/hour.
The aeration of the environment is also necessary for disposing of the incondensable gases
discharged from the distillate storage tank and by the valve VP06, ejected through a chimney.
Refer to the attached drawing TC15000_LYT-NN (SEC. A).
With the incondensable gases, it is also possible that non-condensed vapour
gets out from the top of the evaporator A. If the ventilation, inside the
installation environment is not sufficient, it is suggested to canalize the
emissions with adequate ducts.
TC 15000 41
Pre-installation requirements 4
If the vents cause risks to the safety of exposes persons, the user MUST FIT
the special piping to convey the discharged matter to the outside of the working
area.
4.1.4 Catching spills

Since the machine holds and treats liquids, it is advisable to provide a system for storing and
catching any liquids which may spill out of the machine during maintenance. This spill-catching
system must have a suitable volume (not less than 3000 litres, roughly) and should be made of
materials that are suitable for the chemical characteristics and temperature of the liquids that are
released from the machine. Please refer to the attached drawing TC15000_LYT-NN (SEC. B) for the
characteristics and positioning of the drain system.
4.1.5 Operating pressure and temperatures

The machine is designed to operate in environments with temperatures between 5 [°C] and
50 [°C]. This field of operation can be extended:
• to temperatures between 0 [°C] and 5 [°C], with special precautions during the start-up
phase;
It is prohibited to operate the machine when the ambient temperature is above 50ºC.
The temperature of the feed liquid must be between +20 and +70°C. The optimal ambient
pressure where the machine is installed should be about 1013 mbar (0 metres above sea level).
The nominal performance of the machine (Table 3.2.1) can be ensured only if
the aforementioned conditions are met.
42 TC 15000
5 Packing, handling and storage
CHAPTER 5
This chapter describes the first actions to be taken after the machine arrives at its place of
installation. It provides detailed information on shipping and storage, prior to actual installation.
5.1 Packaging and transport modules

The machine is delivered in a single module, optionally packed in a wooden crate. The dimensions
and weights are indicated in the following table:
Type Reference Load Dimensions (L x P x H) Weight
to Figure [mm x mm x mm] [Kg]
5.1-1
Standard A Single load 5000 x 2100 x 2700 7500
packaging / Blower (in pallet) 1200 x 800 x 1000 250
Packaging with B Single load
5300 x 2220 x 3080 8770
wooden crate
Table 5.1-1 – Dimensions and weight of the boxes for transport
Figure 5.1-1 – Modules for transport
TC 15000 43
Packing, handling and storage 5
5.1.1 Transport and movement
Once ready for shipment, the machine can be transported by semi-trailer, train or ship.
Road haulers are required to strictly comply with traffic regulations in the
countries where haulage takes place
Road haulers must periodically check the condition of the load to ensure that it
has not shifted.
Handling requires the following equipment:

• 1 crane with bucket (see Figure 5.1-2) capable of moving the loads shown in Table 5.1-1.
• 1 forklift for easy movement of the remaining loads (wood crate)
The load capacity of the handling system must be compatible with the weights indicated in Table
5.1-1.
Handling requires the following personnel:
• 1 crane operator who is able to use the forklift as well
Operators involved in the operation are required to use individual protection

gear (see the list provided here and reference in chapter 1).
Personnel involved in the operation must work as set forth in documents

concerning safety in the workplace (operational safety plan and plan of
coordination and safety)
The operations of handling and assembly are to be performed in atmospheric
conditions that do not jeopardize the operations (no strong winds, heavy rain,
ice, etc.)
The cranes must have straps and buckets that are suitable to the handling
needs.
The user is recommended to check that the various components of the machine
have not suffered any damage during transport.
Any damage, defects or differences found when receiving or handling the

machine MUST BE immediately notified in writing by the user to the carrier, the
manufacturer and/or vender.
During the handling operations check that all the safety measures necessary to
avoid risks to persons and damage to the machine have been adopted.
Before handling the various modules, check that no objects are resting on the
module, thus avoiding the risk that these may fall during the handling
operations.
IT IS PROHIBITED to lift the machine by using non-structural elements as

levers, such as electrical panels on the machine, electrical raceways, tubes etc.
The machine MUST BE unloaded from the vehicle used for transport, using a
hoisting system that is suitable for the weight and the dimensions of the object.
MAKE SURE there is enough room to hook and move the modules. See
paragraph 5.1.1.
44 TC 15000
IT IS PROHIBITED to use slings that are in poor condition or with hooks whose
rated capacity is lower than the weights indicated.
IT IS PROHIBITED to use slings of different lengths, as this would mean the

machine being hoisted with the load off balance, thus creating situations of
danger for persons and the load itself.
IT IS PROHIBITED to remain below the suspended loads during the transport

and handling operations.
IT IS PROHIBITED to guide hanging loads with the hands when lifting them.
5.1.1.1 Movement of load without wood crate

Modules A can be moved by screwing the 4 eyebolts into the threaded holes on the frame. The
following figure illustrates the position of the eyebolts: the hoisting slings must be hooked to the
eyebolts, which in turn are to hooked onto the load bucket The load must be evenly spread over
the bucket.
Figure 5.1-2 – Handling of evaporator with crane
5.1.1.2 Movement of load with wood crate

The module can be moved by using belts or straps to support the load shown in Table 5.1-1. The
load must be evenly spread over the straps.
TC 15000 45
Figure 5.1-3 – Movement with crane of evaporator packed in wood crate
5.1.2 Storage and conservation

If the machine needs to be stored for a certain period of time before being installed, it should be
adequately protected and stored sheltered from the elements (including exposure to sunlight), and
a suitable environment (temperature between 5 [°C] and 45 [°C], and relative humidity between
20 [%] and 60 [%], non-condensing).
In these cases, the components should not be removed from the packaging,
or alternatively special precautions should be taken to protect the exposed
parts. The packaging must be removed by the qualified installation personnel.
DO NOT stack objects on the packaging or on the modules of the machine.
Some components of the machine are subject to wear, even when the machine is not in operation.
This situation is physiological and related to the materials used. The components that are most
subject to these problems are: the mechanical seals and the rubber gaskets.
If the machine remains inactive for periods longer than 3 months, the
mechanical seal of the circulating pump G01 and supply pump G02 may be
ruined and consequently there may be leaks when the machine is operated.
If the machine will not be used for over 2 months, check that the lobes of the
blower K01 can be moved at least on a bi-weekly basis to prevent
deterioration of the coupling system.
CHECK the condition of the mechanical seal on the pumps before starting the
machine if it has been inactive for periods longer than 3 months. In particular,
check if the two sides of it are attached and if necessary detach them by
removing the seal.
46 TC 15000
If the machine remains inactive for periods longer 6 months, the gaskets
inside the tube couplings may crack. As a result, the couplings may leak and
consequently prevent the vacuum from being created inside the boiling
chamber or cause the process liquid to leak.
CHECK and if necessary replace the gaskets before starting the machine if it
has been inactive for periods longer than 6 months.
TC 15000 47
48 TC 15000
6 Assembly and positioning of the machine
CHAPTER 6
6 Assembly and positioning of the
machine
The following main operations must be performed for the assembly of this module:
• positioning in the place of installation;
• connections to the plumbing, electrical and pneumatic lines inside the module
The lifting means required for the operations described below include:
• 1 CRANE, capable of moving and lifting loads 1 and 2 see Table 5.1-1 and paragraph
5.1.1.1
• 1 LIFTING BASKET (or equivalent device, such as a suitable ladder or SCAFFOLDING)
which allows the operator to safely reach high places
• 1 forklift
Assembly requires the following personnel:
• 1 CRANE operator
• 1 forklift operator
• 1 mechanical assembler
• 1 operator for the lifting basket
• 1 installation technician
Tools required for assembly include:
• Standard tools for mechanical applications (complete set of wrenches of various sizes,
screwdrivers, Allen wrenches, etc.)
• Standard tools for electrical applications (screwdrivers of various sizes, terminals and
pincers, etc.)
As the first in assembling the module, remove the packaging of the machine and identify all of the
material needed to assemble the module (feet, gaskets, calibrated neck, etc.)
The packaging must be removed by qualified installation personnel. This
removal must be performed carefully and without losing any components
which may be in the packaging.
Be careful when removing the packaging, so as to avoid damage to persons

and/or the machine.
When disposing of the packing material, the legislation in force on waste

disposal MUST be observed.
After opening the packaging, check that the various components of the
machine have not been damaged during transport. If you discover any
damage, please inform the vender or manufacturer immediately
The crane must have straps and buckets that are suitable to the handling
needs.
Any lifting equipment (CRANES, BASKETS or SCAFFOLDING, FORKLIFTS) must

meet the basic requirements set forth by law and must ensure operator
safety.
TC 15000 49
Assembly and positioning of the machine 6
Operators involved in the operation are required to use individual protection

gear (see the list provided here and reference in chapter 1).
Handling and movement are to be performed in suitable atmospheric

conditions (no strong wind, ice, etc.)
For the operations performed above the ground, the operators MUST use the
necessary safety straps.
The operators MUST use suitable equipment that is in good condition.
6.1 Positioning of modules

6.1.1 Positioning of condenser module
Lifting equipment required to position this module include:
• 1 CRANE, capable of moving and lifting load 1, seeTable 5.1-1
Positioning requires the following personnel:
• 1 mechanical assembler
• 1 installation technician
The following tools are required:
The machine is installed in the installation zone: the installation zone must respect the
requirements set forth in paragraph 4.1.
The module can be positioned directly in the place of installation, opportunely oriented, just after
discharged from transport. Before setting down the module, install the support feet, which are to
be screwed into their housings (make reference to par. 4.1.2). Once the machine has been set on
the ground, level it by adjusting the feet located underneath it.
50 TC 15000
6 Assembly and positioning of the machine
Figure 6.1-1 – Condenser module positioning

For the position of the support feet, refer to the attached drawing TC15000_LYT-NN (SEC. A).
Before inserting the feet, you should grease the thread to make insertion easier
Positioning of the module is the responsibility of personnel assigned to

handling, coordinated by the installation technician
Do NOT stand in the operating area of the crane, nor under loads lifted by it.
6.2 Connections to the plumbing, electrical

and pneumatic lines inside the module
6.2.1 Plumbing connections
Lifting equipment required for this operation for this module include:
• 1 CRANE, capable of lifting tubes weighing a maximum of 800 kg
• 1 LIFTING BASKET (or equivalent device, such as a suitable SCAFFOLDING) which allows
the operator to safely reach high places
Positioning requires the following personnel:
• 1 operator for the lifting BASKET
• 1 plumber
TC 15000 51
Assembly and positioning of the machine 6
The following tools are required:
6.2.1.1 Assembly of the system of ventilation, of venting in condensables

and of the skirts
Install the two fans of the ventilation system included on the machine (1). Install the flue with the
seal cones and corresponding gaskets, using silicone if necessary for increased sealing (2). Install
the skirts on the frame (3). See Figure 6.2-1 – Installation of fans, flue and skirts for references.
Figure 6.2-1 – Installation of fans, flue and skirts
Lifting the fans and flue is the responsibility of persons assigned to handling,
coordinated by the installation technician
Do NOT stand in the operating area of the crane, nor under loads lifted by it.
Assembly of the fan and flue is the duty of the mechanical assembler,
coordinated by the installation technician. Personnel are to be lifted using
suitable equipment in accordance with current safety standards
Assembly of the tubes is the responsibility of the mechanical assembler or of

the installation technician.
52 TC 15000
7 Connection to external and service networks
CHAPTER 7
7 Connection to external and
service networks
Once having assembled the machine, the installation foreman must complete the connections to
the user’s process and supply networks:
• connection to the electrical power supply;
• connection to the electrical signals for management of automation
• connection to the air supply;
• fluid connections to the process networks.
7.1 Connection of electrical power

The machine is supplied without the connecting cables to the mains power supply. The user must
contact an authorized technician to size the lines and to choose the cross-section and the type of
the connecting cables. For the sizing of the lines, the authorized technician must refer to the
legislation in force and the power requirements of the machine. The Figure 7.1-1 indicates where
the power cables pass according to the holes on the electrical panel. The electrical connection
must be carried out by the user in compliance with the minimum degree of electrical protection of
the electrical panel (IP 54) and in accordance with good working practice.
The characteristics of the electrical connections are indicated in the following table:
Frequency 50 Hz 60 Hz
Power supply voltage [V] 400 3F 460 3F
Maximum absorbed current [A] 103 104
Power factor [cosø] 0,9 0,9
The preparation and connection to the user’s power supply is the task of a
qualified electrical maintenance officer provided by the user, who shall proceed
as follows.
Make electrical connections with the power supply to the electrical panel
disconnected.
MAKE SURE you properly tighten the connection terminals on the electrical
panel.
The user MUST ENSURE that the section of the electrical line connected to the
machine’s power supply is protected, using a device that is suitable for the
current at the point of connection.
The user MUST CHECK that the system connected to the machine is suitably
earthed, in compliance with the legislation in force, so as to avoid the possibility
of electrocution or damage.
TC 15000 53
Connection to external and service networks 7
It is strongly recommended to install a pad lock over the machine’s main
electric switch and to keep the key. If not differently specified, during
maintenance operations, it is strongly recommended to close the electric board
and to accurately put away the key.
The electric motors installed on the machine have been selected to operate
normally at the voltage and frequency specified. They can also work
satisfactorily at voltages between 96 [%] and 104 [%] of the rated voltage and
with variations in frequency of +/- 2 [%] of the nominal value.
For the connection, proceed as shown in Figure 7.1-1.
Figure 7.1-1 – Electrical connections
7.2 Connection to the electrical signals for

management of automation
In order to operate, the machine must be connected to external signals so that it can be shut
down if the conditions outside the machine do no allow it to operate.
This connection can be made in two ways
• Connection to the signals of the external levels (see paragraphs 2.3.4)
• Management by means of remote control signal (see paragraph 2.3.7)
In both cases, one or more electrical signal cables need to be connected in the main panel of the
machine
Connection of the signals is the duty of a skilled electrical maintenance

technician.
Refer to the machine wiring diagrams for the information required to connect
the signals in the panel
54 TC 15000
The connection to the minimum level signal of the tank of the liquid to be
treated (signal LS11) is OBLIGATORY since it keeps the machine from running
dry
Make electrical connections with the power supply to the electrical panel
disconnected.
MAKE SURE you properly tighten the connection terminals on the electrical
panel.
7.3 Connection to the pneumatic network

It is necessary to provide a polyethylene connection hose 12 X 9 mm for the compressed air line.
The connection must meet the following requirements.
Pressure [kPa] 600

3
Flow rate [Nm /h] 4
3
Flow rate if optional II is also installed [Nm /h] 7
The compressed air has to be dry (not lubricated) and with dew point of 5 [°C].
It is necessary to arrange for a suitable isolating switch upstream the connection, allowing to
isolate the machine from the pneumatic feeding source.
The following figure shows the point of connection to the air supply. It also indicates the valves for
adjusting the pressure in the various branches of the machine’s compressed air circuit.
Figure 7.3.1 - Air connection

TC 15000 55
The compressed air must meet the characteristics shown in the previous table.
The connection to the compressed air system is to be carried out by a

mechanical maintenance technician qualified by the user.
The air provided must have the characteristics of humidity set forth by current
standards.
The supply MUST BE sourced from a centralized distribution system that can
continuously deliver air at a pressure in accordance with the established limits,
even in more extreme load conditions.
The pressure gauge PI12 connected to the pressure reducer PCV12 must show
a pressure between 450 and 650 [kPa]. If the pressure is less than 450 [kPa],
an alarm is automatically activated.
The pressure gauges PI13 and PI14 associated with pressure reducers PCV13-
14 should indicate a pressure indicated between 250 and 300 [kPa]. In the
event of lower pressure the pumps G06 and G07 may not operate correctly. If
the pressure is higher, the pumps may be damaged.
7.4 Plumbing connections

Machine has the following plumbing connections to process lines and to service networks detailed
in the attached drawing TC15000_LYT-NN (SEC. B). Connection numbers and symbols match with
the ones detailed in the attached P&ID.
The following table describes the minimum or maximum distance of the process liquid storage
tanks that are connected to the machine.
ID Description Max distance Max. head
[m] [m.w.c.] with
water (density =
1[kg/dm3])
1 Feed 10 2 (min) (*)
2 Concentrate 10 10
discharge
3 Distillate discharge 20 10
4 Wash water Mains pressure between 1.5 and 3 bar
8 Antifoam 5 0
9 Additive (optional) 5 0
Table 7.4-1 – Fluid connections

(*) minimum force on intake of feed pump G02
Figure 7.4- provides a visual depiction of the information above. Be sure to read and follow it
carefully. For numbering, refer to table detailed on the attached drawing TC15000_LYT-NN (SEC.
B).
56 TC 15000
Figure 7.4-3 – Summary figure of connections

Concerning the letters that appear in the diagram, refer to the comments below.
The distillate discharge line must not have any
siphons, i.e. paths of the tubes which would
cause them to drain by the force of gravity.
A Provide a valved bypass on the distillate
discharge line in order to make distillate
recirculation possible
Provide a valved measurement point on the
concentrate discharge line in order to make it
possible to measure the amount of concentrate
that is discharged. In order to have a
B measurement that is as representative as
possible, place the measurement point as near
as possible to the arrival point at the tank of
the discharge tube.
On the wash water line, provide a detachment
in order to have water available during the
C operations of routine and special maintenance
of the machine
As shown in paragraph 3.1, provide for the use of a filter on the intake line of
the liquid to be treated. Due to the nature of the treated liquids, the filter must
be provided by the user.
In general, any suction filters fitted should not rest on the bottom of the
storage tank of the liquid being treated, but rather should be raised a few
dozen centimetres, to avoid picking up sediments or sludge.
It is recommended to avoid winding paths for the connection tubes.
TC 15000 57
Be sure to use tubes made of material that is suitable for the temperatures and
chemical composition of the carried liquids.
Since it is necessary periodically to check the volume of the concentrate and

distillate released by the machine (see par.11.3), be sure to place the lines so
that it is possible to discharge these liquids in containers suitable for measuring
or, as an alternative, to provide suitable instruments on the connection lines
themselves.
The tubes and fittings for the fluid connections must be prepared by a qualified
mechanical maintenance officer provided by the user, who shall proceed as
specified.
For both the distillate and the concentrate, the drain tubes should not be
immersed in the stored liquid.
It is recommended to avoid winding paths for the connection tubes.
7.5 Arrangement of ventilation and vents

See the description in par.4.1.3.
7.6 Connection of optional devices

The optional devices are controlled by the machine via direct connection to the terminal blocks in
the main electrical panel, in the junction boxes or alternatively by the external connectors located
on the side.
Some optional are installed directly by the manufacturer.
The connections to the control panel must be prepared by qualified installation

technicians.
The type of connection depends on which optional devices are featured on the
specific model. For the identification of the connectors and for further details on
the connection of such optional devices, refer to the wiring diagram.
Each connected accessory sends to the evaporator an alarm signal to indicate if
there are any failures. These signals, managed by an electrical contact, must
also be connected to the machine
58 TC 15000
8 Start-up and commissioning
CHAPTER 8
Commissioning and start-up operations involve the following steps:
• External cleaning;
• Preliminary checks;
• Start-up in stand by mode;
• Pre-startup checks;
• Test with tap water;
• Stopping procedure in stand by mode;
• Stopping procedure;
• Start-up with the processed liquid.
8.1 References to the machine

The normal working position of the operator is in front of the command terminal of the machine
(see the following figure).
Figure 8.1-1 – Front side of the machine and working position
8.1.1 External cleaning

When the connections to the process liquid supplies and to the auxiliary
supplies are complete, and prior to start-up, the installer cleans the machine.
When the maintenance operations are over, the mechanical operator has to
accurately clean the machine.
TC 15000 59
Start-up and commissioning 8
During normal working conditions, the machine operator has to accurately clean
the machine before starting to use it periodically.
The cleaning of the main switch board and of the control panel has to be
carried out carefully.
During cleaning operations it is recommended to use an air compressed jet

and a dry cloth. Furthermore, it is recommended to verify that there are no
traces of oil or other liquids on the various components of the machine:
eventually use a dry cloth to remove them.
8.1.2 Preliminary checks
Preliminary checks are carried out by the installer when the machine runs for
the first time or when exceptional maintenance operations are made.
The operations to do are:

• Check of plumbing connections. Check that all pipe unions are tight
• Check the pressure of the pressure reducers PCV12-14 (if corresponding optional are
installed). Eventually carry out the necessary adjustments.
• Check of the positioning of the manual valves (see Table 8.1.1).
• Check of the electric connections (see installation manual). Check the correct fastening of
the electric terminals that may be loosen during the transport. It is necessary the
assistance of a qualified electrical operator.
• Check the connection of the auxiliary devices. Eventually reconnect the connectors to the
auxiliary devices.
The positioning of manual valves is checked by the machine operator when he

carries out maintenance operations.
Process liquid valves

Description Position
V01: shut-off valves of the feeding lines open
V25: drainage of the feeding pipeline closed
V22, V40: shut-off valves of the antifoam line open
V23, V41: shut-off valves of the additive line open (if provided the additive
metering), otherwise closed
V19-21: shut-off valves of the boiling chamber D01 sensor and open
sight glass washing line
V24: drainage of the boiling chamber D01 closed
V07, V08, V33: shut-off valves of the concentrate circulation open
line
V46: shut-off and deviation valves of the fluxing pump lines open
V15-16: shut-off valves of the distillate discharge line open
V13: drainage of the distillate tank D02 closed
V12, V34, V35, V36: drainage of the heat exchangers closed
60 TC 15000
V31, V11: shut-off valves of the liquid injection line into the open
blower suction
V29-30: shut-off valves of the density sensor open (if optional I is installed)
Table 8.1.1 – Positioning of manual valves
For further information about the functioning of the above mentioned valves,
see chap.2
8.1.3 Start-up in stand by mode
The first start-up procedure in the user site is carried out by the installer during
the installation.
The start-up procedure is carried out by the machine operator every time that
the machine has to restart the treating process.
To identify the position of the main switch board (A), the main switch (0/I) and the control panel
(C).
Figure 8.1-2 – View of electrical panel

• Turn on the machine by switching the main switch “0/I” on the main board A to position
“1”.
• The control panel shows the first standard display page and reaches the stand by mode or
goes in an alarm situation.
TC 15000 61
• The control panel shows the main menu display page. At this stage the machine can run
pressing, for some second, the START button in the CYCLE CONTROL menu.
If the alarm LED is lighted and indications appear on the control panel (C), it is
necessary to fix the alarm causes and correct the settings as explained chap.10
.
8.1.4 Pre-start checks

Pre-start checks are carried out, with the machine in stand by mode, by the
installing operator when the machine is started for the first time or every time
that exceptional maintenance operations are required.

• Check of the rotation direction of electrical motors through a manual operation. Since the
motors were wired at the time of installation, it is necessary to check the direction of
rotation of the pumps, the fans and the blower, turning them manually (see chapter9). If
this does not happen, turn off the machine, take off the power and invert the phases of
the electric supply in the main switch board (see the electric wiring diagrams attached).
The user's qualified electrical maintenance technician must provide assistance to invert the
phases if necessary.
• Check of the settings for the machine use in compliance with user indications.
• Check of maximum misalignment blower-motor, as described in the attached manual of
the coupling.
The maximum misalignments blower-motor of TC 15000, having the coupling
model B200 with 1500 rpm, are:
- axial misalignment: 2.54-5.08 mm
- radial misalignment: 0.25 mm
For further information on the checks to do on the coupling alignment see

enclosed coupling manual (see chap. 13).
8.1.5 Test with tap water

The machine is subjected to a complete running test with tap water at the manufacturer’s factory.
During the test, a certain number of standard values are set to make the machine correctly work.
These values will in any case by checked during the installation phase.
This type of test is carried out by the installer when the machine is started for
the first time or when especial maintenance operations are required.
The aim of this test is to verify that, after the transport and the assembly phases, the machine
runs properly and is able to reach the performance obtained during the test.
For further information see enclosed test sheets (see chap. 13).
With the machine off, the installer follows these instructions:

• Connect the supply of the machine to a mains water outlet. This operation has to be
carried out with the help of the mechanical operator supplied by the user;
• Fill the distillate collection tank D02 with mains water up to the working level (see par.
9.9.5);
• Check the eventual presence of alarms on the control panel and fix them (see chap. 10);
• Start the treatment cycle (see par. 9.8)
62 TC 15000
The start-up of the machine leads to:
The start-up of the machine leads to:
• heating of the liquid charged in the machine
• filling the machine up to the work level
• activation of the feeding recycle configuration
• heating of the liquid in the boiling chamber
• start of the blower and distillation
After the start up phase, it is necessary further time so that all the machine parts reach the final
temperature and a steady state is reached.
At this stage the installer verifies the running of the machine and records the functioning
parameters in order to compare them with the parameters obtained during the test phase (see
attached test sheet).
8.1.6 Stopping procedure in stand-by mode

The installer checks the correct functioning of the stopping procedure when the
machine is started for the first time or when special maintenance operations are
required.
The machine is supplied with a stopping procedure which takes the machine in a stand by mode
The stand by condition doesn’t mean that the machine is turned off or not
active: the machine may restart suddenly and some parts can be under
voltage. Do not accomplish any intervention on the machine in this condition
without the turning off whit the main switch.
The stopping procedure is activated:
• for the intervention of the external tank levels(LOW level in the supply tank, HIGH level in
the distillate tank)
• by means of the remote command signal
The steps which characterize the stopping procedure are:
• deactivation of all the logic systems of the machine
• activation of the boiling chamber liquid circulation system with pause/work
• activation of the blower suction condensed liquid discharge
The main switch has to be used to stop the machine just in emergency case.
8.1.7 Shutdown procedure

The installer checks the correct and complete stopping procedure of the
machine when it is used for the first time, assisted by the user's personnel in
order to make the first adjustment.
The machine operator stops the machine when the treatment of the liquid is
over.
The machine may be set in stand by mode or may be turned off in definitive mode.
To turn off the machine it is necessary to press, for some second, the STOP button in the CYCLE
CONTROL menu. Then it is necessary to take off the current working on the main switch setting it
on “0” position (see Figure 8.1-2).
TC 15000 63
Before cutting off the power with the main switch it is compulsory to do the
stopping procedure of the machine.
8.1.8 Start up with the processed liquid

The installer starts the treatment with the liquid to be processed when the
machine has to be run for the first time and he is helped by the user
personnel in order to do the first regulation.
The machine operator starts the treatment of the liquids and sets the
operating parameters of the machine to better satisfy his own requirements.
The aim of starting this treatment is to set the machine in order to concentrate the liquid to be
treated in compliance with the user requirements. The steps are:
• connect the machine to the line of the liquid to be treated;
• Check that there is a sufficient amount of liquid to treat;
• Check that the anti-foam tanks are full (or those for additive, if the optional are present);
• start-up the machine, which leads to feed the liquid to be treated until the working level is
reached;
• heating of the liquid to be treated, the blower K01 starts and starting of the distillate
production;
• the distillate produced is discharged and the liquid to be treated in concentration phase is
continuously reintegrated;
• regulation of the settings which command the discharge of the concentrate liquid which
will be used by the user (see par.9.8 and 11.2.2).
The process settings must always comply with the contract specifications, and
they must be compatible with the type of liquid treated and the limits of use of
the machine. Before starting the machine, carefully establish the concentration
factor “R” (par.11.2.2) with which the machine is to operate.
On the supply line (1) there is a calibrated bottleneck (H06 on the process
diagram). If the machine is not able to be supplied with a sufficient flow rate,
widen it
On the distillate discharge line (2) there is a calibrated bottleneck (H10 on the
process diagram). If the machine is not able to discharge the produced
discharge with a sufficient flow rate, widen it
Refer to par. 11.2.2 for further information on this.
64 TC 15000
9 Control and signal devices
CHAPTER 9
As mentioned previously, the operation of the machine is supervised and managed by a PLC
(Programmable Logic Controller).
The PLC controls a series of systems for the automatic operation of the various parts of the
machine. These systems control and manage:
• the automatic operation of all the functions based on the preset sequences;
• the measurement and the monitoring of the various I/O (input-output) signals from the
sensors, measurement devices, etc.;
• the automatic stopping of the machine in the event of anomalies or faults;
• the automatic stopping of the machine when there is no liquid to be treated or if the
maximum level is reached in the distillate or the concentrate storage tanks;
• the essential diagnostic indications for the operator.
In the control and the management of the machine the operators essentially interact with the
devices on the main electrical panel cabinet, and in particular with the control terminal.
If the door of the electrical panel is open, three red lights flashing at the top
right signal that power is connected.
TC 15000 65
Control and signal devices 9
9.1 Main electrical panel cabinet

The door of the main electrical panel features a number of control and signal devices, as shown in
the following figure:
Figure 9.1-1- Components in the main electrical panel

Symb Description
ol
1 “24Vac” white indicator light. When on signals the presence of the auxiliary AC power
supply.
2 “24Vdc” white indicator lights. When on they indicate the presence of the auxiliary DC
power supply.
3 Green indicator light. When on signals that the machine is on and is operating correctly.
4 Red indicator light. When on signals that the machine has stopped due to an alarm.
5 White indicator light. When on signals that the machine is in standby (e.g. insufficient
level in the external supply tank).
6 Control terminal. Allows the machine to be used by the operators.
7 Main switch. Lever disconnecting switch that controls the power supply and turns the
machine on (position 1) or off (position 0). It also acts as a door lock, preventing access
to the electrical panel when powered. For special operations, this switch can be locked in
position “0” to prevent work from being performed when the machine is live, or
alternatively the door lock can be disabled to allow work to be performed with the
cabinet open and power connected.
8 Alarm indicator light.
9 Handle for opening the doors on the electrical panel.
66 TC 15000
10 Fans for cooling the components inside the electrical panel.

11 Air outlet for venting the hot air.
12 Button that immediately stops the machine in the event of an emergency: pressing this
button deactivates all the PLC outputs (immediately stopping all the electrical utilities
connected to the panel and controlled by the PLC)
9.2 Control terminal

The terminal is fitted to the door of the main electrical panel cabinet, at the front and in a position
that is easily accessible to the operator.
It is used to perform the operations required for the operation/supervision of the machine. This is
a touch screen terminal: consequently, all the functions are displayed graphically on the screen.
The control terminal must only be used by qualified and/or suitably trained
personnel, who are able to correctly evaluate the consequences deriving from
any changes made.
9.3 Using the control terminal

9.3.1 Modifying numeric or alphanumeric data
To modify the data in a numeric or alphanumeric field associated to a parameter, select the field,
then:
• display the screen containing the parameters to be modified;
• press the field to be modified so as to activate programming mode: a virtual alphanumeric
keypad is displayed at the bottom;
• enter the new value using the alphanumeric character buttons;
• press the enter button to confirm the new settings and exit programming mode, or
alternatively the esc button to exit programming mode without saving the changes made.
To modify the data a password must first be entered.
9.3.2 Modifying a selection field

To modify a data from a range of predefined options in a field associated to a parameter, select
the field and then:
• Press the icon corresponding to the selection field (ON/OFF, choice of two option, ...) to
activate the programming mode choice.
To modify the data a password must first be entered.
9.4 Video pages

The operator interacts with the control terminal by means of a series of pages shown on the
central display. The fields of the terminal may be divided into:
• Display-only numeric fields;
• numeric fields modifiable;
• limited selection fields (ON/OFF) that can be modified on entering the user password;
these are highlighted with a green line;
TC 15000 67
• limited selection fields (ON/OFF) that can be modified on entering the ADV password
known to the manufacturer or the service centres; these are highlighted with a blue line;
The screens must only be used by qualified and/or suitably trained personnel,
who are able to correctly evaluate the consequences deriving from any
changes made.
9.5 Opening video page
The control terminal display, during normal operation or when the machine is started, shows the
opening screen, which describes the identification of the machine and the manufacturer, the
system date and the time, as well as the current operating status.
From this page it is possible, to reach the successive page pressing on the key right arrow or to
select the language pressing on the flag of the nation.
The operating status of the system is shown by the text with the yellow background. These rows
may have the following values:
Machine in cycle: awaiting distillate tank heating
Indicates that the liquid in the distillate storage tank D02 is being heated by the heaters ER01-03.
Machine in cycle: awaiting boiler working level
It indicates that the machine is in stand-by due to the boilers low working level; once the suitable
level is reached, pump G01 will start working, while feeding pump G02 will cease to work.
Machine in cycle: awaiting waste heating in boiler
Indicates that the distillate discharge pump G03 and circulation pump G01 are operating in recycle
mode and the liquid is being heated in the boiler via the heat produced by the electric heaters
ER01-03.
Machine in cycle: awaiting oil blower heating
68 TC 15000
It indicates that the machine is in stand-by due to the low blower oil temperature.
Machine in cycle: awaiting distillation start level
Indicates that the machine has been started but is in stand-by due to the activation of the level
controller, which indicates the beginning of distillation; once the suitable level is reached, pump
G03 will start draining the distilled produce, valve VP03 will be closed and pump G02 will initiate
the continuous supply of the liquid to be treated.
Machine in cycle: evaporation in progress
Indicates that the machine is normally operating.
9.6 Video pages of the main menu

9.6.1 Display pages tree
The display pages are arranged according to a tree structure shown in the following figure:
TC 15000 69
Figure 9.6.1 - Display pages tree diagram

To make the understanding easier, just the main connecting lines are here reported, as some
commands can be used to skip some steps or levels. During the start up phase, the main display
page shows the command that allows to move to the main menu. From the main menu it is
possible to go to other display pages where functioning data and settings are reported.
9.7 Main menu

Pressing the right arrow button in the initial page, the main menu screen will be displayed.
70 TC 15000
The Reset alarms button does not open a submenu, but simply cancels all the
alarms that have been activated and allows the treatment cycle to resume. This button has no
effect if the causes of the alarm are still present. This key is visible in several screens. The
description of this key will not be displayed again.
From this screen it is possible to reach other screens in order to control various functions displayed
on the operation board. The main menu is divided into submenus so as to organize the functions
displayed on the operator panel, taking into account the frequency with which they are used.
Each following page also features the button or the button that return back
to the previous pages.
Below is a description of the submenus that are accessed by pressing the corresponding button.
The pages in the ADV menu (blue line at the top), that is, those containing data that con only be
modified on entering the ADV password, are not described in this manual.
TC 15000 71
9.7.1 Events
When an event like this occurs, it is saved in the plc memory. An event is something (power
on/off, presence of an external signal, etc.) that does not prejudice the machine functioning. The
plc stores the last 30 events.
Line Description
1 The column Nr. contains the code of the event
The column hour shows the time of the event
The column date shows the date of the event
2 Shows the description of the event
3 The column Nr. contains the code of the event
The column hour shows the time of the event
The column date shows the date of the event
4 Shows the description of the event
72 TC 15000
9.7.2 Machine info
This screen is used to enter the data regarding:

• the machine serial number, that is, the unique number that identifies the evaporator
• the machine code, that is, the number that identifies the design
• the code of the wiring diagram
• the code of the programme installed on the PLC
• the code of the programme installed in the HMI (operator panel).
TC 15000 73
9.7.3 Recipes
This screen is used to save, restore and delete the collection of machine settings run in the form of
“recipes”. The recipes can be used to quickly modify the settings and change the operating
conditions of the machine according to the nature of the liquid being treated, or according to the
type of product desired.
If recipes have been saved, pressing the button corresponding to the List option displays a screen
listing the recipes, in increasing order by code.
A recipe can be selected from the list using the buttons to the side to confirm the selection.
Pressing the Restore button loads the currently selected recipe on the list into the PLC memory,
rendering it active. The loading of a recipe involves the creation or the updating of a recipe with
the same settings and the same description as the recipe loaded, but using the code AUTO. This
recipe with the code AUTO is automatically loaded by the PLC when the machine is started the
next time.
Pressing the Save button after having modified the code and/or the description of the recipe saves
the recipe with all the current user settings to the PLC memory.
Pressing the Delete button deletes the current recipe from the memory.
74 TC 15000
9.7.4 Maintenances
From this menu, the user can access the pages described below relating to the planned
maintenance operations. When the date planned for the operation expires, the information
message is displayed, warning the operator to perform the maintenance operation.
Each of the following pages can access the other maintenance pages using the corresponding
buttons.
TC 15000 75
This page displays the data concerning the maintenance of the electrode CE01 that measures the
conductivity of the distillate. Refer to par. 11.3.6 for details on how to perform the maintenance.
The following are displayed:
• the date maintenance was last performed: this must be updated when the maintenance is
completed
• the date planned for the next maintenance: this is calculated by adding the period (next
field) to the last date
• the period that elapses between successive maintenance operations, expressed in
days/months
76 TC 15000
This page displays the data concerning the blower lubricating oil change (only for the substitutions
subsequent to the first, for the first one see maintenance 3), according to the number of operating
hours.
At any oil substitution (included the first one), it is necessary to enter in the first row the number
of hours elapsed from the previous oil change.
Refer to the blower manual enclosed for details on how to perform the maintenance.
For the explanation of the fields on this page, see the previous page.
TC 15000 77
On this page the manufacturer sets the blower operating time after which the lubricating oil needs
to be changed for the first time. Once the set number of hours has elapsed, the information
message (Message code 68) is displayed to warn the operator that the planned maintenance
should be performed; this message appears only at the first change of oil, for the following
substitutions Message code 67 appears.
Once completed, press the Confirm maintenance carried out button to start the machine again.
It is further nececessary to recopy the value (hours) displayed in row 2 of this screen in row to of
the previous screen (maintenance 2) in order to start the count for the subsequent oil substitution.
78 TC 15000
9.7.5 Tele-maintenance
The machine is fitted with a modem for connection to the GSM mobile network and also with a
SIMM enabled for data transfer; the following operations can be performed
• in the event of alarms, send an SMS to the two numbers set on this screen
• make a remote connection to the machine via modem to perform tele-maintenance from
the manufacturer’s offices
Choosing the ability buttons (NO/YES) to enable the SMS messages, activates the service for the
adjoining number.
The SMS Reset button is used to empty the modem memory of any unwanted AT commands
accumulated.
The Test SMS button sends a test message to the numbers set.
The reference number for the centre of competence is displayed in the yellow area of the Service
centre number.
TC 15000 79
9.7.6 Password
This page is used to enter the password for modifying the data.
The first field is used for entering the password, the second for the duration, and the third for
modifying the password.
If the password is changed it should be noted down and kept in a secure place. The default
password for the client is “00001”.
The field with a yellow background displays the current status of the password, which may be:
• Lookup: the password has not been entered or the duration of the password has elapsed; in
this mode, no interaction is possible with the machine via the operator panel, but rather the
data can only be displayed
• Edit user data: the user data, highlighted by a green line, can be modified
• Edit ADV data: reserved for the manufacturer’s service personnel, displays the contents of the
various pages and allows all the machine operating parameters to be modified (including the
reserved parameters highlighted with a blue background).
The field with a yellow background “cpwd” displays the floating password counter.
The button , in the following pages, returns to this page to change the password.
80 TC 15000
9.7.7 ADV settings

When the Optional key is pressed, the following screen is displayed:
This page is used to enable any options installed on the machine. This informs the PLC and
consequently activates the corresponding procedures.
Pressing the Ethernet module button on the main menu the following page appears:
TC 15000 81
In this page it is possible to configure the Ethernet protocol parameters, if the ETHERNET
communication optional system and communication cable to the required network are installed.
• IP address, is the address of the require connection network
• Subnet mask is another identification parameter of the require connection network
• Coupling to other net indicates the coupling mode to the guest network that can take place
“without router” or “with router”.
• Router address
Once the three above lines parameters are set, pressing key “Send to CP ETHERNET” allows
start up and test of communication.
82 TC 15000
9.7.8 Alarms
Selecting ADV displays the following page:
This page is used to set the common values of the alarm activation delays (level, temperature,
pressure and compressed air). When the values read by the sensors exceed the alarm thresholds
set in the corresponding pages, the times set here must elapse before the alarm is activated.
9.7.8.1 Alarm history

Shows the alarm history (see par. 9.12.2 for details).
TC 15000 83
9.8 Cycle control
This page can be reached from the main menu (see par. 9.7) and from the machine synoptic (see
par. 9.9).
From this screen it is possible to switch the machine on or off by keeping the START or STOP
keys pressed for a few seconds, and to choose the concentrate draining mode by pressing the icon
VOLUME SETUP or DENSITY SETUP: the hand switches from one mode to the other at each
touch, the selected button turns green, otherwise it stays red; the DENSITY button remains grey
and cannot be selected if the optional density measuring system is not installed and enabled.
Pressing the Volume setup button opens the following page:
The settings of the concentrate drain parameters are extremely important for
the operation of the machine, and consequently the data entered must be
correct and the concentration ratio must be suitable for the type of process and
fluid supplied: incorrect values may affect the operation and condition of the
machine (see par. 11.2.2).
84 TC 15000
This page is used to set the parameters for the volume drain mode:
• Discharge time, this is the duration in seconds of the discharge of concentrate, as the time
of opening of the valve VP07
• Volume discharged, shows the number of litres of concentrate discharged in each cycle.
• Concentration ratio is the ratio between the flow-rate of concentrate and liquid supplied
(expressed in the form of 1/R, with the denominator R being entered)
For details on the parameters to be entered, see par. 11.2.2.1.
In this page are featured:
• the distillate to discharge, calculate based on the discharged volume and the concentration
ratio;
• the distillate discharged, which shows the distillate litres discharged when the
INITIALIZE button is pressed.
When the distillate discharged reaches the distillate to discharge, the machine begins to unload the
concentrate. By pressing the INITIALIZE button, the counts of the distillate discharged (in this
page) and the total litres of distillate produced, in the Operating data page, are set to zero.
By pressing the Density setup key, the following screen will be displayed:
TC 15000 85
The page shown above is used to set the parameters for the density drain mode (if the optional
system of density is installed and certified):
• density of concentrate discharge is the desired density corresponding to the start of the
concentrate drain cycle
• delta density at end of discharge is the value of density that, subtracted from the start
drain density, corresponds to the density at which the concentrate drain cycle is stopped
• Discharge working time, this is the duration of discharge as the time of opening of valve
VP07
For details on the parameters to be entered, see par. 11.2.2.2.
By pressing the Alarm setup key, the following screen will be displayed:
86 TC 15000
This page is used to set the minimum allowable production of distillate: if the flow-rate of distillate,
measured by the sensor FT01, remains below this value for a time greater than the value set for
the efficiency control delay, the corresponding alarm is activated and the machine stops, showing
an alarm.
TC 15000 87
9.9 Machine synoptic

From the main menu, pressing the Synoptic button opens a menu for displaying and setting all
the process variables.
Each rectangle represents a button that opens a page corresponding to the component or the
assembly displayed in the drawing.
The Cycle control button refers to page that is also accessible from the main menu.
The Additive and Densimeter buttons refer to the pages for the optional systems.
The following pages feature:
• the button, which returns to this page;

• the ADV button opens the pages reserved for the operators authorised by the
manufacturer.
The keys that are marked with a pointing hand are the MANUAL CONTROLS. Pressing them will
activate the indicated machine component. The control remains active as ling as the key is
pressed, while the indicator light at lower right, if green, indicates that the component is active
(not only for manual control but also for automatic control by the PLC).
88 TC 15000
9.9.1 Boiler D01
This page displays:

• the pressure in the boiler, approximated here as the blower K01 suction pressure
measured by the sensor PT01
• the temperature in the boiler, measured by the temperature sensor TT01
• the status of the three levels of the boiler LS01 (green if immersed), LS02 (green if not
immersed) and LS03 (green if immersed).
The manual command Vent incondensable gases, opens the valve VP04 located on top of the
exchanger E01.
The vacuum break manual control opens the valve VP12 located above the boiler D01.
Press the VENT VP04 key on boiler D01 visualization screen to move on to the second level,
which displays:
TC 15000 89
This screen is used to set:

• the suction pressure of the blower K01 above which the venting of the pneumatic valve
VP04 is activated
• the pressure below which venting is deactivated
• the valve opening time in a pause/work cycle during the venting procedure
• the pause time in a cycle
Press the BREAK VACUUM key on boiler D01 visualization screen to move on to the second level,
which displays:
90 TC 15000
This screen is used to set:

• the working frequency of blower K01 at which the vacuum break valve VP12, which
activates along with the blower, stops operating. In this phase, the valve operates
according to the open/close cycle whose times are established in the lines below. The
opening of this valve prevents foam in the boiler.
• duration of opening of valve VP12 for each opening cycle
• interval of time between two successive openings of the pneumatic vacuum break valve
VP12
• the working frequency of the blower at which, during the phase of machine shutdown, the
valve VP12 stops operating
Selecting the boiler button opens the following page.
TC 15000 91
This page is used to set the variables that relate to the operation of the boiler D01:
• Boiler working temperature: this is the temperature above which the heating of the liquid
in the start-up phase is considered concluded and the blower K01 is started
• boiler volume: represents the volume of fluid present, during working phase, inside the
boiler D01
• Temperature max. Manual discharge: when the temperature in the boiling chamber has
passed this value it is not possible to activate manually the concentrate discharge. This is
made in order not to damage the connection tubes with an over-heated fluid
• Boiler maximum working pressure: if the pressure in the boiler does not fall below this
value after the time set in the following field, the machine stops and the maximum boiler
pressure alarm is activated.
• Max time to reach the boiler evaporation pressure: see the previous field.
• Boiler low temperature: this is the minimum temperature in the boiler, below which, after
the set delay, the corresponding alarm is activated
• Low temperature alarm delay: this is the delay after which the low temperature alarm is
activated
• Boiler high temperature: this is the maximum temperature in the boiler, above which, after
the set delay, the corresponding alarm is activated
• High temperature alarm delay: this is the delay after which the high temperature alarm is
activated
Selecting Sensor parameters opens the following page:
92 TC 15000
The data entered here must not be changed from the factory settings.
The internal value is the value read by the PLC, based on the figures coming from the probe, which
will be transformed into temperature based on the scale set below.
TC 15000 93
9.9.2 Blower K01
This page shows all the variables that refer to the blower K01:
• current input
• speed rotation in rpm (revolutions per minute) and frequency in Hz
• Number of hours the blower has been functioning (should this information be lost, there is
a mechanical gauge in the electric board).
• Temperature of lubricating oil on gear side measured by sensor TT07
• discharge – suction pressure differential, measured by the sensor DPT01
• suction and discharge pressure and temperature, measured by the sensors PT01, TT03,
PT01+DPT01, TT04 respectively
When the ADV SETUP key on the blower visualization screen is pressed, the following screen is
displayed:
94 TC 15000
This page shows the process diagram of the steam circuit.

Selecting the components enclosed by a blue rectangle accesses the corresponding pages that
show the sensor parameters. The data on these pages relating to sensors PT01, DPT01, TT03,
TT04, and TT07 must not be changed from the factory settings.
Pressing at pump G05 shows the following screen.
TC 15000 95
This page is used to set the following variables:

• delivery temperature for ON, the delivery temperature of the blower K01 above which the
liquid intake injection system is activated on the blower K01; during the operation of this
system, the solenoid valve EV17 and the pump G05 are activated with pause/work cycles
• delivery temperature OFF, the temperature below which the liquid injection system is
deactivated
• VP17 working time, the duration of the injection phase during the pause/work cycle
• VP17 pause time, the duration of the pause in the pause/work cycle
• delay start of control VP17, the delay time for the activation of the injection system after
the threshold set in the first row has been exceeded
• delay end of control VP17, the delay time for the deactivation of the injection system from
when the delivery temperature falls below the value set in the second row
The manual command that allows the activation of pump G05 and valve VP17 is displayed at
bottom right.
When the Blower K01 key is pressed, the following screen is displayed:
96 TC 15000

• Minimum oil temperature (TT07), the temperature that the lubricating oil in the blower
K01, measured by TT07, must reach within the time set in the fifth row
• Minimum blower stop frequency is the minimum frequency at which blower K01 will stop.
• Delta Pressure minimum regulation frequency is the minimum frequency at which the
inverter that controls blower K01 must function, when delta pressure is above a certain
predetermined value.
• Delta Pressure maximum regulation frequency is the maximum frequency at which the
inverter piloting blower K01 must function, when delta pressure is below a certain
predetermined value.
• Maximum oil heating time, the maximum time that may elapse for the oil temperature,
measured by TT07, to exceed the value set in the first row
• Maximum oil temperature, the maximum acceptable temperature of the lubricating oil
• Maximum temperature in delivery is the maximum allowed temperature in delivery in the
blower; above this temperature the evaporation cycle is interrupted.
When the DP Regulation key is pressed, the following page is displayed:
TC 15000 97

• Starting ramp time, the time in which the blower K01, at a standstill, must reach the final
rotation speed
• Stop ramp time, the time in which the blower K01, from operating speed, must gradually
shut down.
• Rev decrease pressure delta, the differential pressure of the blower K01 measured by
DPT01 above which the rotation speed must decrease by one step
• rev increase pressure delta, the differential pressure below which the rotation speed must
increase by one step
• regulation step, the amplitude steps of increase or decrease of rotation speed of K01
• step delay, the delay that must elapse from when the conditions occur to increase or
decrease by one step the rotation speed of K01
The manual command that allows the setting of blower K01 rotation speed, as a percentage of
the maximum value, is on the bottom right.
Selecting, on this page, ADV Alarms displays the following page:
98 TC 15000

• high pressure delta pre-alarm, the blower differential pressure pre-alarm threshold; if this
is exceeded, an information message is displayed, which does not activate an alarm, but
rather warns the operator to check the correct operation of the machine
• high pressure delta alarm, the differential pressure alarm threshold; if this is exceeded, an
alarm is generated that stops the machine
• pressure delta alarm delay, the delay from when the two previous thresholds are
exceeded, after which the pre-alarm or the alarm is actually generated
When the Drying utility key is pressed, the following page is displayed:
TC 15000 99
The drying utility allows (when evaporation cycle is stopped) to evaporate liquid residuals that
could be found inside G01 blower casement. This in order to avoid corrosion phenomena inside the
impeller.
• Drying frequency is the rotating frequency of the blower during drying cycle. Centrifugal
force and generated heat eliminate all water residuals
• Pause time: indicates the pause time between two succeeding drying
• Work time: indicates the duration of a drying cycle
Selecting current ADV sensor opens the page for calibrating the blower current sensor: the data
entered on this page must not be changed from the factory settings.
100 TC 15000
9.9.3 Circulation G01
This screen is used to manually activate the circulating pump G01, as well as the flushing,
controlled by the pump G04.
The fields marked “SET” display the on and off times for the circulating pump when the machine is
in standby: this function is used to keep stirring the concentrate present in the boiler and in
recirculation, and consequently avoid any crystallization or solid deposits that may block the tubes
involved.
The fields marked “REAL” indicate the times that have effectively elapsed.
When the ADV SETUP key on the circulation pump visualization screen is pressed, the following
screen is displayed:
TC 15000 101
This page shows the process diagram relating to concentrate circulation. Selecting the button at
G04 shows the following page.
102 TC 15000
This page shows the time the fluxing pump G04 starts before the activation of the recirculation
pump G01.
9.9.4 Feed G02
This page is used to:

• manually control the supply pump G02
• view the speed of the pump G02, controlled by the inverter as a percentage of the
maximum speed.
When the ADV SETUP key on the supply visualization screen is pressed, the following screen is
displayed:
TC 15000 103
This page shows the process diagram of the supply circuit. Selecting the components enclosed by
a blue rectangle accesses the corresponding pages, described below.
The screen displayed when pressing at pump G04 has been previously shown.
Pressing the PROCESS key shows the page:
104 TC 15000
This screen is used to display or modify the following values:

• Speed of boiler filling: this is the speed (expressed as a percentage of the maximum revs
per second which can be reached by the motor that drives the pump) which is set during
the filling phase of the boiler.
• Speed in evaporation cycle: this is the speed (expressed as a percentage of the maximum
revs per second which can be reached by the motor that drives the pump) which is set
during the working phase. This speed is varied by the system based on the commutation
of the working level LS01.
• Minimum speed in evaporation cycle: this is the minimum speed (expressed as a
percentage of the maximum number of revs per second that can be reached by the motor
that drives the pump) to which the pump drops during the working cycle. This speed is
varied by the system based on the commutation of the working level LS01.
• Maximum speed in evaporation cycle: this is the maximum speed (expressed as a
percentage of the maximum number of revs per second that can be reached by the motor
that drives the pump) to which the pump drops during the working cycle. This speed is
varied by the system based on the commutation of the working level LS01.
• Adjustment step: expresses the variation in speed (expressed as a percentage of the
maximum number of revs per second that can be reached by the motor that drives the
pump) which the pump undergoes when during the work phase, sensor LS01 detects a
lack or a presence of water in the boiler. If there is a lack of water this step will result in
an increase in speed. On the other hand, if water is present, it will cause a decrease in
speed
• Adjustment delay: expresses the time delay between a detection of lack/presence of water
and the increase/decrease of speed of the pump
Selecting ADV Alarms from the pump G02 menu displays the following page:
TC 15000 105
The following values can be displayed and modified:

• maximum speed of pump G02: this is the speed above which the feed pipeline is
considered blocked
• maximum speed exceeded time: this is the time that must elapse with the speed of the
pump above the limit set for the alarm to be activated
106 TC 15000
9.9.5 Distillate D02
This page displays:

• the level of liquid in the distillate storage tank D02, measured by the sensor LT04
• the speed of the distillate discharge pump G03, controlled by the inverter, expressed as a
percentage of the maximum speed
• the distillate discharged litres, measured by the sensor FT01
• the distillate discharged flow-rate in l/h, measured by the sensor FT01
• the temperature of the distillate in D02, measured by the sensor TT02
• the conductivity of the distillate, measured by the sensor CE01
• the operating status of the heating elements ER01-05: on (green) or off (red)
The distillate discharge pump G03, at the flow-rate set in the manual flow-rate box, can be
activated manually.
When the ADV SETUP key on the distillate visualization screen is pressed, the following screen is
displayed:
TC 15000 107
This page shows the process diagram for the distillate storage and discharge circuit. Selecting the
components enclosed by a blue rectangle accesses the corresponding pages, described below.
The data on the pages relating to the sensors FT01, LT04 and TT02 must not be changed from the
factory settings.
Pressing at pump G03 shows the page:
108 TC 15000
The following values can be displayed and modified:

• supply flow-rate dead band: this is the range of flow-rates around the set value inside
which the pump rotation speed remains constant
• proportional gain for connection between the signal of the flow-rate measured by LT04 to
the pump rotation speed command
• integral time for connection of the signal of the flow-rate measured by LT04 to the pump
rotation speed command
• derivative time for linking the signal of the flow-rate measured by LT04 to the pump
rotation speed command
Pressing the key at tank D02 causes the following page appears
TC 15000 109
Pressing the key Heating causes the following page to appear:
The following data can be entered:
110 TC 15000
• distillate working temperature: this is the set point temperature to be kept inside the
distillate tank D02
• Temperature max. Manual discharge: when the temperature in the boiling chamber has
passed this value it is not possible to activate manually the distillate discharge. This is
made in order not to damage the connection tubes with an over-heated fluid
• temperature ER0x-ER0x ON: this is the temperature measured in the tank D02 below
which the corresponding heaters are on
• temperature ER0x-ER0x OFF: this is the temperature measured in the tank D02 above
which the corresponding heaters are off
Selecting the Levels key from the Distillate menu displays the following page:
This screen is used to enter the following values:

• distillate working level: this is the level to be maintained in the tank D02 by controlling the
distillate discharge pump G03
• distillation start level/distillate discharge: in the start-up phase, when this level is
exceeded, the distillation process is considered as having started and the cycle switches
from recirculation to discharging the distillate.
Selecting Alarms from the Distillate menu displays the following page:
TC 15000 111
The following variables can be entered:

• minimum temperature: this is the temperature in D02 below which the heating system is
considered faulty and the corresponding alarm is activated
• minimum temperature delay: this is the time that must elapse when the temperature in
D02 is less than the minimum set before the alarm is activated
• maximum temperature: if exceeded, the corresponding alarm is activated
• minimum level in D02 below which its relative alarm will be activated
• maximum level in D02: if this is exceeded, its relative alarm will be activated
112 TC 15000
9.9.6 Exchanger E02
This page displays the data involving the exchanger E02:

• the temperature in the boiler, measured by the sensor TT01
• the temperature of the distillate in the storage tank D02, measured by the sensor TT02
• the distillate drain flow-rate, measured by the sensor FT01
TC 15000 113
9.9.7 Concentrate discharge
This page displays the operation of the concentrate drain valve VP07. At the top left is the drain
mode, which may be by volume or density, as selected on the cycle control page (see par. 9.8).
The manual command of valve opening is at the top right. The on and off times for the operation
of the valve and the concentration ratio are displayed at the bottom (fields marked SET), as set in
the User Setup submenu of the cycle control page (see par. 9.8). The fields marked REAL display
the times that have effectively elapsed.
114 TC 15000
9.9.8 Antifoam
This screen is used to set the antifoam metering cycle in the boiling chamber: the fields marked
SET refer to the settings of the antifoam metering on and off times, while those marked REAL
display the effective time elapsed.
The ON/OFF command is used to switch on/switch off the antifoam metering cycle, while the
manual command that opens the pneumatic metering valve VP05 and controls the metering pump
G06, is at the top right.
The Extra metering antifoam configures the duration of the antifoam dosing when the evaporator
start the evaporation cycle. This avoids the formation of foam at the beginning of the cycle, that is
during one of the most critical periods for these phenomena.
The ON/OFF command “Foam control” is used to switch on/switch off the optional of the automatic
control of foam that works only if the same optional is enabled (see par.9.7.7).
Pushing the button SETUP ADV from Antifoam menu, the following page appears.
TC 15000 115
Here it’s possible to insert the following data:

• Delay time after which an alarm appears, if the foam sensor stays active.
116 TC 15000
9.9.9 Washing
This screen is used to set the operation of the washing cycles for the sight glass H02 and the level
sensor LS01 in the boiling chamber and the foam sensor SS01 in the boiling chamber. The first two
washing cycles are activated by the pneumatic valve VP10 and the last one by VP13. The fields
marked SET refer to the washing cycle on and off time settings, while those marked REAL display
the effective time elapsed.
The ON/OFF command is used to switch on/switch off the washing cycle, while the manual
command is at the top right.
TC 15000 117
9.9.10 Conductivity meter
This page displays the conductivity value of the distillate, measured by the sensor CE01. The high
conductivity alarm can be disabled on this page.
Pressing the User setup button accesses the following page:
118 TC 15000
If the maximum set value conductivity is exceeded, the alarm is activated and the machine stops.
The alarm exclusion time is the interval in which the conductivity measuring system does not
generate a new alarm after the previous alarm has been reset, using the Reset alarms command
on the main menu, and the machine has been restarted.
This time allows the machine to produce new clean distillate after having resolved the cause of the
alarm. The time starts counting after the machine has been restarted and reaches stable operating
conditions. If when this time has elapsed the conductivity of the distillate is still not below the
maximum value set, a new alarm will be activated on the machine.
When the ADV SETUP key on the conductivity meter visualization screen is pressed, the following
screen is displayed:
TC 15000 119
This is used to set the time that must elapse when the conductivity measured is greater than the
maximum value set for the activation of the corresponding alarm.
Selecting ADV Sensor accesses the page for calibrating the sensor: this data must not be
changed from the factory values; refer to the conductivity meter manual enclosed.
120 TC 15000
9.9.11 Additive
This screen is used to set the additive metering cycle in the boiling chamber: the fields marked SET
refer to the settings of the additive metering on and off times, while those marked REAL display
the effective time elapsed.
The ON/OFF command is used to switch on/switch off the additive metering cycle, while the
manual command that opens the pneumatic metering valve VP06 and controls the pneumatic
membrane pump G07, is at the top right.
TC 15000 121
9.9.12 Densimeter
This page displays the density of the concentrate measured by the optional densimeter DT01. The
instrument will not work correctly if the flow-rate passing through is not high enough.
When the ADV SETUP key on the densimeter visualization screen is pressed, the following screen
is displayed:
122 TC 15000
The following variables can be entered:

• set maximum density: this is the maximum acceptable density of the concentrate, above
which the corresponding alarm is activated
• high density alarm delay: this is the time that must elapse with the density greater than
the maximum set before the alarm is activated
• Densimeter anomaly alarm delay: delay time before any alarm condition concerning
instrument DT01 (densimeter) causes and alarm to be generated.
Selecting Sensor Parameter accesses the pages for calibrating the sensor: this data must not be
changed from the factory values; refer to the sensor manual enclosed.
TC 15000 123
9.10 Operating data
This section displays the machine data:

• External levels (if installed and connected to the electrical panel, respectively, LS11, LS10 e
LS12): green key with OK indication in normal conditions, red key with indication HIGH or
LOW and the machine in standby
• Remote control: the current status of the remote control is displayed
• Blower current indicator (measured inside the electrical panel, see the wiring diagram
enclosed)
• Flow-rate of the distillate drained, measured by the sensors FT01
• Litres of the distillate produced
To the right of the numeric fields there is a bar that also shows the end scale values of the
instruments.
Indications of minimum and maximum levels in the supplied and distilled tanks, and the OFF
signalling for the remote control both cause a situation of pre-alarm which puts the machine into
stand-by. The red maximum level key in the concentrate tank, instead, causes an alarm signal that
shuts down the machine.
Pressing opens the second page of the operating data:
124 TC 15000
The following data are indicated on this page:

• Blower K01 suction pressure, measured by the sensor PT01
• Blower K01 differential pressure, measured by the sensor DPT01
• Blower K01 delivery pressure, the sum of the two previous values
• Blower K01 suction temperature, measured by the sensor TT03
• Blower K01 delivery temperature, measured by the sensor TT04
• Temperature in the boiler D01, measured by the sensor TT01
• Temperature of the distillate in D02, measured by the sensor TT02
• Conductivity of the distillate, measured by the sensor CE01
TC 15000 125
9.11 User setup

9.11.1 Utility
Utility out of the machine working cycle for the user.
In this screen it is possible to directly fill up the boiler without activating the starting procedures
and to initiate reflux heating in the boiler (when the evaporation cycle is stopped), while keeping
liquid temperature within pre-established values (Temperature ON/OFF).
It is also possible to start (Drying blower ON/OFF) the drying cycle of the blower following the
parameters set in the par.9.9.2. The fields marked SET refer to the settings of the drying cycle on
and off times, while those marked REAL display the effective time elapsed.
126 TC 15000
9.11.2 Setup HMI
page 004
These pages display or modify (after having entered the password) the date and time set in the
operator panel.
The Empty alarm buffer button deletes the alarm log stored in the memory.
9.12 Alarm and information pages

9.12.1 Alarm pages and information messages
The alarm pages are displayed by the machine when an alarm condition arises, or alternatively
when the red button , that appears in the screen of the panel, is pressed (only when an
alarm condition is present). This button is active until all the causes of the alarms have been
resolved and reset using the Reset alarms button on the main menu. The alarms are
accompanied by an audible signal. The information messages, on the other hand, are displayed in
a similar way to the alarms.
The page is divided into two columns, similar in appearance to the screen shown below, and
displays four alarms at a time:
TC 15000 127
1 DESCRIPTION OF ALARM A
2
3
4
5 XXXX >DD-MM-YYYY HH:MM:SS

6 #DD-MM-YYYY HH:MM:SS
DESCRIPTION OF ALARM B
XXXX >DD-MM-YYYY HH:MM:SS

#DD-MM-YYYY HH:MM:SS
Row Description
1-4 contains the description of the alarm.
5 contains the code of the alarm (“XXXX”) and the date and time when the system
generated the alarm situation
6 contains the date and time when the alarm was muted
The scrollbar is visible on the right of the screen, as well as the X closing key with which it is
possible to return to the previous screen.
The alarms are shown in increasing order of activation date and time.
The alarms may be in active or muted status. The active status means that the control terminal
emits an intermittent audible signal. The active alarms are displayed with a triangular danger
symbol on a red background.
The alarm can be muted using the triangular danger button.
Alarms are acknowledged and silenced one at a time.
The alarm situations that are resolved after being muted can be deleted by pressing the Reset
alarms button on the main menu.
9.12.2 Alarm log pages

If alarms have been activated and the Empty alarm buffer function has not yet been run (see
par. ), pressing the Alarm history button from the main menu displays the pages in the log of
resolved alarms. The page is divided into two columns, similar in appearance to the screen shown
below, and displays four alarms all the time:
128 TC 15000
1 H DESCRIPTION OF ALARM A
2
3 XXXX
4
5 >DD-MM-YYYY HH:MM:SS
6 &DD-MM-YYYY HH:MM:SS
7 #DD-MM-YYYY HH:MM:SS
H DESCRIPTION OF ALARM B
XXXX
>DD-MM-YYYY HH:MM:SS
&DD-MM-YYYY HH:MM:SS
#DD-MM-YYYY HH:MM:SS
Row Description
1-4 the first column shows the code of the alarm (“XXXX”) in row 3, while the second column
contains the description of the alarm.
5 date and time when the system generated the alarm situation
6 date and time when the alarm situation was resolved
7 contains the date and time when the alarm was muted
Pushing the button Recording it’s possible to enter in the recording page that shows the
machine’s principle components state at the moment when the alarm appeared.
TC 15000 129
Line Description
1 Shows the alarm number related to the record and the progressive of the record. The
recording can contain up to 5 records.
2-5 Shows the values measured with the instruments in the machine at the moment when
the alarm appared. Make reference to the process scheme to know their location and to
the legend in par.2.1.
6
Pushing the buttons “ ” and “ ” it’s possible to move in

the record and display different recording.i
130 TC 15000
10 Diagnostics
CHAPTER 10
10 Diagnostics
The machine features a self-diagnosis sub-program that continuously checks any possible causes
of malfunctions, checks the signals reads by the sensors, compares the limits set by the user,
monitors the recent alarms and informs of the need to perform maintenance operations.
10.1 Alarm signals and information

The machine provides the user two types of diagnostic signals, corresponding to:
• alarm situations
• information messages
The former refer to situations that compromise the correct operation of the machine (faults,
breakages, errors in the settings etc.).
The latter refer to situations that are not normal but that do not immediately affect the correct
operation of the machine (routine maintenance, system memory buffer full, etc.)
The alarm situations cause the machine to stop operating. The alarm situations are recorded in a
log of limited size that lists the most recent alarm signals. This may be useful for checking if any
situations tend to be repeated.
10.1.1 Alarm signals

The alarm situations are brought to the attention of the operator in the following ways:
• The red indicator light on the main electrical panel cabinet turns on.
• An intermittent audible signal is emitted by the control terminal.
Refer to par. 9.12 for further information regarding the alarm screens.
10.1.2 Information message signals

The generation of information messages does not cause the machine to go into standby, nor does
it stop the process. The operator is informed of the messages in a more discrete manner.
10.2 Alarm situations: troubleshooting

The descriptions in the following paragraphs analyze the various causes of and possible solutions
to the alarm situations, so as to allow correct operation of the machine to resume.
The various paragraphs include a graphic representation of the alarm message, as shown on the
display. Each alarm has a corresponding code.
If after having applied the instructions shown in this chapter the alarm situation could
not be resolved, contact the manufacturer’s or reseller’s service department.
Any operations performed on the machine in order to resolve alarm situations MUST
BE carried out by qualified, trained and authorised service personnel as set forth in
par.1.6. Evaluate on a case-by-case bases the personnel that must intervene in order
to resolve alarm situations.
TC 15000 131
Diagnostics 10
For more details on the maintenance operations designed to resolve the alarm
situations, refer to chap. 11.
The causes of the alarm may be related to the malfunction of the sensor that has
generated the alarm: if the causes of the alarm cannot be identified, check the
correct operation of the sensor.
10.2.1 Alarm code 00

During the operation of the circulating pump G01 the thermal magnetic circuit breaker 13QF1 is
activated due to a higher current input than the rated value (see the wiring diagrams enclosed).
ACTIVATION OF CIRCUIT BREAKER OF CIRCULATION

PUMP G01
Cause Explanation/Solution
Calibration of circuit Refer to the electrical diagrams. Open the electrical panel (disconnect
breaker needs adjusting the power supply to the machine) and, using a small screwdriver,
slightly increase the setting of the circuit breaker protection.
Winding of pump G01 The procedure for resetting a thermal magnetic circuit breaker is
motor short-circuited shown in par. 11.6.23. If the problem persists, contact the
manufacturer’s or reseller’s service department.
Pump G01 motor locked The procedure for resetting a thermal magnetic circuit breaker is
shown in par. 11.6.23. If the problem persists, contact the
Pump G01 blocked See par. 11.6.6. If the problem persists, contact the manufacturer’s or
reseller’s service department.
slightly increase the setting of the circuit breaker protection. If the
problem persists, contact the manufacturer’s or reseller’s service
department.
The machine has reached Check that the quality of the feed liquid has not undergone qualitative
excessive concentration changes (composition, concentration, density, viscosity, etc.). Check,
and if necessary modify, the machine process parameters of the
machine, as specified in par.9.8.

During the operation of the process liquid supply pump G02 the thermal magnetic circuit breaker
14QF1 is activated due to a higher current input than the rated value (see the wiring diagrams
enclosed).
132 TC 15000
10 Diagnostics
PUMP G02
Pump G02 blocked See par. 11.6.6. If the problem persists, contact the manufacturer’s or
reseller’s service department.
Feed line not correctly Check that the feed line complies with the provisions of par.7.4. Check
installed that the line is not clogged. Monitor the pump speed (par.9.9.4). If it is
always high (100%), widen the calibrated neck H06 (with the
permission of the manufacturer)

During the operation of the distillate discharge pump G03 the thermal magnetic circuit breaker
15QF1 is activated due to a higher current input than the rated value (see the wiring diagrams
enclosed).

PUMP G03
Pump G03 blocked See par.11.6.10. If the problem persists, contact the manufacturer’s
or reseller’s service department.
Distillate discharge line Check that the discharge line complies with the provisions of par.7.4.
not correctly installed Check that the line is not clogged. Monitor the pump speed (par.9.9.5).
If it is always high (100%), widen the calibrated neck H10 (with the
permission of the manufacturer)
TC 15000 133
Diagnostics 10
During the operation of the blower K01 the thermal magnetic circuit breaker 16QF1 is activated
due to a higher current input than the rated value (see the wiring diagrams enclosed).

PUMP K01
Winding of the blower The procedure for resetting a thermal magnetic circuit breaker is
K01 motor short-circuited shown in par. 11.6.23. If the problem persists, contact the
Blower K01 motor locked The procedure for resetting a thermal magnetic circuit breaker is

During the operation of the heating element ER01 the thermal magnetic circuit breaker 19QF1 is
ACTIVATION OF CIRCUIT BREAKER OF DISITILLATE

HEATING ELEMENT ER01
Heater short-circuited The procedure for resetting a thermal magnetic circuit breaker is
Electrical breakage of the The procedure for resetting a thermal magnetic circuit breaker is
sheaths shown in par. 11.6.23. If the problem persists, contact the
134 TC 15000
10 Diagnostics
ACTIVATION OF CIRCUIT BREAKER

OF HEATING ELEMENT
FOR DISTILLATE ER02
For comparison see alarm 04.
ACTIVATION OF THE MOTOR PROTECTION

OF THE DISTILLATE
HEATER ER03
For comparison see alarm 04.

During the operation of the fans the thermal magnetic circuit breaker 18QF1 is activated due to a
higher current input than the rated value (see the wiring diagrams enclosed).

FOR FAN G10
Fan motor locked The procedure for resetting a thermal magnetic circuit breaker is

During operation and adjustment of blower K01, in the inverter 16G1 that pilots it, an alarm has
occurred.
TC 15000 135
Diagnostics 10
INVERTER ALARM
BLOWER K01
Anomaly in the inverter See the attached electrical diagrams. Open the electrical panel
that manages the blower (disconnect the machine's power supply), re-start the machine with the
K01 panel open and check if the alarm occurs again. If it does, check the
display of the inverter and take note of the alarm number (or code).
Consult the enclosed manual of the inverter to identify and resolve the
alarm which has occurred.

During operation and adjustment of pump G02, in the inverter 14G1 that pilots it, an alarm has
occurred.
PUMP INVERTER ALARM

FEED G02
Fault in the pump G02 See the attached electrical diagrams. Open the electrical panel
inverter (disconnect the machine's power supply), re-start the machine with the
panel open and check if the alarm occurs again. If it does, check the

During operation and adjustment of pump G03, in the inverter 15G1 that pilots it, an alarm has
occurred.
PUMP INVERTER ALARM

DISTILLATE G03
Fault in the pump G03 See the attached electrical diagrams. Open the electrical panel
inverter (disconnect the machine's power supply), re-start the machine with the
panel open and check if the alarm occurs again. If it does, check the
136 TC 15000
10 Diagnostics
AUXILIARIES SWITCH OFF
There is no voltage 24 Check the voltage
Volt in direct current
The emergency module Check the state of emergency module
has not yet been put back
in operation
Door to boiling chamber Check door status.
opened.
The emergency button on To start the machine again, release the emergency button and reset
the side of the electrical the alarms.
panel has been pressed

Machine stopped due to an emergency.
MACHINE IN EMERGENCY
Emergency button pressed!
The emergency To start the machine again, release the emergency button and reset the
button on the side alarms.
of the electrical
panel has been
pressed

The level in the boiler has risen above of the level sensor LS02. Before re-starting the machine,
partially drain the boiler to restore a suitable level.
HIGH LEVEL BOILER
TC 15000 137
Diagnostics 10
Level sensor LS01 One of the sensors LS01 or LS02 may be dirty or faulty. Clean them and
or LS02 malfunction check (see par. 11.6.11).
Concentrate drain If the parameters entered in the User submenu of the Cycle control menu
parameters (see par.9.8) are not correct or are contrasting.
incorrect
Malfunction of valve Check proper operation of the valve (by means of a manual activation). Make
VP01 sure it actually closes. Clean it if necessary (see par. 11.6.16).
Feed line not Check that the feed line complies with the provisions of par.7.4. In particular,
correctly installed check that there is not excessive pressure on the line. Monitor the speed of
the pump (par.9.9.4). If it is always low (0%) while the level in the boiler
increases, reduce the feed pressure or insert a narrower calibrated neck
(H06)(with the manufacturer's permission)

The level in the boiler has fallen below the level sensor LS03.
LOW LEVEL BOILER
Level sensor LS01 One of the sensors LS01 or LS03 may be dirty or faulty. Clean them and
or LS03 malfunction check (see par. 11.6.11).
Supply line blocked Check that the line is free and that the exchangers E02 and E03 (if the
optional system X is installed) are not blocked
Malfunction in the Check, using the manual command on the operator panel, whether the pump
pump G02 can supply the set flow-rate.
Supply level sensor The supply tank is erroneously signalled as being full and no fluid is supplied
LS11 malfunction Check for correct electro-mechanical operation of the level sensor LS11
Impediments in the One of the manual supply line on/off valves may have been left closed
supply line accidentally
Malfunction of valve Check proper operation of the valve (by means of a manual activation). Make
VP01 sure it actually closes. Clean it if necessary (see par. 11.6.16).
Feed line not Check that the feed line complies with the provisions of par.7.4. Check that
correctly installed the line is not clogged. Monitor the pump speed (par.9.9.4). If it is always
high (100%), widen the calibrated neck H06 (with the permission of the
manufacturer)
Process parameters Check that the quality of the feed liquid has not undergone qualitative
not correct. changes (composition, concentration, density, viscosity, etc.). Check, and if
necessary modify, the machine process parameters of the machine, as
specified in par.9.8.

The flushing liquid storage tank D03 has reached the minimum level.
138 TC 15000
10 Diagnostics
MINIMUM LEVEL FLUXING TANK
Leaks in the lines Check the integrity of these lines and the corresponding hydraulic
connected to the connections
tank D03
Breakage of If the seal of pump G06 breaks, you should note traces of liquid under that
mechanical seal of pump. Check the integrity of the seal and replace it if necessary (see par.
pump G01 or G04 11.6.9).
Level sensor LS05 Check the sensor electrically (communication with the PLC) and replace it if
damaged necessary

The flushing liquid storage tank D03 has reached the maximum level.
MAXIMUM LEVEL FLUXING TANK
Breakage of Check the integrity of the seal and replace it if necessary (see par. 11.6.9).
mechanical seal of
pump G01
Level sensor LS09 Check the sensor electrically (communication with the PLC) and replace it if
damaged necessary

The antifoam storage tank D04 has reached the minimum level.
MINIMUM LEVEL ANTIFOAM
Antifoam finished Top-up the antifoam tank D04
Level sensor LS06 Check the correct operation of the sensor
malfunction
TC 15000 139
Diagnostics 10
The additive storage tank D05 has reached the minimum level.
MINIMUM LEVEL ADDITIVE
Additive finished Top-up the additive tank D05
malfunction

The foam sensor shows the presence of foam for a time higher than the delay time (see
par.9.9.8). The alarm works only if the optional of measurement on foam into the boiler is installed
and enabled
FOAM DETECT INSIDE BOILER
Failure of the Check the cause of the alarm and reset the machine
antifoam metering Check the proper functioning of the antifoam metering device (see
device par.11.3.5).
Change in the Check the type of antifoam in tank D04. Check if it is a product authorized by
quality of antifoam the constructor and check its dilution. Use only products authorized by the
constructor and change the diluition in order to avoid the presence of foam
Change in the Check the type of feed liquid treated in the machine. Eventually modify the
quality of the feed limits as described in par.9.9.8
liquid
Failure of the foam Bad functioning of foam sensor. Consult sensor’s manual to solve the
sensor problem

The distillate storage tank D02 has reached the minimum level (see par. 9.9.5).
MINIMUM LEVEL
DISTILLATE TANK D02
140 TC 15000
10 Diagnostics
Distillate discharge Check that the discharge line complies with the provisions of par.7.4. Check
line not correctly that there are no siphons, i.e. tube paths that might empty the tubes by the
installed force of gravity. Monitor the speed of the pump (par.9.9.5). If it is always low
(0%) while the level in the tank decreases, eliminate any siphons or insert a
narrower calibrated neck (H10)(with the manufacturer's permission)
Level sensor LT04 Clean the level sensor and check the correct reading (see par.11.6.12). To
malfunction reset the alarm, you need to refill tank D02 with water from the mains
Leakage from the Check for leakage from the tank and repair them. If the seal of a pump
tank or mechanical breaks, you should note traces of liquid under that pump. Check the integrity
failure of the seals of the pumps and if necessary replace the mechanical seal (see par. 11.6.9).
of pumps G03 or
G05
Automation Contact the machine manufacturer
parameters to be
reset

The distillate storage tank D02 has reached the maximum level (see par. 9.9.5).
MAXIMUM LEVEL
DISTILLATE TANK D02
Malfunction in the To reset the alarm, it is necessary to empty tank D02 until the working level
level control system is reached
Automation Contact the machine manufacturer
parameters to be
reset
Calibrated neck Insert a wider neck (with the permission of the manufacturer)
H10 too tight
Level sensor LT04 Clean the level sensor and check the correct reading (see par.11.6.12).
malfunction

The external concentrate storage tank has reached the maximum level. Following this alarm the
machine stops and the operator receives a warning that the tank must be emptied.
MAXIMUM LEVEL
CONCENTRATE STORAGE TANK
TC 15000 141
Diagnostics 10
External Empty the tank
concentrate storage
tank full
malfunction

The level of the lubricating oil in the sump on the control side (motor side) has reached the
minimum level.
MINIMUM OIL LEVEL SUMP

CONTROL SIDE BLOWER K01
Level sensor LS13 Check in the sump sight glass if the oil level is in fact low.
malfunction
Oil leaks or oil See the blower manual enclosed
consumption

The level of the lubricating oil in the sump on the gear side (the side opposite the motor) has
reached the minimum level.
MINIMUM OIL LEVEL SUMP

GEAR SIDE BLOWER K01
For comparison, see alarm 24, with respect to sensor LS14.

The blower K01 discharge temperature has exceeded the maximum value.
HIGH DELIVERY
BLOWER K01
142 TC 15000
10 Diagnostics
Inefficient heat The heat exchangers E01, E02 and E03 (if the optional system X is installed)
exchange are dirty: clean them (see chap. 11).
Inefficient injection Check that the liquid injection line is not blocked (tubes, filter F01, pump
of liquid to blower G05, valve VP17, flow meter FI01, spray H07) and clean if necessary (see
intake chap. 11). The injection flow-rate indicated by the flow meter FI01 must be
0.2 litres/min.
Supply temperature The temperature of the liquid supplied is too low.
too low

The blower K01 pressure differential measured by the sensor DPT01 has exceeded the maximum
value.
HIGH PRESSURE DELTA

BLOWER K01
Inefficient heat The heat exchangers E01, E02 and E03 (if the optional system X is installed)
exchange are dirty: clean them (see chap. 11).
The machine has Check that the quality of the feed liquid has not undergone qualitative
reached excessive changes (composition, concentration, density, viscosity, etc.). Check, and if
concentration necessary modify, the machine process parameters of the machine, as
specified in par.9.8.
Obstruction in the Check that the recirculation of liquid or that for concentrate are not clogged;
recirculation line or clean as necessary (see chap. 11).
in the concentrate
discharge line
Infiltration of air or Check the seal of the machine for air infiltration (par.11.5.1) If there are non-
non-condensable condensable gases, suspend treatment of the liquid or proceed with
gases elimination of the gases through pre-treatment of the current
Blower K01 dirty Clean the blower (par.11.6.7)
Sensor DPT01 dirty To check if this occurs, manually start the blower with the machine off. If the
or damaged Delta P shown is 0, replace the sensor DPT01

In the start-up phase, the temperature of the lubricating oil has not reached the minimum
temperature in the set time.
LOW OIL TEMPERATURE IN BLOWER

K01
TC 15000 143
Diagnostics 10
Malfunction of the Check the reason why the heaters have not adequately heated the blower
heaters ER02 in the (e.g. no longer attached to the casing of the blower)
blower
HIGH OIL TEMPERATURE BLOWER

K01
Blower anomalies Check if the planned maintenance of the blower oil change has been
performed; in the affirmative, contact the manufacturer’s or reseller’s service
department
Oil leaks or oil See the blower manual enclosed
consumption
Friction Check if the planned maintenance of the blower oil change has been
performed; if it has, contact the manufacturer

The pressure in the boiler measured by the sensor PT01 at the blower intake is high for an
extended time.
HIGH PRESSURE BOILER
Excessive presence This cause is confirmed if the productivity of distillate is low at the same
of incondensable time. Carefully degas the supply fluid before continuing with the evaporation
gases in the supply process
fluid
Infiltration of air The presence of significant infiltrations of air in the parts of the machine
operating at low pressure has the same effect as incondensable gases in the
supply fluid.

During the operation of the blower heaters ER04 the thermal magnetic circuit breaker 27QF1 is
144 TC 15000
10 Diagnostics
OF THE HEATERS
ER04
Heater short-circuited The procedure for resetting a thermal magnetic circuit breaker is
Electrical breakage of the The procedure for resetting a thermal magnetic circuit breaker is
insulation shown in par. 11.6.23. If the problem persists, contact the

This alarm situation occurs when the sensor that measures the density of the concentrate DT01
reaches a density value that is higher than the set value. This alarm situation may only arise if the
optional density control device has been correctly installed, configured and enabled.
HIGH DENSITY CONCENTRATE
Impediments in the Check that there are no impediments in the concentrate drain line (line
concentrate drain line blocked, manual valves closed, pneumatic valve VP07 or its control
devices malfunctioning)
Incorrect setting of the Check the parameters set in par.9.8. In particular, check and if
process parameters necessary reduce the discharge Delta.

This alarm situation is generated when the conductivity of the distillate, measured by the probe
CE01/CT01, exceeds the value set. To start the machine again, bypass the alarm; the alarm is then
bypassed for a set time to allow the compressors to start again and produce new distillate. in this
way, the production of new distillate should clean the intake circuit where the electrode CE01 is
fitted and consequently the conductivity should fall below the maximum limit. This prevents the
machine from stopping again due to the same alarm; otherwise, the alarm signal will be activated
again after the set time.
TC 15000 145
Diagnostics 10
HIGH CONDUCTIVITY DISTILLATE
Entrainment of liquid The entrainment of liquid may be due to the presence of foam that
reaches the exchanger E01, where the steam condenses.
If an additive metering system is fitted to limit the amount of foam,
modify the operating parameters or check that it is working correctly
(see par.11.3.5).
Excessive concentration An excessive concentration of process fluid may worsen the quality of
factor the distillate. Modify the process settings to decrease the concentration
factor.
Changed quality of the Check the type of liquid treated by the machine. If necessary, modify
treated liquid the thresholds referred to in par. 9.9.10
Conductivity sensor CE01 Check the cleaning of the sensor and clean it if necessary (see
dirty par.11.3.6 and 9.7.4)

During the heating of the distillate tank, the temperature of the liquid does not reach the working
temperature in the set time.
LOW TEMPERATURE OF TANK

D02 IN THE DISTILLATE
Malfunction of the heating Check the proper operation of the heating elements With a tester
elements ER01-05 check the output signals from the PLC, and the power provided down
the line from the remote switch.

The temperature in the distillate tank D02 has exceeded the maximum value. The function of this
alarm is to protect the heating elements and prevent the liquid from boiling.
HIGH TEMPERATURE IN TANK D02

OF THE DISTILLATE
The heating elements are Check the reason why the heaters stay on. With a tester check the
on above the control output signals from the PLC, and the power provided down the line
value from the remote switch. Check correct operation of the latter.
146 TC 15000
10 Diagnostics
The temperature in the boiler measured by the sensor TT01 has reached the minimum value for an
extended time.
LOW TEMPERATURE BOILER
Inefficient heat exchange The heat exchangers E01, E02 and E03 (if the optional system X is
installed) may be dirty: if so, clean them (see chap.11)
Heating elements ER01- Clean the heating elements (see par. 11.6.11) and check the electrical
ER05 dirty or not connections
functioning properly
Supply temperature too The temperature of the liquid supplied is too low.
low

The temperature in the boiler measured by the sensor TT01 has reached the maximum value for
an extended time.
HIGH TEMPERATURE BOILER
Excessive liquid Check the process parameters on the operator panel (par.9.8)
concentration in the boiler
Infiltration of air/presence Proceed in the same way as indicated for theAlarm code 29
of non-condensable gas
Electrical heating Check the electrical power wiring to the heating element and check the
elements ER01-ER05 actual electrical input using an amperometric pincer
malfunctioning
The heating elements Check the reason why the heaters stay on.
ER01-ER05 stay on above
the control value

The production of distillate is excessively low. The alarm thresholds are set in the page as referred
to in par. 9.9.5.
TC 15000 147
Diagnostics 10
LOW EFFICIENCY DISTILLATION
Excessive liquid Check the process parameters on the operator panel, according to the
concentration in the boiler operating mode(see par.9.8).
Inefficient heat exchange The heat exchangers E01, E02 and E03 (if the optional system X is
installed) may be dirty: if so, clean them (see chap.11)
Significant presence of Check if the process fluid contains a significant amount of
incondensable gases incondensable gases: if so, fit a degassing device upstream the
machine.
Significant infiltration of Check the hydraulic seal on the machine (see par. 11.5.1).
air in the parts of the
machine operating at low
pressure
Insufficient or no The formation of foam makes it more difficult for the liquid inside the
antifoam boiling chamber to evaporate. In addition, this not only pollutes the
distillate, but may also foul the de-mister H04 and the exchangers E01
and E03 (if the optional system X is installed). Suitably calibrate the
antifoam metering assembly and check its operation.
Alarm threshold too high Check the settings on the alarm configuration page (see par. 9.9.5).

The pressure of the compressed air that supplies the pneumatic circuit has fallen below the value
set by the manufacturer. This alarm is reset automatically when the pressure returns within the
range of acceptable values.
LOW PRESSURE COMPRESSED AIR
Low pressure in the This alarm is activated by the pressure switch PS14 and indicates that the
air supply compressed air pressure has fallen below the minimum operating value. This
may be due to a drop in pressure in the user’s supply network.
To re-start the machine, check that the compressed air pressure, measured
by the pressure gauge PI12, is between 550 and 650 kPa.
148 TC 15000
10 Diagnostics
ACTIVATION SAFETY THERMOSTAT TS05,

HIGH TEMPERATURE HEATERS
DISTILLATE TANK D02
The temperature of The heating element was on but was not immerged in the liquid:
heating element ER01 has possible problem with the setting of the level of liquid present in D02:
exceeded the setpoint on proceed in the same manner as described for Alarm code 20
the safety thermostat
TS05.
Level sensor LT04 The supply tank is erroneously signalled as being full and no fluid is
malfunction supplied Check proper operation of level sensor LT04 (see par.11.6.12)
Heating element Proceed in the same way as described for theAlarm code 34
malfunctioning

During the operation of the flushing pump G04, the thermal magnetic circuit breaker 17QF1 is

OF THE PUMP
FOR FLUXING G04
Pump G04 motor blocked The procedure for resetting a thermal magnetic circuit breaker is

The safety limit switch FC1 located on the boiling chamber D01 access door has given a signal. The
evaporator can not restart until the door is closet and the signal is reset.
TC 15000 149
Diagnostics 10
MACHINE IN EMERGENCY
Boiler door safety limit switch!
Boiling chamber door Shut the door
open
Malfunctioning of the Check the electric connections of the safety limit to the electric board.
safety limit switch FC1 If needed change the electric cable. Check the safety limit device
instruction book.

During the operation of the injection liquid pump G05, the thermal magnetic circuit breaker 17QF2
is activated due to a higher current input than the rated value (see the wiring diagrams enclosed).
ACTIVATION OF THE MOTOR PROTECTION

OF THE
INJECTION LIQUID PUMP G05
Pump G05 motor blocked The procedure for resetting a thermal magnetic circuit breaker is

This alarm situation takes place whenever the sensor for the measurement of the density of
concentrate DT01 is in alarm condition. This alarm situation may only arise if the optional density
control device has been correctly installed, configured and enabled.
OPERATING ANOMALY IN DENSIMETER
150 TC 15000
10 Diagnostics
Dernsimeter in alarm Check the alarm shown on the instrument and resolve it, if possible.
status Refer to the manual of the densimeter DT01.

This alarm indicates that one of the accessory devices (see Table 2.1.2) associated with the
machine has given an alarm signal.
EXTERNAL ACCESSORIES ALARM
Failure of one of Check the cause of the alarm and reset the machine
the accessories
installed on the
machine
Accessory Consult the electrical diagrams both of the machine and of the accessory.
connected Check that the connection is adequate (normally open or closed) and
incorrectly or poorly properly made (suitable cable etc.)
10.3 Information messages

These messages are displayed and are reset in the same way as the alarms. They do not,
however, stop the operation of the machine, but rather warn the operator that non-urgent action is
required (see par 9.12.1).
10.3.1 Message code 64

This pre-alarm is identical to Alarm code 25, only with a lower threshold (see the alarm to identify
the causes).
PRE-ALARM HIGH TEMPERATURE

DELIVERY

This pre-alarm is identical to Alarm code 26, only with a lower threshold (see the alarm to identify
the causes).
TC 15000 151
Diagnostics 10
HIGH PRESSURE DELTA PRE-ALARM
IN BLOWER

This warns the operator to perform the planned maintenance involving the cleaning of the distillate
conductivity sensor CE01. Remember to update the corresponding page with the date the
maintenance operation was performed (see par.9.7.4).
ROUTINE MAINTENANCE 1
Clean electrode CE01 conductivity
meter
See par.11.3.6 for details on maintenance.

This warns the operator to perform the planned maintenance involving changing the oil in the
blower. Remember to change the oil in both compartments: drive and gears.
Change the oil in the blower
For replacement see par.11.3.8.

Once the oil has been changed, remember to update the maintenance 2 page on the operator
panel with the date the operation was performed (see par. 9.7.4).

This warns the operator to perform the planned maintenance involving the first oil change on the
blower. Remember to change the oil in both compartments: drive and gears.
Change the oil in the blower
For replacement see par.11.3.8.

Once the oil has been changed, remember to press the confirm maintenance carried out button
on the maintenance 3 page on the operator panel (see par. 9.7.4).
152 TC 15000
10 Diagnostics
ALARM BUFFER 80% FULL!

EMPTY !
The memory used to save the alarm log is almost full: empty it using the Empty alarm buffer
button on the configuration page on the operator panel (see par. 9.11.2)
TC 15000 153
10 Diagnostics
TC 15000 154
11 Control, adjustment, maintenance
CHAPTER 11
This chapter describes the maintenance operations which have to be scrupulously followed by the
personnel. The operations are:
• machine performances check;
• functioning adjustment to increase the performances;
• machine maintenance.
The maintenance operations may be:
• programmed;
• extraordinary.
The first category is related to those operations which have to be carried out at fixed intervals
suggested by VWS ITALIA, necessary for the correct machine functioning and preservation. The
frequency is to be considered “advised” and it was defined on the base of the VWS ITALIA
experience; it could be changed depending on the specific customer requirements.
For the second kind of maintenance, it is not possible to foresee the frequency and the endurance.
It is needed when the machine functioning is not regular; the frequency depends on the machine
conduction and on the wastewater to be treated type. If the working conditions are regular, after a
primary check time, it is possible to define an optimal frequency of “extraordinary” maintenance
that can be included in the periodic maintenance calendar of the user. To ensure a regular
machine working, minimizing the interventions time and maximizing the efficiency of the
interventions themselves, it is suggested anyway to act in preventive way.
11.1 Generality and safety

To guarantee the machine efficiency, it is recommended to scrupulously follow the instructions and
the warnings described in the present chapter.
The constructor will not be held liable for any injury to persons or damage to property resulting
from failure to abide by the warnings and directions given.
For safety reasons, all maintenance/adjustment operations should be carried

out by qualified technicians.
The machine treats liquids which may be hazardous if touched, inhaled,

ingested, etc. All personnel who work on the machine must be informed by
the managers of the organization that uses the system on the types of liquid
that are present in the machine and the risks they may cause. Always keep
the safety information on the liquids available.
The technicians MUST have all the instruments necessary to allow them to
work in safety.
The operators MUST use suitable equipment that is in good condition.
TC 15000 155
Control, adjustment, maintenance 11
Any work on electrical equipment HAS to be carried out only after it has
been disconnected from its power supply.
Any work on pneumatic equipment HAS to be carried out only after it has
been disconnected from its supply system.
Any type of intervention on the lines containing fluids MUST be preceded by

a drainage and suitable cooling. The temperatures of that pipelines may
reach 100°C with the danger of burns and the process liquids may be toxic or
corrosive
All work that require an operator to be at a certain height must be carried

out using equipment that is compliant with standards governing the
construction and use of ladders and scaffolding
All environmental pollutants that need to be eliminated after maintenance

operations (such as oils) MUST BE DISPOSED OF in accordance with
current regulations and laws. If necessary, contact an authorized organization
for their disposal.
It is strongly recommended to install a pad lock over the machine’s main

electric switch and to keep the key. If not differently specified, during
maintenance operations, it is strongly recommended to close the electric
board and to accurately put away the key.
Upon completion of work, the technicians HAVE to check that no tools have
been left inside the protective devices or guards, or in the work area of line.
During maintenance, access to the work zone IS PROHIBITED to all

unauthorized personnel, except for employees who carry out
maintenance/adjustment.
For maintenance/adjustment operations involving equipment not

manufactured by the constructor, please refer to the relevant documentation
enclosed with this manual.
If it is necessary to remove any installed protective device or guard in order
to work without difficulty on the machine, it is recommended to re-assembly
it upon completion of work and to check its correct operation before starting
the machine again.
It is advisable to familiarize with the control terminal before operating the

machine: to this end, refer to chapter 9.
11.2 Daily maintenance

Daily maintenance consists mainly of a series of controls aimed at checking the correct operation
of the various steps of the system.
The machine performances check includes several measurements referred to the process liquids
and to the machine components.
11.2.1 Monitoring of data

The monitoring of operating data is useful for preventing anomalies or making changes in control
parameters to improve machine performances.
156 TC 15000
To record these data, it is possible to use a data chart similar to the one reported in the attached
documents. The chart filling in leads to monitoring several functioning parameters and a series of
measurements, reported in the same chart.
11.2.2 Adjustments of the treatment process

The process adjustment is carried out on the base of the intended concentration and quality of the
distillate. These parameters may change with the type of liquid treated and therefore the
adjustments, at least in a general sense, should be changed from one day to the next.
The amount of produced distillate depends on the nature of the liquid to be treated: the more
concentrated liquid in the boiling chamber, the less produced distillate flow-rate. This is due to a
heat exchanging conditions falling in the heat exchangers and to a percentage decreasing of water
in the concentrate left.
A high concentration in the boiling chamber may lead to substances entrainment in the distillate.
When entrainments caused by foam formation occur, the distillate is polluted and therefore
characterized by a worse quality.
The concentration ratio “R”, which quantitatively defines the evaporation
process (see par. 9.8) varies depending on the chemical and physical
characteristics of each fluid. It is advisable to establish it based on careful
analytical characterization of the fluid to be treated.
It is prohibited to re-circulate the concentrate to increase the actual yield. This
would be tantamount to feeding the machine with a fluid different from that
permitted by VWS.
Before proceeding with any change in the process parameters of the machine, it
is recommended to get in touch with VWS Italia technical assistance staff.
Otherwise, VWS Italia denies any responsibility for any damage coming to the
evaporator from a parameter modify done without its agreement.
If the work concentration is close to the saturation one, pay attention to the
long machine stops; in this case possible clogging can occur due to the
precipitation and/or crystallization of the liquid in the boiling chamber or in the
tubes. If the machine will not be used for a long period of time, drain
completely the machine and wash it with tap water turning on the concentrate
circulation and discharge.
The process is also influenced by the auxiliary liquids metering which may be used to increase the
process liquid characteristics during the evaporation phase.
11.2.2.1 Concentration ratio adjustment in “Volume” mode

When the machine works in “Volume” mode (see par. 9.8) it is necessary to set the concentration
ratio which is desirable to obtain.
When the machine is in normal operating conditions, proceed as follows:
• measure the concentrate volume discharged each cycle [l] (see par. 11.2.1);
• input the drained volume thus obtained and the desired concentration ratio.
It is recommended to periodically repeat the operations above listed. Furthermore, it is strongly
suggested to carry out the following checks:
• measure the litres discharged and the density of the liquid to be treated [kg/dm3] (see par.
11.3.3);
• wait for the concentrate discharge, measure the density obtained and eventually increase
or decrease the concentration ratio
During the first operating period of the machine, these adjustments have to be carried out every
four hours.
Remember, however, that considering the functional constraints of the machine, the concentrate
must be compliant with the specifications in par.3.1.
TC 15000 157
11.2.2.2 Concentrate density adjustment in “Density” model
This type of machine functioning is possible only when the density control optional instrument is
installed, calibrated and enabled. It is necessary to set the desirable density value (see par. 9.8).
When the concentrate density value is set, start the treating process. When the machine is in
normal operating conditions, proceed as follows:
• set the initial value of the desired density;
• wait for the concentrate discharge, measure the density obtained and compare it with the
set one.
It is recommended to periodically repeat the operations above listed.
During the first operating period of the machine, these adjustments have to be carried out every
four hours.
Remember, however, that considering the functional constraints of the machine, the concentrate
must be compliant with the specifications in par.3.1.
11.2.3 Checking for formation of foam in the evaporator

When the evaporator is in operation, foam may form inside the boiler D01. Foams are caused by
the carrying of solid contaminants into the distillate. Therefore, you must check for this on a daily
basis. If the amount of foam should increase, act on the metering of the anti-foam product, both in
terms of automatic metering and in terms of manual extra metering (see paragraph 9.9.8 )
The foam may cause substantial fouling and resulting damage in blower K01
In special conditions (e.g. start-up of evaporator from “0”, liquids that are
especially prone to create foams or variation of the feed liquid) , this check
should be carried out three times a day
11.2.4 Anti-foam level check

When the level in the storage tank D04 is low, it is advisable to add more antifoam to the tank to
avoid machine stoppage due to triggering of low antifoam level alarm. It is advisable to check that
the antifoam level drops, as this is a sign that the automatic inlet system is working correctly.
11.2.5 Anti-foam level check

If the additive metering device is installed and enabled, it is recommended to check the level in
tank D05. If the level is low, add more additive agent in order to avoid machine stoppage due to
triggering of the low additive level alarm.
11.3 Monthly maintenance

11.3.1 Measurement of the flow rate of the produced
distillate
This operation is necessary if there are any doubts about the calibration of sensor FT01
To carry out this operation, it is necessary to have a graduated receiver, with

known and suitable capacity (20 litres), a scale and a stopwatch.
To get more reliable data, it is recommended to make several measurements

and to calculate their average.

• Disconnect the fitting of the distillate discharge (see7.4) from the process line of the user.
• Have the machine discharge the distillate into the provided empty container
158 TC 15000
• When the machine starts discharging the distillate into the container, start the stopwatch
• Wait a suitable amount of time (to be measured using the stopwatch)
• At this stage, if a graduated receiver is available, it is sufficient to measure the volume.
Otherwise, you will need to weigh the collection container as soon as it is filled. The
volume [litres] is equal to the weight of the liquid collected [kg]
• The flow rate of distillate [litres / hour] can be found by the following calculation
(Vd)
D = ------------- 3600
td
D Flow rate of produced distillate [l/h]

Vd volume of collected distillate [l]
td Elapsed time [sec]
• Remove the hose and re-connect to the process network of the user.
11.3.2 Concentrate discharged volume measurement

The amount of concentrate discharged in each single cycle is controlled through the PLC and it
depends on the operating mode of the machine (see par.9.8). It is also one of the fundamental
parameters that control the "VOLUME" operating mode (see par. 9.8).
In any case, it is useful to perform monthly checks of the amount of concentrate drained in each
draining cycle.
To carry out this operation, it is necessary to have a graduated receiver, with

known capacity, and a scale.

For the concentrate outlet line, the possibility to discharge into a recipient must
be inserted at the line arrival point (in order to take into account, in
measuring, the pressure drops generated by the line). See Figure 7.4-

• Prepare the concentrate withdrawing system at the same position where the machine
discharges normally (same discharge height and tube length); this has to be done in order
to improve the accuracy of the measure, taking into account the pressure drops of the line
• Wait for one concentrate discharge prepare for the withdrawal.
• Wait for one concentrate discharge or change the pause settings between two consecutive
discharges to decrease the waiting time.
• Carefully check that all the discharged concentrate is collected into the provided receiver.
• At this stage, if a graduated receiver is available, it is sufficient to measure the volume.
Otherwise, it is necessary to measure the concentrate density as explained in par. 11.3.3.
Weight the storage tank as soon as it has been filled and make the following calculation (it
is necessary to know the tank weight):
TC 15000 159
(W – Wt)
Vc = -------------
Dc
Vc concentrate volume discharged [l]

W weight of the receiver plus the concentrate [kg]
Wt receiver weight (tare) [kg]
Dc concentrate density [kg/dm3]
11.3.3 Control of the density of discharged concentrate

If you should need to measure the density of the concentrate (see 11.2.1), proceed as follows.
To carry out this operation, it is necessary to have a thermometer, a low and
large receiver to collect the concentrate, a high and narrow receiver and an
adequate densimeter, or a graduated receiver, with known capacity, and a
scale.


• Place a storage receiver underneath the boiling chamber draining valve (valve V224 of the
attached process diagram).
• Carefully open the valve and collect a concentrate sample, then close the valve.
• Measure the sample temperature and wait until 20 [°C] are reached.
If densimeters are available, pour the sample in the high and narrow receiver, plunge one of the
densimeter into it and carry out the measurement. If the density is not included in the instrument
measurement threshold, try to change the instrument.
If densimeters are not available, pour part of the sample in the known capacity and weight
receiver and weight the receiver itself. Then, make the following calculation:
(W – Wt)
Dc = -------------
Vc
Vc concentrate volume in the known capacity receiver [l]

W weight of the receiver plus the concentrate [kg]
Wt receiver weight (tare) [kg]
Dc concentrate density [kg/dm3]
To carry out accurate measurements, it is necessary to use reduced measuring scales densimeters
or high sensibility scales.
If high percentages of solid materials are present, the density measured

through the above described methods is not quite reliable and therefore its use
is poor.
160 TC 15000
11.3.4 Cleaning of the separator filters of the condensation
of the compressed air
Wear protective goggles: the pressure of the air could cause condensate to
spray out.
The condensation separator filter of the pressure reducers PCV12-14 are used to keep humidity or
oil from getting to the solenoid valves, which may compromise operation.
Since a small amount of humidity or of lubricating oil or present in the compressed air supply, it is
necessary to clean the compressed air filter periodically proceeding as follows:
• Check and verify the compressed air filter located below the pressure reducer and the
condensate presence in the collecting bowl.
• To drain the condensate, press upwards the drainage tube located below the collecting
bowl.
11.3.5 Check of anti-foam metering units

The antifoam agent may clog its pipeline or the feed pipeline which meters the liquid into the
boiling chamber. Therefore it is necessary to check the functioning of these components
periodically.
The check of the line of the service network that carries anti-foam to the machine is performed by
the user. In order to ensure correct operation of the line on board the machine for the metering
into the boiling chamber, you may proceed as follows:
• Insert the antifoam scavenge tube in a small container, previously filled with water
• Carry out two antifoam suction cycles with the manual command (see par.9.9.8);
• Repeat this operation several times and check if the level of liquid in the container falls;
• Put the scavenge tube back in the antifoam tank D04
• If the device is working correctly, re-activate the antifoam metering; otherwise, check that
no clogging is present in the suction circuit, otherwise perform the cleaning.
11.3.6 Check and cleaning of the conductivity

measurement probes (CE01)
It is necessary to carry out the cleaning of the probes CE01.
Cleaning of the conductivity-meter probe is in any case necessary if there is

considerable entrainment and pollution of distillate.
The steps to follow are:

• Press the STOP button in the CYCLE CONTROL to stop the machine;
• turn off the machine by means of the main switch;
• Wait for the temperature to drop
• Disconnect the electrode connecting cable;
• Carefully unscrew the conductivity probe from its housing
• Carefully clean the electrode with water and, if necessary, with a soft cloth to remove
sediment;
• Wash the end of the probe with potable water;
• Re-connect the electrode connecting cable;
• Check the transducer calibration (see the conductivity-meter manual attached);
• Re-insert the probe in its location;
• Restart the machine.
TC 15000 161
11.3.7 Cleaning of the filter in water spray line in blower
delivery (F01)
Distillate entrainments may cause fouling and clogging accumulations inside the filter (F01) in the
water spray line in blower delivery. normal wash operations should be enough to avoid the
accumulation of these incrustations.
The washing procedure has to be carried out as follows:
• close the shut-off valves of the filter (V31);
• Take out the filter and clean it with water;
• Extract, and if necessary clean, the injection nozzle H07
• Re-open valves of the filter that has just been cleaned.
11.3.8 Changing the oil of blower K01

The blower K01 oil has to be substituted every 1000 hours of functioning; the first time it has to be
substituted in a shorter range of time (500 hours). Both at the first deadline and the following, you
will be shown an information message (see par. 10.3.4 and 10.3.5) as a reminder. For the settings
see par 9.7.4, while for the substitution execution procedure see the blower's attached manual.
It is required to periodically analize the oil quality in order to evaluate the need
of more or less frequent substitutions. Contact the constructor or the vender
technical assistance department for further details.
The operation requires use of suitable equipment to lift involved operators. Be

sure to use ladders and scaffolding that are compliant with standards on work
safety
The operation and those related to it may be carried out by a qualified

maintenance technician
During the operation, be sure to use all necessary individual protection gear
11.4 Semi-annual maintenance

11.4.1 Electrical terminals check
During the normal operating conditions, vibrations may loosen the electrical terminals of terminal
boards, meters, magneto-thermal switches, etc. in the machine. Therefore, about six months after
installation of the machine, it is advisable to check and if necessary to tighten the terminals of the
electrical contacts, with special attention to the power contacts.
This operation is reserved to electrical qualified technicians or to the personnel

of the constructor or vender technical assistance department.
Before carrying out these operations, the machine has to be turned off and the power supply has
to be disconnected; it is recommended to check the boards methodically (see attached wiring
diagrams).
162 TC 15000
11.4.2 Cleaning of electric board ventilators
Inside the machine electric board ventilators are installed that keep constant the temperature
inside the electric board itself. These ventilators have a filter that, as time goes by, gets stuck with
the air dust (particularly in dusty installation environments). Therefore, you will need to clean
them. It is therefore necessary to proceed as it follows:
• Disconnect the power supply to the machine with the main switch
• Dismantle the ventilator’s coverings
• Take away the filters and clean them with compressed air
• Re-assemble the filters and the ventilator’s coverings
• Give back tension to the machine via the main interrupter
11.4.3 Cleaning of the liquid to be treated storage tank

Check the cleaning conditions of feeding fluid storage tank, removing the clogging carefully. It is
recommended to remove the clogging to avoid suction tube clogging phenomena.
This operation has to be carried out by the mechanical personnel supplied by

the user.
11.5 Yearly maintenance

11.5.1 Check of hydraulic interconnection parts (and check
of the vacuum)
The operation and those related to it may be carried out by a qualified
maintenance technician

safety
The process line on board and the connections to the user supplies are characterized by several
fittings and clamps.
It is recommended to carefully check fittings and clamps hold, to prevent eventual leaks. If some
leaks are found, try to tighten the fitting, otherwise change the gasket.
Some servicing pipelines are formed by hoses and fitted through hose-clamps: check and
eventually tighten the hose-clamps.
It can be useful to check the vacuum, that is the absence of air infiltration.
An easy way to do that is described here:
• Check the level of the liquid into the boiler: if it is lower that the work level, fill it up until
the work level
• Read the pressure value into the boiler (see par.9.9.1)
• Discharge the liquid of the boiler by using the manual discharge of the concentrate (see
par.11.6.18)
TC 15000 163
• The discharge of the liquid creates vacuum into the boiler. Read the value of the pressure
into the boiler (see par.9.9.1)
• Go on.emptying the boiler until the pressure value into the boiler reaches a value at least
20-30 kPa lower than the atmospheric pressure (noticed at the beginning of the
procedure). Note the pressure value reached in this way.
• Wait at leas 12 hours.
• Check the pressure value into the boiler. If it’s higher than before there are air infiltrations.
In this case check the seal of all the gaskets.
11.6 Special maintenance

11.6.1 Measurement of non-standard data
11.6.1.1 Verification of pH
In order to check correct operation of the machine, it may be useful to measure the pH of the
distillate produced by the machine, as well as the pH of the process liquid that feeds the evaporate
and the liquids in the boiler. These measurements are useful to characterize the process liquids
and therefore to better evaluate the machine performances.
To carry out this operation, it is necessary to have a portable pH-meter

adequately calibrated.


• Collect part of the evaporated liquid from the draining valve of the distillate storage tank
D02 into a clean and non metal receiver.
• wait for the liquid cooling up to temperatures that can’t damage the pH probe or affect the
correct measuring
• Plunge the portable pH-meter probe into the receiver and carry out the measurement
following the instructions of the instrument.
• Collect part of the liquid to be treated from the process line upstream the machine into a
clean and non metal receiver.
• Collect a portion of liquid circulating in D01 from valve V24 in a clean, non-metallic
container.
11.6.1.2 Verification of electrical conductivity
In order to check the correct operation of the machine, it may be useful to check the conductivity
of the two currents of distillate produced by the evaporator and of the process liquid that feeds it.
These measurements are useful to characterize the process liquids and therefore to better evaluate
the machine performances.
The measurement of the conductivity of the distillate can be seen on the video page in par.9.9.10,
otherwise, for the purpose of checking, you can measure it as described below.
To carry out this operation, it is necessary to have a portable conductivity-

meter adequately calibrated.
164 TC 15000


• Collect part of the distillate from the draining valve of the distillate storage tank D02 into a
clean container that is resistant to high temperatures.
• Plunge the portable conductivity-meter probe into the receiver and carry out the
measurement following the instructions of the instrument.
• Collect part of the liquid to be treated from the process line upstream the machine into a
clean and non metal receiver.
• Plunge the portable conductivity-meter probe into the receiver and carry out the
measurement following the instructions of the instrument.
The electrical conductivity of aqueous solutions is function of the temperature:

therefore, to compare the conductivity measurements carried out, it is
recommended to effect them at the same temperature.
If the measured value is significantly far (> 5%) from the value measured by
probes CE01, calibrate the device (see the attached conductivity sensor
manual).
11.6.2 Inspection and cleaning of tube side of heat

exchanger E01
Heat exchangers E01 inspection frequency depends on the characteristics of the liquid to be
treated. In the first two months after the start up, these inspections have to be carried out once a
week to discover which kind of fouling is caused by the liquid and to decide the inspections
frequency when the machine will be in normal operating conditions.
The operation and those related to it can be carried out by a maintenance

technician with a standard toolbox
To carry out maintenance operations, it is necessary to have an electric torch

and the tube cleaner supplied with the machine.
The steps of the tubes of the E01 exchangers cleaning procedure are:
• Drain the process liquid from heat exchanger by opening the drainage valves V24, V34,
V35, V36;
During this operation, it is recommended to place several containers to collect

possible leaks of the process liquid.

• Remove the covers from the heat exchanger E01 by removing the screws of the flange.
Make sure you do not damage the gaskets
TC 15000 165
• by means of a electric torch check the cleaning state of the tubes and evaluate the fouling
degree; check also the cleaning state at the shells side and eventually perform the
cleaning (see par.11.6.19)
If necessary proceed with the mechanical cleaning as follows:
• use the provided tube cleaner for the cleaning of the tube internals
• If the tubes are clogged, try to deliver them with the pig or contact the constructor
service;
Once finished these operations, proceed with the following phases for the machine functioning
restoring:
• Re-install, in reverse order, the covers removed along with their gaskets
• Close the drainage valves V24, V34, V35 and V36;
• Restart the machine;
It could happen that the mechanical cleaning is not sufficient to remove fouling, if necessary
proceed with the chemical cleaning as follows:
• Turn off the machine through the main switch;
• Drain the liquid from the boiling chamber and the heat exchangers through the drainage
valves (V34, V35, V36, V24);
• close the valve V33;
• Turn on the machine through the main switch;
Put on suitable means of protection, then open the CLEANER tanks. The
CLEANER is an acidic product so it CAN NOT be used with cyanides or
chlorine-base compounds.
In any case, for the choice of the cleaning product, contact the manufacturer
or VWS Italia technical service.
• Filler the boiler with the CLEANER. To do this, use pump G07 if available. Otherwise,
proceed with a filling system that does not cause personnel to come into contact with the
CLEANER.
• Use the manual commands or act on the drain on and off times of the G01 circulation
pump to allow circulation of the necessary amount of CLEANER until the washing is over;
• Then fill up the boiling chamber with a neutralizer and proceed as with the cleaning
product
• When washing is complete, shut the machine down with the main switch and again drain
the boiling chamber and the exchangers through the respective drainage valves (V34, V35,
V36 and V24);
• Open the valve V33;
11.6.3 Inspection and cleaning of heat exchanger E02


and the tube cleaner supplied with the machine.
166 TC 15000
The procedure for the tubes cleaning of the exchanger E02 is the following:
• Close valves V01 and V16;
• Wait for the temperature to drop to ambient levels
• Open valve V14;
• drain completely the exchanger through the valve V12 and V25
• Remove the tubes connected to the exchanger (only those on the tube side, where the
valve V14 is installed);
• Remove the flat covers and the gaskets mounted on the exchanger;
• Using an electric torch, visually check the pipes' cleanliness and evaluate the degree of
fouling.
If necessary proceed with the mechanical cleaning as follows:
• use the provided tube cleaner for the cleaning of the tube internals
• If the tubes are clogged, try to deliver them with the tube cleaner or contact the
manufacture or vender;
• Put the covers back in place (with the corresponding gaskets) on the heads of the
exchanger;
• Replace the tubes connected to the tube side of the exchanger;
If you also decide to clean the shell side, proceed as follows:
• Disconnect the tubes (shell side) coming from the exchanger (the delivery tube from pump
G03);
• Starting from this, insert water on the shell side, letting it drain from valve V13
• Wait until clear water comes out of the exchanger;
• Reconnect the distillate tube;
Once finished these operations, proceed with the following phases for the machine functioning
restoring:
• remount backward the disassembled parts (flange, tubes)
• open the valves V01 and V16 and close the drainages V12, V14 and V25
11.6.4 Inspection and cleaning of the thermal recovery

exchanger (E03) (if optional X is present)

and the tube cleaner supplied with the machine. To clean the shell side, you
should use a high-pressure water cleaner
To carry out maintenance operation it is necessary to have some grease to

lubricate the O-rings and the gaskets to make easier their assembling.
The heat exchanger E03 inspection frequency depends on the characteristics of the liquid to be
treated. In the first two months after the start up, these inspections have to be carried out once a
TC 15000 167
week to discover which kind of fouling is caused by the liquid and to decide the inspections
frequency when the machine will be in normal operating conditions.
The fluid that circulates in the heat exchanger E03 is more concentrated than the liquid to be
treated, so the E03 cleaning is more frequent than the other heat exchangers.
The steps of heat exchanger E03 cleaning procedure are:
• Wait for the temperature to drop to ambient levels
• Close valves V33 and V01;
• Open the drainage valves V25 and V24;
• Use the manual command of solenoid valve EV12 in order to allow the air entrance and the
drainage; place suitable containers to collect possible leaks of the process liquid;
• Disassemble both the flanges of heat exchanger;
• Remove the bolts, the check screws and open the heat exchanger;
• Clean the internal tube (concentrate flow) with the pipe cleaner. Add water to favour
removal of debris;
• Clean the external tube (feed flow) with the high-pressure water cleaner;
• Put the removed parts back in place in reverse order (tubes, flares, flanges, bolts);
• Close the drainage valves V25 and V24;
• Open the valves V33 and V01;
11.6.5 Inspection and cleaning of the distillate tank (D02)

technician with a standard toolbox and possibly with a high-pressure water
cleaner

and a high-pressure water cleaner.
Distillate entrainments may cause fouling and clogging accumulations inside the tank. The distillate
may be so polluted that it causes a fall in efficiency of the heat exchange of the heating resistors
ER01-05.
The washing procedure has to be carried out as follows:
• Drain the distillate storage tank through drainage valve V13;
• Wait for the temperature to drop;
• Disconnect the sensor LT04 so that it is not affected by maintenance operations;
• Fill the tank with tap water or with distillate through the drainage valve (a message on the
display informs that the work level has been reached;
• For more thorough cleaning, remove flange H33
• Use a flashlight to inspect the cleanliness of the tank
• Use a high-pressure water cleaner to carefully clean the tank;
• Remove (by unscrewing it from the housing) and if necessary clean the heating elements
of possible incrustations ER01-03;
168 TC 15000
• Before restarting the machine, make sure that the intake of pumps G03 and G05 are free
of any debris.
• Connect the sensor LT04
• Close the flange H33
• Close the valve V13;
11.6.6 Cleaning of the pumps for circulation (G01) and

feed (G02)
Wear suitable means of protection compatible with the treated liquids.
The circulation and feeding pumps are subjected to a continuous contact with the concentrated
process liquid, therefore their inner components are subjected to the worst dirty conditions.
Ordinary washing procedures and forced circulation may be sufficient to avoid any fouling
accumulation, but it could be necessary to carry on a cleaning operation of the pump on the table.
Pump cleaning operation should be carried out at the same time of heat
exchangers E01, E02 (see 11.6.1 and 11.6.2).
To clean pumps G01 and G02, proceed as follows:

• Disconnect the power supply to the machine using the main switch
• Close the shut-off pumps of the valves which are:
V07 for G01

• V01 for G02
• Completely drain the process liquid in the pump by opening of the drainage valves. They
are:
V24 for G01

V25 for G02

• Disassembly the fittings which connect pump to the process line;
• Remove the protective cover and disconnect the electric wires;
• Loosen and remove the bolts which connect the pump to the machine frame;
• Wash the inner components of the pump with water or another liquid compatible with the
process liquid;
• Take out the pump and check the external impeller through the suction and delivery holes.
If there is any solid material, try to remove it mechanically;
• If necessary, empty the pump and carefully clean all of its parts (rotors, mechanical seals,
etc.);
For further information about pump maintenance, see attached instructions

supplied by the pump constructor.
TC 15000 169
During the pump re-assembling operations, pay attention to replace the

gaskets correctly.
• Put the pump back on the frame and re-establish all electrical and plumbing connections.
Make sure the pump turns in the right direction.
• Re-open the shut-off valves and close the drainage valves
• Re-connect the power supply to the machine with the main switch
11.6.7 Cleaning the blower (K01)

It could be necessary to carry on a cleaning operation of the steam blower.


safety
For further information about this operation, see attached manual and contact
the constructor for the first cleaning operation.
The blower washing procedure has to be carried out as follows:

• Disconnect the temperature sensors (make a note for the correct connection);
• Disassemble the delivery and the suction connection tubes of the blower;
• Remove the delivery tube of the blower with suitable lifting equipment;
• Gently clean the delivery tube and the rotors of the blower with a suitable solvent or with
hot water (eventually using a pressure device), Make sure that no objects fall inside of it;
• Be sure not to fill the intake tube of the blower with water. In fact, it should never have
liquid flowing onto it
Use ONLY solvents that are compatible with the material the blower is made of.
See the manual of the blower for chemical compatibility of the materials.
Keep away from use abrasive material or object for not damage the blower. See
the manual of the blower for chemical compatibility of the materials.
• Reassemble backwards the blower;

• Turn the machine on with the main switch
170 TC 15000
11.6.8 Cleaning of the condensate flow sensors (FT01) (if
optional IX is present)
It could be necessary to carry on a cleaning operation of the distillate flow sensor (FT01). This
operation is required only if optional IX is installed and enabled for the measurement of the flow
rate of the discharged distillate.
For further information about this operation, see attached manual.
11.6.9 Replacement of the mechanical seal of the pumps

for circulation, discharge or feeding
The circulation or the feeding pumps are subjected to a continuous stress due to the process liquid
density and viscosity and therefore their inner components are subjected to the worst wear and
tear conditions.
If some leaks occur or if the system is not able to keep the vacuum because of mechanic seals
breakage, it is necessary to carry on maintenance operations of the pump on the table. The
mechanic seal breakage during normal operating conditions leads to flushing water leaks which
may cause a machine efficiency drop.

Mechanical seal replacement operations should be carried out at the same time as
cleaning operations (see par. 11.6.6).
To replace the mechanic seal, see attached instructions supplied by the pump
constructor.
11.6.10 Maintenance of the distillate discharge pump G03,

liquid injection pump G05 and fluxing pump G04
The maintenance operations on these pumps must be carried at the workbench. The procedure is:

For further information about pump maintenance, see attached instructions

supplied by the pump constructor.
TC 15000 171

gaskets correctly.
• Disconnect the power supply to the machine using the main switch
• If you want to work on pumps G03 or G05, drain the tank D02 by opening valve V13
• If you want to work on the pump G04, drain the tank D03 by disconnecting the delivery
hose of the pump
• Close the shut-off valves
V15-V16 for G03

V26-V11 for G05
V46 for G04

• Remove the fittings that connect the pumps to the tank D02 (G03 or G05) or to the tank
D03 (G04);
• Remove the protective cover and disconnect the electric wires;
• Loosen and remove the bolts which connect the pumps to the machine frame;
process liquid;
• Take out the pump and check the external impeller through the suction and delivery holes.
If there is any solid material, try to remove it mechanically;
• If clogging and fouling are present inside the impeller, it is recommended to replace it
because its cleaning could be very difficult or even impossible;
• Assembly the pump to the machine frame and restore all the hydraulic and electric
connections;
• Close valve V13 or reconnect the delivery hose of pump G04;
• Fill tank D02 or D03 with water up to the working level;
• Open the shut-off valves;
• Re-connect the power supply to the machine with the main switch
11.6.11 Cleaning the boiler and replacing the filling bodies

If, during the inspection of the boiling chamber D01, it is noticed that the grid which supports the
packing elements is dirty, it is necessary to clean or eventually replace the packing elements
themselves.


safety
172 TC 15000

Boiler cleaning
If only the lower part of the boiler and the lower layer of the filling bodies are dirty, wash as
follows:
• Wait for the temperature in the boiler to drop
• Open the door, after checking that the level of fluid in the boiler is below that of the door
• Remove sediments with a tap water jet or using an hydro-cleaning machine; if the problem
persists, replace the packing elements;
• Carefully clean the walls of the boiler with a jet of water, also making sure to clean the
levels in the boiler
• Use a jet of water that is not excessively strong to clean the level sensors LS01,02.03. If
necessary, once you have removed the electrical connections (which should be protected
against splashes), unscrew the sensors and clean them by gently wiping the blades of the
sensors with a cloth
Replacement
If the packing elements are clogged and dirty and the washing procedure has not led to good
results, replace them as follows:
• Drain the boiling chamber;
• Before operating, wait a couple of minutes after the boiling chamber door opening and the
room aeration.
• Set a container to collect the packing elements;
• Open the upper side door (accessing the upper part of the boiler using the ladder) to drain
the filling bodies;
• Take out the packing elements which have to be disposed;
• If necessary, wash the boiling chamber with water;
• Close the upper side door;
• Put in new packing elements random through the two doors located on the boiling
chamber dome;
• Close the door of the boiler;
11.6.12 Maintenance of level sensor LT04 of the distillate

tank
As time goes by, the level sensor LT04 (connected to tank D02) may have some functioning
problems caused by deposits and residue inside the tube which joins it to the distillate tank.

TC 15000 173
The maintenance steps are:
• Check the quality of the reading of the sensor. Connect the hose to the drain (valve V13)
and lift it. The column of liquid in the tube must be at the same height as shown in the
video9.9.5
• Drain the distillate storage tank using valve V13;
• Wait for the temperature to drop;
• Take off the fittings which connect the sensor to the distillate tank;
• Check cleaning conditions of the tube which connects the level sensor to the tank and
eventually remove detritus and residue using brushes or other tools;
• Check cleaning conditions of the sensor and eventually carry out a diaphragm cleaning,
avoiding pressures which may damage the sensor;
• Reassemble the sensor on the tube fitting;
• Re-fill the distillate tank with mains water through the vent conduit. A message on the
control panel will advise you when the working level has been reached)
• Check the quality of the reading of the sensor. Connect the hose to the drain (valve V13)
and lift it. The column of liquid in the tube must be at the same height as shown in the
video9.9.5
If the level sensor is still not working after these operations, contact the constructor or vender
technical assistance department.
11.6.13 Cleaning of concentrate and distillate discharge

tubes
Liquid discharge tubes are subjected to fouling which may accumulate with time.
The operations to carry out are:
• Drain the boiling chamber and the distillate tank (open valves V24 and V13);
• Disassembly piping and line parts (pumps, valves, fittings, sensors, etc.) remembering the
components assembly order;
• Check cleaning conditions of piping and line parts;
• carry out a washing with water or with a chemical agent and, if necessary, mechanically
remove detritus and residua using brushes or other tools. Carry out a final washing with
water;
• Clean carefully the sensors to avoid any damage;
• Reassembly piping and line parts;
11.6.14 Maintenance of metering pumps G06 and G07

These pumps may need to be cleaned at the workbench
The procedure is carried out as follows:

• Close the shut-off valves V41 and V23 (for G07) and V22 and V40 (for G06)
• Disassembly the fittings which connect the pumps to the process line;
• Disconnect the pneumatic supply;
• Loosen and remove the bolts which connect the pump to the machine frame;
174 TC 15000
process liquid;
• Take off the pump and check the impeller through suction and delivery holes. If there is
any solid material, try to remove it mechanically;
If there are clogging and fouling also inside the diaphragms, since the cleaning
procedure should be quite difficult (or even impossible), it is recommended to
disassembly the pump totally (see instruction manual supplied by the pump
constructor).

gaskets correctly.
• Reassembly the pump on the machine frame and restore all hydraulic and pneumatic
connections;
• Open the shut-off valves;
• Turn the machine on with the main switch
11.6.15 Cleaning and maintenance of diaphragm valves

with pneumatic actuator
This operation is carried out if there is leakage or clogging. This may be caused by a deterioration
of the closure membrane or its fouling. The procedure is:
• Isolate the process lines upstream and downstream the pneumatic valve, referring to the
attached process diagram;
• Disconnect the pneumatic supply of the diaphragm valve which has to be fixed;
• Take out the diaphragm valve from the process line, taking care of collecting eventual
liquid leaks coming out the isolated line;
• Take out the four fixing screws from the lower part of the diaphragm valve and remove its
upper part;
Never loosen the screws which fasten the actuator: it is supplied with stretched
springs which, if unfastened, may damage people or objects.
Disassembly the butterfly pneumatic valve following the instructions supplied

by the constructor.
• Clean the valve diaphragm and body;

• If the diaphragm is damaged, change it;
• Reassembly the pneumatic valve tightening the four screws and checking the correct
components placement;
If it is difficult to insert the screws, inlet 500 kPa compressed air into the
pneumatic valve actuator so that the diaphragm is pushed inside.
• Connect the diaphragm pneumatic valve to the process line;

• Connect the diaphragm valve to the pneumatic supply;
• Restore the opening of the valves used to isolate the diaphragm valve;
TC 15000 175
11.6.16 Cleaning and maintenance of butterfly valves with
pneumatic actuator
This operation is carried out if there is leakage or clogging. This may be caused by a deterioration
of the closure membrane or its fouling. Proceed as follows:
• Isolate the process lines upstream and downstream the pneumatic butterfly valve,
referring to the attached process diagram;
• Disconnect the pneumatic supply of the butterfly valve which has to be fixed;
• Take out the butterfly valve from the process line, taking care of collecting eventual liquid
leaks coming out the isolated line;
• Take out the four fixing screws from the lower part of the butterfly valve and remove its
upper part;
Never loosen the screws which fasten the actuator: it is supplied with stretched
springs which, if unfastened, may damage people or objects.
Disassembly the butterfly pneumatic valve following the instructions supplied

by the constructor.
• Clean the valve butterfly and body;

• If the butterfly is damaged, change the whole valve;
• Reassembly the pneumatic valve tightening the four screws and checking the correct
components placement;
• Connect the butterfly pneumatic valve to the process line;
• Connect the butterfly valve to the pneumatic supply;
• Restore the opening of the valves used to isolate the butterfly valve;
11.6.17 Check of the solenoid valves of the pneumatic

circuit
This operation is carried out whenever there are doubts on the correct functioning of the air
compressed unit solenoid valves, which control the pneumatic valves opening. Proceed as follows:
• Locate the solenoid valve EV05 and disassembly the electric connection unscrewing the
fixing screw (the pneumatic valve VP05 is normally closed and for this reason nothing
happens);
• Locate the suspected valve and disassembly the electric connection unscrewing the fixing
screw;
• Place the electric connection of solenoid valve EV05 on the suspected valve;
• Disconnect the compressed air tube at the outlet of the suspect solenoid valve;
• activate the manual command for the antifoam metering which should activate the
solenoid valve EV05;
• Check if there is a correspondence between the command associated to the key and air
coming out the suspected solenoid valve;
• If the solenoid valve is not working, check the coil and/or electric circulation. To carry out
these operations, contact the constructor or vender technical assistance department;
If the suspect solenoid valve is just the solenoid valve EV05 itself, use as a
check the solenoid valve EV06 associated with the additive metering control
• Connect the electric connections to the solenoid valves;
176 TC 15000
11.6.18 Manual concentrate discharge procedure

If maintenance operations on the concentrate hydraulic circuit or on the boiling chamber are
required, it is necessary to drain the boiling chamber and the parts connected to it.
This operation is recommended also when a fluid, different from the one previously treated, has to
be concentrated, in order to avoid different products mixing. To discharge the concentrate,
proceed as follows:
• Proceed by manually activating the discharge pump until reaching level LS01 (par.9.9.7 )
• If necessary, drain the boiling chamber and the circulation lines by means of the valves
V24 and V25.
11.6.19 Inspection and cleaning of shell of heat exchanger

E01
Cleaning of the shell of exchanger E01 should not be necessary so often, since possible fouling
may be due to foam or additives entrainment or to a high concentration ratio.


Proceed as follows:
• Drain the heat exchangers as described in par. 11.6.1;
• Make sure that the level of distillate in D02 is not high. If necessary, drain it
• Disconnect the level sensor LT04;
During this operation, it is recommended to place several containers to collect

possible leaks of the process liquid.
• Remove te flange and disconnect the pipe between K01 and E01 making sure that the
sensor TT04 is in the right placement;
• Using an electric torch, visually check the shells cleanliness.
• Perform washing using a high-pressure water cleaner with water that will collected at the
outlet of the distillate discharge tube;
• Before restarting the machine, make sure that the intake of pumps G03 and G05 are free
of any debris.
• Connect the pipe between K01 and E01 making sure that the sensor TT04 is in the right
placement;
• Connect the level sensor LT04;
• Turn on the machine using the main switch;
TC 15000 177
11.6.20 Check of hot air extraction fan and electrical panel
filter
If the temperature is over 45°C, check the fan normal working and the state of filter preservation.
11.6.21 Calibration of electrical conductivity transducer

(CT01)
Transducer calibration is carried out every time a significant difference between the measurement
made by the electrodes and the measurement made by a calibrated portable instrument is
detected.
The calibration of transducer CT01 must be carried out also when electrode CE01 is replaced.
Proceed as described in the attached manual of the conductivity transducer.
11.6.22 Check of fuses

This operation is carried out when the electric component protected by a fuse does not work.
This operation has to be carried out by electrical qualified personnel able to

read and correctly interpret the wiring diagrams.
Isolate the machine from the power supply using the switch upstream from the
machine.
• Open the electric cabinet and, with the help of the wiring diagram, find the fuse to be
checked;
• Lower the fuse-holder and take out the fuse or fuses;
• Check the electrical continuity of the fuse with a tester. If there is no continuity, replace
the fuse with a similar one;
• Close the electric cabinet, supply power to the machine and start it again at the main
switch.
11.6.23 Resetting the motor protections

This operation is carried out when an alarm due to a motor-protection intervention is triggered.
This operation has to be carried out by electrical qualified personnel able to

read and correctly interpret the wiring diagrams.
Isolate the machine from the power supply using the switch upstream from the
machine.
• Open the electric cabinet and, with the help of the wiring diagram, find the motor-
protection device to be checked
• Push the button to restore the motor-protection device;
• Close the electric cabinet, supply power to the machine and start it again at the main
switch.
If the motor-protection device is triggered again, check it and eventually

replace the electric component connected to it.
178 TC 15000
11.6.24 Procedure for drainage of liquids in the machine
The procedure specified below is to be carried out if the machine will be
installed in a place where the temperature reaches 0°C. This procedure is
aimed at preventing possible freezing of the liquid in the machine
11.6.24.1 Preliminary operations

Then refer to the numbering attached to the process diagram of the machine
11.6.24.2 Drainage of "same" and "concentrate" line

• Open the manual valve V24. Make sure that the liquid can be discharged freely
• Open the manual valve V34, V35, V36. Make sure that the liquid can be discharged freely
• Force the opening of pneumatic valve VP01 (manually acting on solenoid valve EV01)
When the operation is complete, after you have made sure that the liquid is complete drained,
proceed in reverse order so as to reset the conditions of the machine:
• Release solenoid valves EV01 and EV07
• Close manual valves V24, V25 V34, V35, V36. Check and decide autonomously if open
valve V33.
11.6.24.3 Drainage of distillate line

• Open the manual valves V12, V13, V14 making sure that the liquid can be freely
discharged
• Open the plug located under the filter F01, making sure that the liquid can be freely
discharged
• Open plugs H22 located downstream no return valve VR02 (on delivery line of pump G03),
making sure that the liquid can be freely discharged
• Release solenoid valve EV08 and EV17
• Close manual valves V12, V13 and V14.
• Close the plugs H22.
• Close the plug located under the filter F01.
11.6.24.4 Drainage of fluxing system

• Open manual valve V46
• Detach the hose on the delivery of pump G04. Make sure the liquid can be freely
discharged
• Use a jet of compressed air to dry the outer faces of the mechanical seal of pump G01
• Re-attach the hose located on the delivery of pump G04
TC 15000 179
11.6.25 Prolonged machine shutdown

If the machine is shut down for longer than twenty-four hours, the liquid in the boiling chamber
has to be discharged (see par. 11.6.18) and the machine has to be washed. Some of the machine
components are subjected to wear and tear even when the machine is not running: this situation is
physiologic and is related to the materials which have been used. If the machine does not work for
longer than 180 days, the circulation pump G01 and feeding pump G02 mechanic seal may run out
and leak when the machine is restarted. Refer to par. 0 for further information on the replacement
of the seal.
180 TC 15000
MAINTENANCE INFORMATION FOR EVAPORATOR VWS TC 15000
plant way of conduction.

The mentioned scheduling is a mere estimation and is referred to standard working conditions of the plant. Scheduling can change due to real plant working conditions and to
FREQUENCY (every-)
System section/operation Day Month Six months Year To be defined

CONTROLS
Measurement of machine data on VWS card (par 11.2.1) X
Adjustment of process parameters (par. 11.2.2) X
Check of foam formation in D01 (par. 11.2.3) X
Check of operation of anti-foam metering device (par. 11.3.5) X
Check level in tank D04 of the anti-foam (par. 11.2.4) X
Check level in tank D05 of the additive (par. 11.2.5)) X
Check of the amount of concentrate discharged by the evaporator (par.11.3.1) X
Check of the production of distillate (par.11.3.1) X
FILTERING DEVICES
Cleaning of filter F01 (par. 11.3.7) X
Cleaning of compressed air filter PCV12, PCV13, PCV14 (par. 11.3.1) X
CONDUCTIVITY METER PROBE CE01
Control and cleaning of probe (par. 11.3.6) X
Transducer calibration(par. 11.6.21) X
EXCHANGERS E01-E02-E03 /BOILER D01 /TANK D02
Mechanical cleaning E01 tube side (par. 11.6.2) X
Chemical cleaning E01 tube side (par. 11.6.2) X
Mechanical cleaning E01 shell side (par. 11.6.2) X
Cleaning mechanical exchanger E02 (par. 11.6.3) X
Cleaning mechanical exchanger E03 (par. 11.6.4) X
Cleaning of boiling chamber D01 and filling body (par. 11.6.11) X
Cleaning of tank D02 (par. 11.6.5) X
PLUMBING CONNECTIONS
Check of seal of plumbing connections and vacuum seal (par. 11.5.1) X
Cleaning of concentrate and discharge tubes (par. 11.6.13) X
BLOWER K01
Oil change (par. 11.3.8) X (first change 500 h
after start-up)
Cleaning of blower (par. 11.6.7) X
ELECTRICAL PANEL AND ELECTRICAL DEVICES IN FIELD
Check of tightening of electrical terminals (par. 11.4.1) X
TC 15000 181
182 TC 15000
Obtained data chart
R.d.I. n°_____________ Att.n°___________
model: ______________ Serial n° ______________

um
Operator
Date
Time
Working hours of the blower (par.9.9.2) h
FUNCTIONING DATA
Pressure in the boiler (par.9.9.1) KPa
Temperature in the boiler (par.9.9.1) °C
Pressure in the blower suction(par.9.9.2) KPa
Temp.in the blower suction (par.9.9.2) °C
Delta pressure (par.9.9.2) KPa
Delivery pressure (par.9.9.2) KPa
Delivery temperature (par.9.9.2) °C
Electric consumption of blower (par.9.9.2) A
Blower speed (par.9.9.2) Hz
Supply pump speed (par. 9.9.4) %
Flow rate of distillate pump (par.9.9.5) l/h
Speed of distillate pump (par.9.9.5) %
Conductivity of distillate (par.9.9.10) µS/cm
Liters of produced distillate (par.9.9.5) l
Density of concentrate (par.9.9.12) g/l

USER SETUP
Way of work (volume/density) (par.9.8)
Concentration ratio (par.9.8)
Concentrate discharge density (par.9.8) g/l
Opening discharge conc. valve. (par.9.8) sec
antifoam pause/work (par.9.9.8) min/sec / / / /
Additive pause/work (par.9.11) min/sec / / / /

MEASUREMENTS
Amuont of concentrate per each discharge (measured at
l
the end of the line) (par.11.3.2)
pH feed liquid (par.11.6.1.1) pH
pH in distillate (par.11.6.1.1) pH
pH in concentrate(par.11.6.1.1) pH
Room temperature °C

MAINTENANCE/CONTROL
Foam in boiler (YES/NO)
Control levels of chemicals (OK/KO)
Cleaning of heater E01 (YES/NO)
Cleaning of levels in the boiler (YES/NO)
Alarms (number)
Notes (activities carried out)

Client signature VWS Italia technician signature date
TC 15000 183
184 TC 15000
12 Disassembly and demolition
CHAPTER 12
12 Disassembly and demolition
12.1 Disassembly
If the user decides to move or remove the machine, it is necessary to prepare it for disassembly.
The steps to follow are:
• empty the boiling chamber;
• wash and cleaning the machine;
• drain the distillate storage tank (see par. 11.6.3);
• isolate the machine from the various supply networks, using the corresponding isolating
devices;
• disconnect the connections to the various supply sources
12.2 Demolition
When the machine has terminated its life cycle and before proceeding with final dismantling, it is
necessary to carry out a series of operations to minimize the environmental impact related to
disposal of system components, as required by laws and regulations in force.
Proceed as follows:
• disassemble the machine (see par. 12.1);
• recover and dispose the blower oil;
Store the lubricating oil in a tank and then dispose it through specialized organization.
• destruction of the CE mark plate (see par. 1.1);

• dispose the machine casing.
Once all the process fluids and other polluting elements have been removed, the
disposal of the casing should be commissioned to a specialized organization.
TC 15000 185
Disassembly and demolition 12
186 TC 15000
13 Attachments
CHAPTER 13
13 Attachments
The following documentation is attached to this manual:
1. Conformity Statement CE.
2. Certificate of Guarantee.
3. Copy of number plate on board.
4. TC 15000_LYT NN (lay out drawing)
5. Test sheet.
6. Spare parts list.
7. Process diagram
8. Wiring diagrams.
9. List of the documents related to the components.
10. Documents related to the components.
Each single attached document is inserted in a plastic envelope identified by a

number of the list described above.
TC 15000 187

Y. Evaporator TC 15000 PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Y. Evaporator TC 15000 PDF

Загружено:

Авторское право:

Доступные форматы

TC 15000

USE AND MAINTENANCE

Written by Elena Mussio (VWS Italia)

2 Functional description _____________________________________ 23

4 Pre-installation requirements _______________________________ 39

5 Packing, handling and storage ______________________________ 43

6 Assembly and positioning of the machine ______________________ 49

7 Connection to external and service networks ___________________ 53

8 Start-up and commissioning ________________________________ 59

9 Control and signal devices __________________________________ 65

10 Diagnostics ____________________________________________ 131

11 Control, adjustment, maintenance __________________________ 155

12 Disassembly and demolition _______________________________ 185

13 Attachments ___________________________________________ 187

The manual contains continual references to the concepts expressed in this

1.1 Identification of the machine

Figure 1.1-1 - Identification plates and CE mark

Figure 1.1-2 – Position of the identification labels on the electrical panel

1.2 Graphic symbols used

1.2.1 General symbols

It points out warnings, notes, suggestions and important operating methods to

It indicates manual paragraphs which are related to other sections of the

1.2.2 Danger signals

General danger warning:

1.2.3 Prohibition signs

General forbidden state warning:

Do not stand in the manoeuvre and lifting areas

Do not climb on the system structures

1.2.4 Obligation state

General obligation signal:

1.3 Generality about the manual

1.3.2 Instructions on using the manual

Any unauthorized copying, total or partial, of this manual is strictly

If there is a real need, further copies or editing of this manual may be

1.4 Measure units

1.4.1 International System base units

Table 1.4.1 – Base units

1.4.2 International System derived units

decibel with A type weighting

Table 1.4.2 – Derived units

Table 1.4.3 – Conversion factors

1.5 Personal protection devices

It is compulsory to wear suitable clothing, avoiding loose clothing parts which

It is compulsory to use acoustic protection devices (headset) when working

It is compulsory to use of protection devices (mask) to protect the respiratory

It is obligatory to use type S1 safety shoes

It is compulsory to use head protection devices (helmet) when it is necessary to

It is compulsory to use protection devices (slinging) to safeguard the personnel

1.6 Qualification of operators

The use of the machine is strictly FORBIDDEN to operators which take

Access to the machine is absolutely PROHIBITED to persons who are not

The knowledge of the information included in this manual is COMPULSORY,

1.6.2 Operators types

PERSONNEL REQUIRED DURING MOVEMENT/INSTALLATION/DISASSEMBLY OF THE

Operation made by untrained personnel may lead to dangerous situations.

Qualified operators HAVE to have an overall knowledge of required safety

1.6.3 Handling personnel

Persons assigned to handling must have all qualifications or certifications

1.6.4 Mechanical assembler

The technical installation personnel (provided by the manufacturer, by the

1.6.8 Machine operator

The machine operator is able to:

1.6.9 Maintenance technician