Affag

ITALIMPIANTI ORAFI
S.p.A.
Manual n. affag Revision 1.0 dtd 23-03-06 Page 1 of 28 Macchina : AFF20AG-1
Via Provinciale di Civitella, 8 52041 BADIA AL PINO (AR) - Italy Telefono : +39 0575-4491 Fax :+39 0575-449300
AFF/20AG-1
Instruction and maintenance manual
ITALIMPIANTI ORAFI
S.p.A.
Index 1 2 ID PLATE ___________________________________________________________ 4 INTRODUCTION ______________________________________________________ 5 2.1 2.2 2.3 3 4 Instruction manual _________________________________________________ 5 Personnel requirements _____________________________________________ 6 Rating plates _____________________________________________________ 8
LAYOUT ____________________________________________________________ 9 Description _________________________________________________________ 10 4.1 Units___________________________________________________________ 10 10 10 11 11 4.2 Technical data ___________________________________________________ 4.2.1 RAD/AU rectifier______________________________________________ 4.2.2 IAAG refining cell _____________________________________________ 4.2.3 VAG/A circulation tank _________________________________________
Specific Safety Standards_____________________________________________ 12 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Risks due to electricity _____________________________________________ 12 Risks due to extreme temperatures ___________________________________ 12 Fire risks _______________________________________________________ 12 Risks of explosion ________________________________________________ 12 Risks due to noise ________________________________________________ 13 Risks due to emissions of powder, gas etc _____________________________ 13 Breakdowns during use ____________________________________________ 13 Foreseen and not foreseen uses of the machine_________________________ 13 Requirements for the personnel______________________________________ 14 TRANSPORT____________________________________________________ 15 Foreseen prearrangements _________________________________________ 15 Unpacking ______________________________________________________ 15 Positioning ______________________________________________________ 16 17 17 18 19 20 21
INSTALLATION______________________________________________________ 15 6.1 6.2 6.3 6.4
6.5 Assembly _______________________________________________________ 6.5.1 Frame______________________________________________________ 6.5.2 Rectifier ____________________________________________________ 6.5.3 VAG/A circulation tank _________________________________________ 6.5.4 IAAG refining cell _____________________________________________ 6.5.5 Discharge valves _____________________________________________
6.6 Connections _____________________________________________________ 22 6.6.1 Power supply ________________________________________________ 22 6.6.2 Fume suction tubes supply _____________________________________ 22
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ELECTROLYTIC SILVER REFINING _____________________________________ 23 7.1 7.2 Generic preliminary operations ______________________________________ 23 Preliminary operations for refining silver _______________________________ 23 24 24 24 24 26
7.3 The refining process ______________________________________________ 7.3.1 Starting the rectifier ___________________________________________ 7.3.2 Stopping the rectifier __________________________________________ 7.3.3 Recovering daily production_____________________________________ 7.3.4 Treating the AgNo3 solution_____________________________________ 8 8.1
ORDINARY MAINTENANCE ___________________________________________ 27 Tubes control ____________________________________________________ 27 8.2 Rectifier maintenance _____________________________________________ 27 8.2.1 Filter maintenance ____________________________________________ 27 8.2.2 Electric and electronic components maintenance ____________________ 27
RESPONSABILITY ___________________________________________________ 28
ITALIMPIANTI ORAFI
S.p.A.
1 ID PLATE
Manufacturer : Address :
ITALIMPIANTI ORAFI SpA Via Provinciale di Civitella, 8 52041 BADIA AL PINO (AREZZO) Italy Tel. : (+39) 0575 449.1 Fax : (+39) 0575 449.300
Year :
2007
The manual contains information protected by patents. All rights are reserved. Italimpianti Orafi S.p.A. follows a sales policy that allows for a continual improvement of its products. For this reason, this information can be changed without any forewarning. It is forbidden to copy this manual, even in part, without Italimpianti Orafis written consent. Italimpianti Orafis logo is deposited.
ITALIMPIANTI ORAFI
S.p.A.
2 INTRODUCTION
2.1 Instruction manual
The purpose of this instruction and maintenance manual is to provide all the necessary information to safely operate this machine. The manufacturer of the latter is at disposal for any questions the user might have. The instruction manual is divided into main chapters and subchapters, all listed in the index. In these chapters and subchapters the instructions may be accompanied by graphic or photographic illustrations. The intended uses of the machine are clearly stated in the enclosed description. You will find the following symbols in this manual: IMPORTANT : instructions of particular importance NOTE : informative notes
PROHIBITION : prohibited operations TECHNICAL ASSISTANCE : contact the assistance centre WARNING
Italimpianti Orafi S.p.A. follows a sales policy that allows for a continual improvement of its products. For this reason, this information contained in the present manual can be changed without any forewarning. This instruction manual must be stored for future reference.
ITALIMPIANTI ORAFI
S.p.A.
2.2
Personnel requirements
There are general safety aspects that must be brought to the attention of the personnel : Read the present manual carefully and follow the instructions herein ; Keep the present manual in a place accessible by all workers ; The present manual is an integral part of the machine, in case of loss or deterioration, ask the manufacturer for another copy; Use the machine only if authorised and properly trained; Do not remove or tamper with the protective carters, protective covers or safety devices; In cases of removal or tampering of protective carters, protective covers or safety devices, immediately warn the manager. Immediately turn the machine off; Always wear the foreseen individual protection devices. Description of the definitions found in this manual:
TRAINED PERSONNEL: refers the worker authorised to work with the unit must have carefully read the present manual and been appropriately trained and informed as to all safety and hygiene aspects by the employer. HEAD OF DEPARTMENT : refers to the head of department responsible for unit. Must keep the key to the padlock on the main switch of the unit. ELECTRICAL MAINTENANCE MAN : refers to the worker authorised to carry out maintenance operations on electrical components inside the machine. Must have carefully read the present manual, been appropriately trained and informed as to all safety and hygiene aspects by the employer and have specific experience. MECHANICAL MAINTENANCE MAN : refers to the worker authorised to carry out maintenance operations on mechanical and hydraulic components inside the machine. Must have carefully read the present manual, been appropriately trained and informed as to all safety and hygiene aspects by the employer and have specific experience
ITALIMPIANTI ORAFI
S.p.A.
Bear the following safety features in mind : The present manual supplies all the necessary safety indications and instructions according to the Safety Norms en force. This does not represent a substitution to the good sense and experience of the operator.
The employer must analyse the various functions and characteristics of the machine, the adopted safety precautions, any eventual personal protection devices, and any remaining risks. Subsequent to this analysis, he must evaluate which personnel should be authorised to operate the machine.
ITALIMPIANTI ORAFI
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2.3
Rating plates
WARNING, ELECTRICAL POWER RISKS ACCESS THE ELECTRICAL EQUIPMENT ONLY AFTER HAVING TURNED OFF THE POWER SUPPLY AND WAITED FOR A MINIMUM OF 120 SECONDS WARNING, RISKS DUE TO EXTREME TEMPERATURES
WARNING, RISKS DUE TO FLAMMABLE GASES
WARNING, LOW FREQUENCY ELECTROMAGNETIC FIELDS.
NON
IONIZING
RADIATION,
PERSONS WITH PACEMAKERS OR OTHER ELECTRONIC DEVICES ARE NOT ALLOWED TO APPROACH THE UNIT
FORBIDDEN TO USE WATER TO PUT OUT EVENTUAL FIRES
NON-AUTHORISED PERSONNEL ARE FORBIDDEN ACCESS TO THE INSIDE OF THE UNIT
OBLIGATION TO WEAR HEAT PROTECTIVE GLOVES
ITALIMPIANTI ORAFI
S.p.A.
3 LAYOUT
ITALIMPIANTI ORAFI
S.p.A.
4 Description
4.1 Units
The unit consists of: Framework & platform RAD/AU rectifier IAAG refining cell VAG/A circulation tank
4.2
4.2.1
Technical data
RAD/AU rectifier
The rectifier is used to supply electric current to the refining cell. It is also provided with an electronic voltage stabilizer. RECTIFIER POWER SUPPLY Rated supply voltage : 400 V ac three-phase Rated frequency : 50 - 60 Hz Rated apparent power : 17 KVA Rated input : 25 A Max. voltage variation compared to rated value: +/- 10% Neutral (N) is not required for the electrical equipment OPERATING CONDITIONS Ambient temperature: lower limit 10 C; top limit 40 C. Ventilation of room: ensure that there are suitable apertures for ventilation. The fans air flow is 2800 m3/h.
PROTECTION SYSTEMS Overload protection: magneto thermal power supply switch Protective devices against short-circuit overloads and differential in the users power supply panel are required. We recommend you to connect the external protection conductor to the terminal marked PE. The minimum cross-section of the external copper conductor must be in conformity with table No. 1 of CEI - EN - 60204.
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RECTIFIER OUTPUT Rated current : 1500 A Rated voltage : from 0 to 8 V Rated power : 12 KW Current regulation : from 0 to 100% Voltage regulation : from 0 to 100% Operation: by constant current or constant voltage
4.2.2
IAAG refining cell
The IAAG refining cell has a capacity of 275 lt and is supplied with : Stainless steel cathodes Antiacid filter anode bags Suction hood
4.2.3
VAG/A circulation tank
This tank fills the refining cell and maintains the liquid level inside it constant using a pneumatic pump.
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5 Specific Safety Standards

5.1 Risks due to electricity
This section describes the technical solutions that have been adopted to comply with the Essential Safety Qualifications (RES) established by the machinery directive 89/392/EEC. It is essential for the room where the unit is installed to be fitted with a differential switch. The electric installation is in conformity with Standard 60204-1 concerning the prevention of all electrical risks. In detail : As a prevention against risks, under normal working conditions, of coming into contact with parts that are under tension, paragraph #6 has been applied where, for all the enclosures, the chosen grade of protection (IP54 according to Standard EN 60529) is overabundant. As prevention against risks, in a breakdown condition, of coming into contact with parts that are under tension, the equipotential connections foreseen by paragraph #8 have been made. There are extremely low tensions present on the anode bars (max. 10 Volts). Any eventual risks linked to these tension levels are cancelled by wearing neoprene gloves that have to worn as a protection against chemical agents.
5.2
N/A
Risks due to extreme temperatures
5.3
Fire risks
The floor does not have to be combustible (no reaction to fire according to ISO 3261). Risks of overheating and/or fire due to short-circuits or overloads of electrical components have been prevented by applying the equipment protections indicated in paragraph 7 of Norm EN 60204-1.
5.4
Risks of explosion
The Requirements of the personnel section describes the level of training the workers must have to use and carry out maintenance on the plant.
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5.5 Risks due to noise
S.p.A.
The acoustic noise Leq that was measured resulted less than 70 dB (A)
5.6
Risks due to emissions of powder, gas etc
The Maintenance section underlines the need to carry out maintenance operations to the valves and connections fitted on the machine. The operator must foresee sufficient ventilation for the room in which the machine is placed
5.7
Breakdowns during use
The Maintenance section of the manual indicates the types of frequency of the maintenance operations required for safety reasons as well as parts subject to use and instructions to change them.
5.8
Foreseen and not foreseen uses of the machine
Any other use is forbidden and the producer declines all responsibility in such cases. The plant works with acids, which are harmful. The floor does not have to be combustible (no reaction to fire according to ISO 3261). The storage and use of flammable materials near the machine is not allowed. The user will have to make sure that the room in which the plant is installed and the means to install it are in conformity with the safety standards. An adequate aspiration must be foreseen. The storage and use of flammable materials near the machine is not allowed. The operator will have make sure that the environment in which the machine is installed and the means used to do this are in conformity with the safety standards. He must also make sure that there is sufficient ventilation. If necessary, the building in which the machine is placed, or the machine itself if it is partially or completely exposed to the open air, must be protected from atmospheric electrical discharges (ex. : lightning). The level of acoustic noise of the machine can be influenced by its surroundings. It is advisable to use a preferential power supply system for the plant.
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ITALIMPIANTI ORAFI
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5.9
Requirements for the personnel

It is necessary to select qualified and attentive personnel. Their training is essential to safely use the plant and for the maintenance operations that have to be carried out periodically. Experts authorised by the user of the plant must carefully train all the personnel. Courses to update them must be foreseen. The personnel must have access to this manual and any other necessary information at all times. The personnel must be trained and must be sure, when entering the room, that it has been sufficiently aired and does not contain toxic or asphyxiating gases. They should also know how to work in confined spaces. The following I.P.Ds (Individual Protection Devices) must be used: o Antiacid neoprene gloves o Antiacid glasses o Antiacid shoes o Antiacid overall
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ITALIMPIANTI ORAFI
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6 INSTALLATION
6.1 TRANSPORT
Examine with care all the components of the shipment. Inform Italimpianti Orafi of any damage. These operations must be carried out by specialised personnel who must be wearing the following protective clothing (IPD individual protective devices) : Gloves against mechanical aggression Safety shoes Avoid where possible excessive oscillations.
6.2
Foreseen prearrangements
The floor should not be combustible (no reaction to fire according to ISO 3261).
6.3
Unpacking
Remove the packing with utmost care making sure not to damage its contents. Examine with care all the components of the shipment. Warn Italimpianti Orafi by fax if there are signs of damage occurred during transport. The floor does not have to be combustible (no reaction to fire according to ISO 3261). The storage and use of flammable materials near the machine is not allowed. The user will have make sure that the environment in which the machine is installed and the means used to do this are in conformity with the safety norms. He must also make sure that there is sufficient ventilation. If necessary, the building in which the machine is placed, or the machine itself if it is partially or completely exposed to the open air, must be protected from atmospheric electrical discharges (ex. : lightning). The level of acoustic noise of the machine can be influenced by its surroundings.
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6.4
Positioning
After unpacking, proceed to position all the units as shown below :
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6.5
6.5.1
Assembly
Frame
Assemble the metal frame following the frame reference numbers. Make sure all connection bolts are properly tightened before proceeding. Position the metal frame accordingly.
Framework
Connection bolts
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6.5.2
Rectifier
Position the rectifier on top of the metal frame. Move the unit using a forklift truck.
Rectifier
Note there are references holes on the frame platform. Align the rectifiers base plate with these holes. See the following pictures for a visual reference. Make sure all connection bolts are properly tightened before proceeding.
Reference holes
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ITALIMPIANTI ORAFI
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6.5.3
Position the circulation tank on top of the metal frame. Move the unit using a forklift truck.
Note there are references holes on the frame platform. Align the tanks base plate with these holes. See the following pictures for a visual reference. Make sure all connection bolts are properly tightened before proceeding.
Connection bolts
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ITALIMPIANTI ORAFI
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6.5.4
IAAG refining cell
Position the refining cell tank on top of the metal frame. Move the unit using a forklift truck.
IAAG refining cell
Note there are references holes on the frame platform. Align the cells base plate with these holes. See the following pictures for a visual reference. Make sure all connection bolts are properly tightened before proceeding.
Connection bolts
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ITALIMPIANTI ORAFI
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6.5.5
Discharge valves
Assemble the two valves to the bottom of the IAAG cells
Partially assembled IAAG valve
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6.6
Connections
All electrical connections must be carried out only by the ELECTRIC MAINTENANCE MAN, as specified at the beginning of this instruction manual. 6.6.1 Power supply
380 V threephase with ground. If in doubt, contact the assistance centre. The electrical connection line must be protected from overloads and short-circuits.
6.6.2
Fume suction tubes supply
Connect the fume suction tubes as illustrated in the picture below.
Fume suction tubes
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ITALIMPIANTI ORAFI
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7 ELECTROLYTIC SILVER REFINING
PUT ON GLOVES, FACE MASK, GLASSES AND PROTECTIVE CLOTHING BEFORE STARTING
7.1
Generic preliminary operations
Preliminary operations are all those operations that have to be carried out every time work is started, especially after a long shutdown period. Make sure the water circulates properly with subsequent detailed verification of all parts subject to use (transport guides) and relevant waterworks connections. Make sure there are no water losses. Contact the assistance centre if there are water leaks. Make sure all electrical connections are secure.
7.2
Preliminary operations for refining silver

Proceed to remove the protective films from the cathodes inside the IAAG cells. If necessary, disconnect each connection bar at the back of the cell. Fill the IAAG tank to maximum of its total capacity with the electrolyte solution Place the silver anodes inside the anode bags inside the IAAG refining cell.
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ITALIMPIANTI ORAFI
7.3 The refining process
S.p.A.
You can now begin to refine the silver in the IAAG cell.
7.3.1
Starting the rectifier
Set the rectifiers main power switch to the ON or the 1 position. The three red LINE lights on the control panel should light up to indicate the presence of power. Select constant voltage using the VOLTAGE/CURRENT selector. Set the desired voltage value (in Volts) by turning the dial of the potentiometer (VOLT. CURR. REG.). Set a value of 1 1.2 V. Start the working cycle by pressing the START button. Make sure that the instruments indicate the voltage value.
7.3.2
Stopping the rectifier
The delivery of power can be stopped manually by pressing the STOP button on the control panel. Set the main power switch to either the OFF or the 0 position to disable the power supply whenever the rectifier will no longer be used. If the rectifier is disabled while still functioning by setting the main power switch in either the OFF or the 0 position without first pressing the STOP button on the front control panel, the over voltage that is created might damage the machine. Before switching the rectifier off, first stop the delivery of power using the STOP button.
7.3.3
Recovering daily production
Shut down the rectifier using its main switch.
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The silver crystals will have deposited on the bottom the IAAG cell. If necessary, use a water gun to clean the cathodes of any crystals. Put the trolley unit for transferring the solution from main tank under the discharge valves.
Valve 1
Valve 2
Trolley unit
Discharge valve 1 should open and the filter crystals should be visible through the inspection window. Close valve 1 and open valve 2. The silver crystals, with some of the solution, will drop into the trolley unit. Close valve 2 and re-open valve 1. More silver crystals will now be visible. Repeat these operations until all the crystals have been discharged. Replenish the IAAG cell accordingly.
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7.3.4
Treating the AgNo3 solution
Exhausted AgNo3 solution obviously contains silver as well as copper, both in solution. There are two possible methods to follow to recover the silver :
7.3.4.1 Method 1
This method consists of recovering the silver from the solution by precipitating it as a metal. Put the solution into a large tank Place copper sheets inside the tank. The silver will begin to precipitate to the bottom. After several hours it will become necessary to see if there is still silver in solution; follow the instructions below to do this. Dissolve a spoonful of table salt in a glass of water Add a few drops of this liquid to the solution. If the liquid does not turn milky in colour then all the silver has precipitated and we are now left with a copper nitrate solution (CuNo3). Discharge and filter the solution. The silver will stay on the paper. The CuNo3 solution should be sent to a suitable storage tank and subsequently treated accordingly.
7.3.4.2
Method 2
This method consists of recovering the silver by precipitating it as AgCl. Make a large batch of salt dissolved in water Add this liquid to the main solution until it stops turning milky in colour, meaning that all the silver has precipitated. Discharge and filter the solution. The silver chloride will stay on the paper.
You must now transform the AgCl to metallic Ag; do this by melting the AgCl in a gas furnace and adding soda solvay (Na2Co3) in a one to one ratio.
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8 ORDINARY MAINTENANCE
The MECHANICAL or ELECTRONIC MAINTENANCE MAN as specified in chapter 1.2 must carry out all maintenance operations inside the converter. All maintenance operations must be carried out : With the power supply off.
8.1
Tubes control
To be carried out on a cold unit (room temperature) Weekly check the expiry date of the tubes and rubberholders and change them if there are signs of wear such as cracks or abnormal bends.
8.2
8.2.1
Rectifier maintenance
Filter maintenance
The rectifiers are equipped with air filters positioned low on both sides which must be periodically cleaned or replaced. Make sure that the filters are perfectly dry before insertion. Clogged filters reduce ventilation efficiency and increase the machines internal temperature, and this can trigger the intervention of the maximum temperature sensors.
8.2.2
Electric and electronic components maintenance
Good quality, highly reliable components and cards have been installed, which require no special maintenance. Qualified, authorised personnel should carry out cleaning inside the unit and any maintenance work. Before carrying out any cleaning or maintenance operations, disconnect the rectifier from the main power supply. The lateral panels can be removed for the necessary cleaning and maintenance operations using the appropriate wrench. Make sure that the respective unipotential cable (YELLOWGREEN) is connected to the terminal before returning the panels to their original positions. Make sure that all the earth wires are well secured.
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9 RESPONSABILITY
The manufacturer declines all responsibility in cases of : Incorrect use of the machine; Not foreseen or impropriate use of the machine; Modifications to the machine ; Removal or tampering with repair operations to the machines ; Use of the machine in impropriate environments ; Installation of the machines in an unsuitable environment ; Incorrect use of IPDs ; Use of machine by non-qualified personnel
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Manual n. affag Revision 1.0 dtd 23-03-06 Page 1 of 28 Macchina : AFF20AG-1

Instruction and maintenance manual

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INSTALLATION______________________________________________________ 15 6.1 6.2 6.3 6.4

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WARNING, RISKS DUE TO FLAMMABLE GASES

WARNING, LOW FREQUENCY ELECTROMAGNETIC FIELDS.

FORBIDDEN TO USE WATER TO PUT OUT EVENTUAL FIRES

NON-AUTHORISED PERSONNEL ARE FORBIDDEN ACCESS TO THE INSIDE OF THE UNIT

OBLIGATION TO WEAR HEAT PROTECTIVE GLOVES

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IAAG refining cell

VAG/A circulation tank

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5 Specific Safety Standards

Risks due to extreme temperatures

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Risks due to emissions of powder, gas etc

Breakdowns during use

Foreseen and not foreseen uses of the machine

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Requirements for the personnel

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After unpacking, proceed to position all the units as shown below :

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VAG/A circulation tank

VAG/A circulation tank

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IAAG refining cell

IAAG refining cell

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Assemble the two valves to the bottom of the IAAG cells

Partially assembled IAAG valve

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Fume suction tubes supply

Connect the fume suction tubes as illustrated in the picture below.

Fume suction tubes

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7 ELECTROLYTIC SILVER REFINING

Generic preliminary operations

Preliminary operations for refining silver

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Starting the rectifier

Stopping the rectifier

Recovering daily production

Shut down the rectifier using its main switch.

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Treating the AgNo3 solution

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Electric and electronic components maintenance

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