Professional Documents
Culture Documents
BETRIEBSANLEITUNG
HANDLEIDING
FOREWORD
Dear Customer,
we wish to thank you for selecting our product and ensure you our best
assistance in order to enable you to make the most of your machine.
Also, we remind you that a good understanding of the contents of this manual -
through careful reading of all sections - is essential for the correct, safe use and
operation of the machine you have purchased.
For any further support or information, you may contact us at the below listed
address.
Yours faithfully,
0C00SE0C.DOC 0.0.1
Niro Soavi S.p.A
CONTENTS - SECTIONS
1. Technical Specifications
2. General Information
3. Machine Operation and Use
4. Maintenance
5. List of Spare Parts
6. Wiring Diagrams
7. Documentation about Suppliers and Components
Before installing the machine you must be thoroughly familiar with the
information given in Section 2, Chapter 2.8 and, in particular, paragraph 2.8.5.
0C00SE0C.DOC 0.0.2
Niro Soavi S.p.A
SECTION 1
TECHNICAL SPECIFICATIONS
1.1. TECHNICAL DATA
1.2. FLOW-SHEET
1.3. FLOW-SHEET LEGEND (SPEC 102)
1.4. MACHINE INSTALLATION DRAWING
1.5. UTILITIES SPECIFICATIONS (SPEC 103)
1.6. RUNNING SEQUENCE (ONLY IF MACHINE IS SUPPLIED
WITHOUT ELECTRICAL POWER BOARD BY NIRO SOAVI)
1.7. ELECTRICAL SPECIFICATIONS
1.8. DECLARATION OF CONFORMITY CE
1c00se0c.doc 1.0.1
Niro Soavi S.p.A
1 GENERAL
1.1 Serial Number 4537
1.2 Kind of Machine HOMOGENIZER
1.3 Model ARIETE
1.4 Type NS3006H
1.5 Execution Sanitary
1.6 Special Features 3A+ELECTROPOLISHED
1.7 MAX Operating Pressure 1000 bar
1.8 Flow Rate Type F
1.9 MIN Flow Rate / l/h @ / Hz
1.10 MAX Flow Rate 120 l/h @ / Hz
1.11 MIN Feed Pressure 5-6 bar
1.12 MAX Backpressure 10 bar
2 OPERATING CONDITIONS
2.1 Product CELL RUPTURE
2.2 MAX Viscosity <500 cP
2.3 MAX Relative Humidity 90 %
2.4 Ambient Temperature 40 C
2.5 MAX Altitude 1000 m
2.6 MAX operating temperature <90 C
2.7 MAX temperature CIP / SIP <140 C
3 TECHNICAL FEATURES
3.1 COMPRESSION BLOCK
3.1.1 Type MONOBLOCK VHP
3.1.2 Number of plungers 3
3.1.3 Material of plungers CERAMIC
3.1.4 Plunger diameter 12,7 mm
3.1.5 Stroke 40 mm
3.1.6 Pumping valve type PVB 1/2"
3.1.7 Overpressure valve SPRING LOADED setpoint 1100 bar
3.1.8 Connection, Inlet 3/4" TRICLAMP
3.1.9 Connection, Outlet 3/4" TRICLAMP
Scheda_c.doc 1.1.2
Niro Soavi S.p.A
3.4 LUBRICATION
3.4.1 Type SPLASH
3.4.2 Lubricating system SPLASH SYSTEM
3.4.3 Oil Cooling system SPLASH SYSTEM
4 OPTIONS
4.1 Suction side pulsation damper /
4.2 Delivery side pulsation damper /
4.3 Feeding pump /
4.4 Inlet pressure gauge /
4.5 Electric Power Board /
4.6 Overpressure Valve in Line / setpoint / Bar /
Scheda_c.doc 1.1.2
SPEC-E1C
Niro-Soavi S.p.A. ASYNCHRONOUS MOTORS
Specialty Products via M. da Erba Edoari, 29/A 26.02.02 0
Division 43100 PARMA (ITALY)
COMPRESSED AIR
Required Min Max
Pressure (Bar) 7,5 10
COMPRESSED AIR YES 3
Consumption(Nm /h) 0
Pressure (Bar)
Temperature (C)
3
Consumption(Nm /h)
STEAM
Required Min Max
Pressure (Bar) (1)
STERILE CONDENSATE
NO Temperature (C)
PRODUCTION
Consumption (l/h)
(1) THE CLIENT MUST INSTALL A PRESSURE REDUCER AT THE STEAM INLET CONNECTION TO ADAPT THE PRESSURE TO THE MACHINE'S REQUIREMENTS
ELECTRICITY
Electrical supply (V/Hz) V = 3x 460 Hz = 60
Power absorbed (kW) kW = 4,9
Current absorbed (A) A= 9,9
Note :
LEGEND SPEC - 102 C
Niro-Soavi S.p.A. TO CONCEPT FLOW SHEET
Specialty Products via M. da Erba Edoari, 29/A ____________________ REV.
Division 43100 PARMA (ITALY) DATE
PHONE : +39.0521.965411 - FAX : +39.0521.242819
Page 1 of 2 ____________________ 0
SIG.
IN MAIN PANEL
MANUAL ACTUATOR NOT FOR REMOTE
CONTROL
LIMIT VALUE H
H: HIGH OR OPEN AUTOMATIC ACTUATOR WITH INTEGRATED
MANUAL CONTROL FACILITY
L: LOW OR CLOSED
DIAPHRAGM ACTUATOR
POINT OF MEASUREMENT
T
WITHOUT INSTRUMENTATION
SOLENOID ACTUATOR
PISTON ACTUATOR
2. PROCESS LINES
ELECTRIC AC MOTOR
PRIMARY FLOW LINE, GENERAL
ADJUSTABLE SPEED CONTROL
SECONDARY FLOW LINE, GENERAL
HYDRAULIC
2-STEP HOMOGENIZER
CAPILLARY
FILTER, GENERAL
A ALARM
B DISPLAY OF STATE (2)
C CONTROLLING (4)
D DENSITY DIFFERENCE
E ALL ELECTRICAL VARIABLES (5) SENSING ELEMENT
F FLOW RATE RATIO
G GAUGING, POSITION OR LENGTH
H HAND (MANUALLY INITIATED) OPERATED
I INDICATING (3)
J SCAN
K TIME OR PROGRAMMED TIME
L LEVEL
M MOISTURE OR HUMIDITY
N USER'S CHOICE USER'S CHOICE
O USER'S CHOICE
P PRESSURE OR VACUUM TEST-POINT CONNECTION
Q QUALITY (5) INTEGRATE OR TOTALIZE INTEGRATING OR SUMMATING
R NUCLEAR RADIATION RECORDING
S SPEED OR FREQUENCY SWITCHING (2)
T TEMPERATURE TRANSMITTING
U MULTIVARIABLE MULTIFUNCTION UNIT
V VISCOSITY VALVE, DAMPER, ACTU, ELEMENT
W WEIGHT OR FORCE
X UNSPECIFIED (5) UNCLASSIFIED FUNCTIONS
Y VIBRATION COMPUTING RELAY, RELAY
Z EMERG. / SAFETY ACTING (2)
ACTION RESULT
1 INSERT THE MAIN SWITCH
A SWITCHBOARD ENERGIZED
44__4537-E4C.xls
Niro Soavi S.p.A
DECLARATION OF CONFORMITY
The undersigned
DECLARES
under his own responsability that the above mentioned Machine, object of this
declaration,
IS IN CONFORMITY
The above identified Machine has successfully passed all the trials and tests to
which it has been submitted.
PARMA 04/04/2002
D_ce_r1c.doc 0.0.1
Niro Soavi S.p.A
SECTION 2
GENERAL INFORMATION - INDEX
2.1. SAFETY
2.1.1 SAFETY INFORMATION
2.1.2 PERSONNEL SAFETY
2.1.3 USE OF THE MACHINE IN DANGEROUS ZONES
2.2. CE MARK AND ISO 9000 CERTIFICATION
2.3. IDENTIFICATION OF THE MACHINE
2.4. GUARANTEE
2.4.1 SCOPE OF THE GUARANTEE
2.4.2 DURATION OF THE GUARANTEE
2.4.3 APPLICATION OF THE GUARANTEE
2.4.4 EXCLUSIONS AND LIMITATIONS
2.4.5 HOW TO RETURN THE DEFECTIVE MATERIAL
2.5. HANDLING
2.6. RECEIVING AND CHECKING THE MACHINE
2.7. STORAGE
2.7.1 STORAGE BEFORE INSTALLATION
2.7.2 STORAGE FOR PERIODS LONGER THAN 3 MONTHS
2.8. INSTALLATION
2.8.1 POSITIONING
2.8.2 ACCESS TO THE INSIDE OF THE MACHINE
2.8.3 MACHINE LEVELING
2.8.4 CONNECTION TO UTILITIES AND PRODUCT LINE
2.8.5 INSTALLATION
2.8.6 POSITIONING THE ELECTRIC EQUIPMENT
2.8.7 ELECTRICAL CONNECTIONS
2.8.8 DIRECTION OF ROTATION OF ELECTRIC MOTORS
2.9. SPECIAL NOTES
2.9.1 CONTROL BOARD TO BE PROVIDED BY THE CUSTOMER
2.9.2 ELECTRIC MOTOR SUPPLIED BY THE CUSTOMER
2.10. NOTES ON MACHINE TEST
2.11. CLEANING THE MACHINE
2.12. DEMOLITION AND DISPOSAL
2.13. OPTIONS
2.13.1 SECOND STAGE HOMOGENIZING VALVE
2.13.2 ASEPTIC EXECUTION
2.13.2.1 STERILIZING THE MACHINE
2.13.2.2 REGULATING THE FLOW OF COOLING WATER
2.13.2.3 DESCALING AND WASHING
2.13.3 PARTIAL HOMOGENIZING SYSTEM
2.13.3.1 HOW THE BYPASS SYSTEM WORKS
2C001E0C.DOC 2.1.0
Niro Soavi S.p.A
2.1. SAFETY
These INSTRUCTIONS FOR USE & MAINTENANCE are part of the machine
and should accompany it throughout its service life until disposed of.
Before starting ANY operation, consult the relevant Section of these
INSTRUCTIONS.
Make sure that nobody has access to the machine before getting thoroughly
acquainted with these Instructions.
2C001E0C.DOC 2.1.1
Niro Soavi S.p.A
2C001E0C.DOC 2.1.2
Niro Soavi S.p.A
All personnel must be aware of the potential hazards present in the danger
zone and connected with the use of dangerous products for the safety of
persons and of the environment.
Any tools and equipment used inside danger zones must be suitable for use in
these conditions; the user of the machine is responsible for selecting them and
making them available as well as for the way they are used.
2C001E0C.DOC 2.1.3
Niro Soavi S.p.A
The machine has been designed and built in accordance with EEC standards
on the safety of equipment (CEE/98/37).
NIRO-SOAVI guarantees that this machine complies with the above-mentioned
standard by marking the front of the machine with "CE" as shown in figure 2.2.1
here below, on the front part of the machine.
In Section 1 TECHNICAL SPECIFICATIONS we have attached the
Declaration of Conformity CE of the machine.
YEAR
MAX PRESS.
3
RATED FLOW (dm /h)
TYPE S.N.
FIGURE 2.2.1
In addition to this, NIRO SOAVI is certified according to UNI EN ISO 9001 for
design, manufacturing and servicing of homogenisers and high pressure
pumps, therefore your machine has been enginnereed and produced according
to approved quality procedures.
See figure 2.2.2 for the UNI EN ISO 9001 Quality System Certificate.
2C001E0C.DOC 2.2.1
Niro Soavi S.p.A
FIGURE 2.2.2
2C001E0C.DOC 2.2.2
Niro Soavi S.p.A
The machine is identified by the name plate (fig.2.2.1) located on the front panel
(or on the pulley protection panel, for the Hercules versions without casing),
which includes
- the manufacturer's name
- model and type
- serial number.
The serial number is also punched on the compression head.
This number should always be quoted in any correspondence addressed to
NIRO-SOAVI's Customer Service in order to identify the machine properly.
2C001E0C.DOC 2.3.1
Niro Soavi S.p.A
2.4. GUARANTEE
If not specified otherwise in the order confirmation, the terms and conditions of
guarantee are as follows:
For this reason, we strongly recommend that the instructions contained in this
Manual are understood and followed, as a pre-condition for the correct and safe
use of the machine.
Using the machine and reading the INSTRUCTIONS FOR USE AND
MAINTENANCE imply integral acceptance of Warranty conditions.
For further information about application of the Warranty, see General Terms of
Sale.
2C001E0C.DOC 2.4.1
Niro Soavi S.p.A
2C001E0C.DOC 2.4.2
Niro Soavi S.p.A
2.5. HANDLING
The machine is sent to the Customer usually packed in a properly sized wooden
crate and wrapped in plastic film for additional protection, unless otherwise
specified in the Order Confirmation.
The wooden crate allows the machine to be handled with a fork lift or crane, and
appropriate marks are provided on the crate at the points for running steel
cables or belts for lifting (figure 2.5.1).
FIGURE 2.5.1
2C001E0C.DOC 2.5.1
Niro Soavi S.p.A
Concerning the dimensions and weight of the machine, see the Installation
Drawing shown in Section 1 TECHNICAL SPECIFICATIONS, in order to use
the proper lifting equipment.
The weight given is merely indicative and should be used only to select the
correct handling and transport means.
Please note that the center of gravity of the machine lies towards the
compression head (front part).
When handling unpacked machines use fork lifts (unless otherwise specified in
the handling instructions) and make sure that the compression head lies on the
operator's side. Forks should be adequately spaced and sized so as to
accomodate the entire base of the frame (figure 2.5.2) to prevent damage to the
machine frame or panels.
Side panels can be removed during transport to prevent damage; the front part
of the bodywork, under the compression head, has not been constructed to
support the weight of the machine. Do not use this part as a lifting point as this
could result in damage.
G G
FIGURE 2.5.2
2C001E0C.DOC 2.5.2
Niro Soavi S.p.A
WARNING: Before handling the machine, make sure that the route to be
followed and the intended place of installation are clear of any obstacle.
2C001E0C.DOC 2.5.3
Niro Soavi S.p.A
Unless specified otherwise in the Order Confirmation, once the machine has left
the Manufacturer's premises, any damage shall be under the responsibility of
the carrier - whether an independent one or a Customer's employee.
Therefore, when receiving the machine, the following should be checked:
- contents of the packing against the Packing List;
- integrity of the packing, so that any evident damage can be immediately
reported to the carrier;
- any damage suffered by the machine as a result of improper transport by the
carrier.
In order to minimize the amount of inconvenience for the Customer, NIRO-
SOAVI Shipping Department is always available to assist with clarifications,
evaluation of any damages, and any other action required to restore the
machine to its proper and safe conditions.
2C001E0C.DOC 2.6.1
Niro Soavi S.p.A
2.7. STORAGE
WARNING: Storage temperature should not be less than -5C and more
than +55C; humidity should be less than 95%, with no-condensate.
Vibrations should be avoided as much as possible.
If the machine is expected to remain stored for over three months before
installation, provide a closed storage place protected from bad weather, dust or
corrosive releases, as described before. Observe the above precautions for
electric components.
In addition YOU MUST:
- loosen the tension of V-Belts using the appropriate tighteners (sees Section 3
- MAINTENANCE);
- disassemble the plungers and seal packings (see Section 3 -
MAINTENANCE)
WARNING: In case the machine plungers are chrome coated, or are using
a tungsten carbide detonated coating (see Section 1 TECHNICAL
SPECIFICATIONS), they must be disassembled together with the packings
if the machine is in storage more than ONE month.
2C001E0C.DOC 2.7.1
Niro Soavi S.p.A
2.8. INSTALLATION
2.8.1 POSITIONING
The correct positioning of the machine within the production line is a pre-
condition for ideal performance and easy access for ordinary maintenance.
For this reason, according to the machine dimensions (see Section 1
TECHNICAL SPECIFICATIONS), allow enough space around the machine for
the service personnel to carry out the necessary maintenance.
Specifically, allow clearance for the eventual replacement of the main motor
using suitable lifting gear (crane or fork lift).
The front part and head require routine servicing; allow sufficient space to
permit complete removal of the head if required.
In addition, make sure the machine is not placed near sources of heat which
may undermine the necessary cooling, or near obstacles which may obstruct a
free air flow.
Plan suitable drainage points to be available in the area where the machine is
installed, in order to avoid its flooding, and avoid water hosing of the machine
through ventilation openings.
CAUTION: the floor on which the machine stands must have a bearing
capacity of at least 150% of the machine's weight indicated in the
Installation Drawing in Section 1 TECHNICAL SPECIFICATIONS.
2C001E0C.DOC 2.8.1
Niro Soavi S.p.A
- protection of the internal components from dirt, water or fouling with product;
- easy cleaning of the external parts;
- operator's protection from moving, under voltage or hot parts which may be
hazardous for the personnel, in compliance with EC standards and CE mark
requirements, and safety regulations in force in the country where the
machine is installed.
2C001E0C.DOC 2.8.2
Niro Soavi S.p.A
FIGURE 2.8.1
2C001E0C.DOC 2.8.3
Niro Soavi S.p.A
For the specific requirements of each machine, type of connections and fluid
specifications, please refer to Section 1 TECHNICAL SPECIFICATIONS.
As far as the utility connections, we recommend providing on/off solenoid valves
designed to open at the machine start (if not already included in the machine) to
be placed at the machines utilities inlet ports.
In particular, the manual valves of the lubrication water circuit should remain
always open, in a position which allows controlling an adequate flow of water for
lubrication or production of enough condensate (for the aseptic version).
Keep in mind that excessive lubrication water can lead to flooding of the sump
where water is collected, with the risk of water going into the drive section and
polluting the lubrication oil; for this reason it is important to regularly drain any
condensate or water that may be found in the lubrication circuit, as described in
Section 4 - MAINTENANCE.
WARNING: For the machines provided with aseptic system, the Customer
shall be responsible to install a steam pressure reducer to protect the
aseptic system and ensure operators safety. Fluid specifications are
shown in Section 1 TECHNICAL SPECIFICATIONS.
In case a pipe is used for the water drainage, when calculating the required
diameter and slopes, remember that water is discharged by gravity and not by
pressure. Provide an adequate degree of slope in the system to avoid water to
accumulate in the sump.
WARNING: For the disposal of waste water or cooling water, refer to the
specific regulations in force locally. No traces of lubrication oil or product
residues are allowed in the effluents disposed.
2C001E0C.DOC 2.8.4
Niro Soavi S.p.A
Cooling air is discharged through grids, situated on the top of the machine,
controlled by a fan of suitable size for free discharge (not for all models).
In case the discharged air needs to be conveyed via ducts, please contact
NIRO-SOAVI's Technical Office for details.
FIGURE 2.8.2
2C001E0C.DOC 2.8.5
Niro Soavi S.p.A
2.8.5 INSTALLATION
These guidelines are provided to ensure correct machine installation and
operation and guarantee long life to the machine and its components while
preventing situations of danger for operators.
to feed the machine use an infeed pump with delivery 1.2 times greater than
the rated flow in case of machines with 3 or more pistons, and 1.5 times in
case of machines with 1 or 2 pistons. Pump delivery must be calculated at
least over the minimum pressure required for feeding.
it is necessary to use a feeding pump for each single machine; do not install
two or more machines in parallel with one single feeding pump to prevent
dangerour pulsation interferences
the feeding line between the feed pump and the homogenizer or piston pump
must be direct, possibly without bends, and with a size equal to or greater
than the size of the homogenizer/piston pump, without section variations, to
2C001E0C.DOC 2.8.6
Niro Soavi S.p.A
we recommend you install a pressure gauge near the area where product is
fed into the homogenizer / piston pump in order to check infeed pressure; this
pressure gauge can be supplied as an optional by NIRO SOAVI and can be
standard, with minimum contact or with continuous analog signal for remote
control.
if filters need to be installed on the feeding line, you must allow a clear area
at least 3 times the size of the pipe used; you also need to install a pressure
gauge downstream the filter to check actual infeed pressure and prevent filter
clogging and danger of cavitation of the machine. For cleaning purposes we
recommend installing parallel filters to be used alternatingly.
the pulsation damper must be installed in a vertical position; do not install the
damper so that the flow enters the damper directly, otherwise the damper will
fill up too quickly and become less effective as no air will be left at the top
if the feed pump is connected to a tank, ensure that no air is sucked in by the
suction inlet through the creation of vortices by fitting suitable internal barriers
to divert the flow; the suction inlet must be sotto battente? at all times
2C001E0C.DOC 2.8.7
Niro Soavi S.p.A
Never use the machine to fully drain the feeding tank, to avoid product
suddenly running out during operation under pressure, but provide at least
one level sensor to remove pressure (in the case of a homogenizer) and
stop the machine before the product being fed runs out
the product treated must contain no air or gas, to prevent cavitation problems
in the machine. If the product contains air because it is very viscous or due to
previous processing phases, you need to remove the air using appropriate
deaeration equipment
the machine is fitted with automatic pumping spring valves; the load is
defined according to the type of valve and the characteristics of the product.
This means that if the machine has been stopped or is inactive, and the
feeding line is open and under pressure, you are able to check the flow of
product through the machine. To make sure there is no product flowing
through the machine when the machine is inactive, the user must provide a
cutoff valve for the feeding line upstream the machine.
2C001E0C.DOC 2.8.8
Niro Soavi S.p.A
2C001E0C.DOC 2.8.9
Niro Soavi S.p.A
The electric connections between machine and electric power board and
between electric power board and power mains must be made by the Customer
who is also responsible for checking that they have been properly executed and
that they comply with the wiring diagram, before the machine is started up.
NIRO SOAVI shall not be liable for injury to people or damage to objects
caused by incorrect connection of electric equipment; all electric connection
must be checked by authorized personnel.
If in doubt please contact NIRO SOAVI.
2C001E0C.DOC 2.8.10
Niro Soavi S.p.A
main motor: the correct direction of rotation is shown by the arrow on the
flywheel; it is COUNTERCLOCKWISE for machines with FORCED
LUBRICATION and gear reducer); COUNTERCLOCKWISE for machines
with splash lubrication (see Section 1 - TECHNICAL SPECIFICATIONS),
unless otherwise specified by the direction of the arrows on the machine
(flywheel and/or motor)
oil pump motor (only for machines with motor-driven lubrication pump): follow
the direction of the arrow printed on the pump body. In case of mistake, the
low pressure in the circuit triggers the pressure switch, which prevents the
machine operation;
electric fan of main motor (only for machines designed for variable speed):
follow the direction indicated by the arrow;
electric fan of machine body: follow the direction indicated by the arrow;
Auxiliary motors may be installed depending on the type of machine: verify the
actual installation with reference to the technical sheet and the wiring diagrams,
Section 1 -TECHNICAL SPECIFICATIONS.
If the direction of rotation is not correct, reverse any of the two phases of the
supply cord.
2C001E0C.DOC 2.8.11
Niro Soavi S.p.A
CAUTION: The control board should be built in accordance with the local
operational and safety regulations in force.
The electric motor shall be made in accordance with the general specifications
laid down by NIRO-SOAVI as to POWER, NUMBER OF POLES, SIZE,
SERVICE (Section 1 - TECHNICAL SPECIFICATIONS).
The motor shall be placed either on the supporting plate and secured by bolts in
the holes provided (or made at the time of installation) taking care that the
motive pulley is in line with the flywheel.
2C001E0C.DOC 2.9.1
Niro Soavi S.p.A
CAUTION: Should the Customer decide not to ask for the attendance of
our engineer at the time of the start-up, NIRO-SOAVI shall not be liable for
damages to persons or property caused by failure to observe the
instructions provided in this Manual (INSTRUCTIONS FOR USE AND
MAINTENANCE).
2C001E0C.DOC 2.10.1
Niro Soavi S.p.A
The machine is supplied with external paneling in glazed stainless steel plate
(ARIETE version) which is easy to clean with water.
Washing prevents the deposit of product residuals on the machine: wash the
bodywork with running water from time to time, paying particular attention to the
compression head and the sump.
If required you may use a cloth and any standard mild detergent.
To prevent water from entering the machine, place a suitable covering over the
ventilation hole; do not wet the electric panel or the control panel.
The HERCULES industrial version is supplied without external paneling, but
only with protection panels to cover moving parts: in this case make sure you do
not wet unnecessarily the electrical components of the machine.
WARNING: Before washing with running water, make sure that power has
been cut off by means of the sectioning switch of the supply line that
should be locked with appropriate padlock.
2C001E0C.DOC 2.11.1
Niro Soavi S.p.A
The demolition and disposal of the machine must be carried out in compliance
with various procedures according to the type of material to be disposed of.
First of all, it is necessary to:
- discharge lubricating and hydraulic oils for separate disposal;
- disassemble the electric system (components, cables and protection
sheaths) and all the plastic parts for separate disposal.
The machine is manufactured with the following materials, in various quantities:
- stainless steel;
- steel alloys and steel for construction purposes;
- cast iron.
The following are also present in very limited amounts:
- aluminium;
- copper;
- bronze;
- ceramic;
- PTFE;
- nitrile;
- viton;
- PVC.
- PEEK
- Elastomers and plastic materials.
2C001E0C.DOC 2.12.1
Niro Soavi S.p.A
2.13. OPTIONS
The formula which relates the homogenizing pressures in a two stage system
(see figure 2.13.1) is the following:
Ptot = P1 = P2 + dP
where:
Ptot = P1 is the total pressure measured on the compression head,
equivalent to the 1st stage pressure
dP = P1 - P2 is the pressure difference between the 1st and the 2nd stage,
applied in the passage through the 1st stage valve.
2C001E0C.DOC 2.13.1
Niro Soavi S.p.A
P2
dP
Ptot = P1
FIGURE 2.13.1
2C001E0C.DOC 2.13.2
Niro Soavi S.p.A
During operation, the cooling water on/off valve (whether manual or solenoid)
should remain open.
An additional manual valve on the outlet of the exchanger has been provided to
control the water flow and obtain sterile condensate at a temperature of 40 to
50C. This has the extra advantage of helping reduce any waste of softened
water.
The use of water even when softened - for steam condensation inevitably
produces some deposits of lime in the exchanger.
Whenever a reduced exchange power is noticed - evidenced by an insufficiently
cooled condensation - a descaling of the aseptic system is required.
It is impossible to predict the frequency of this operation, since the formation of
lime deposits depends largely on the hardness of the water available.
For more details on maintenance operations, see Section 4 - MAINTENANCE.
2C001E0C.DOC 2.13.3
Niro Soavi S.p.A
FIGURE 2.13.2
2C001E0C.DOC 2.13.4
Niro Soavi S.p.A
To make the by-pass circuit work properly, it is necessary to open and close the
pneumatic butterfly valve (position A, figure 2.13.3) with a signal coming from
the centrifuge.
This valve must be closed during normal operation, opened during desludging
phase and cleaning of the equipment.
FIGURE 2.13.3
Follow the instructions below for the correct operation of the system:
Open the pneumatic butterfly valve few seconds before the desludging phase
of the centrifuge; the single-acting check valve installed prevents the product
to be homogenized from flowing through the by-pass even when the butterfly
valve is open
2C001E0C.DOC 2.13.5
Niro Soavi S.p.A
Close the pneumatic butterfly valve few seconds after the desludging phase
of the centrifuge has been completed;
SKIMMED 70%
515% 100%
CREAM 1525%
FIGURE 2.13.4
2C001E0C.DOC 2.13.6
Niro Soavi S.p.A
SECTION 3
OPERATION & USE OF THE MACHINE -
INDEX
3.1. GENERALS
3.2. CHECKS BEFORE START-UP
3.3. START-UP PROCEDURE
3.3.1 OPERATORS POSITION
3.3.2 CONTROL PANEL
3.3.3 START-UP
3.4. OPERATION AND ADJUSTMENT
3.4.1 HOMOGENIZING PRESSURE ADJUSTMENT 1 STAGE
3.4.2 HOMOGENIZING PRESSURE ADJUSTMENT - 2 STAGES
3.4.3 REMOTE PNEUMATIC CONTROL (OPTIONAL)
3.5. MACHINE STOP
3.5.1 EMERGENCY STOP
3.6. CLEANING
3.7. SAFETY DEVICES
3.7.1 OVERPRESSURE VALVE
3.7.1.1 OPERATION
3.7.1.2 CLEANING
3.7.2 PROTECTIONS ON MAIN MOTOR
3.7.3 EMERGENCY PUSH-BUTTON
3.7.4 COMPRESSION HEAD GUARD
3.8. TROUBLESHOOTING
3.9. SPECIAL FEATURES OF NON STANDARD MACHINES
3C001E0C.DOC 3.1.0
Niro Soavi S.p.A
3.1. GENERALS
To find out about the specific configuretion of the machine, model, technical data,
accessories and optionals, see Section 1 - TECHNICAL SPECIFICATIONS.
3C001E0C.DOC 3.1.1
Niro Soavi S.p.A
Check the V-belt drive assembly. For the correct tensioning and alignment of
belts refer to Section 4 - MAINTENANCE.
3C001E0C.DOC 3.2.1
Niro Soavi S.p.A
Verify the level of lubrication oil through the sightglass: this should be
covered with oil by 3/4 or reach the level shown on the special visual
indicator. When checking the oil level, the machine should be stopped,
because normally the start-up causes the level to lower as it fills the circuits.
If topping-up is needed, use only the oil types indicated in Section 4 -
MAINTENANCE.
For machines equipped with gear reducer, check the level of lubrication oil
through the inspection hole provided on the reducer. If topping-up is needed,
use only the oil type indicated in Section 4 -- MAINTENANCE.
Make sure that the high pressure flanges, unions and nuts in the
compression head are properly tightened to the values shown in the
"Tightening torque" table, Section 4 - MAINTENANCE, .
Verify that plungers are tight and that seal packings are in place, if they have
been removed during storage or after standstill of over 3 months.
Check the direction of rotation of motors as described in Section 2 -
GENERALS, chapter 2.8.7.
Make sure that all protection panels are in place and securely fixed.
Make sure that the homogenizing pressure controls (figure 3.2.1) (air-
operated switch A and reducer B) are either completely loosened or on the
OFF position, and that any manual controls are fully loosened (fig.3.2.2)
Verify that all safety and protection devices are in perfect operating condition.
Make sure that any valves and parts of the system downstream the
homogenizer are open to prevent overpressure in pipes when the
homogenizer is started.
3C001E0C.DOC 3.2.2
Niro Soavi S.p.A
2
C
1
A
FIGURE 3.2.1
FIGURE 3.2.2
3C001E0C.DOC 3.2.3
Niro Soavi S.p.A
FIGURE 3.3.1
3C001E0C.DOC 3.3.1
Niro Soavi S.p.A
NIRO SOAVI
FIGURE 3.3.2
3C001E0C.DOC 3.3.2
Niro Soavi S.p.A
3.3.3 START-UP
WARNING: The lubrication oil indicated in the specifications is suitable
for operating temperatures between +5C ed i +40C: DO NOT START the
machine if ambient temperature is lower than +5C to avoid damage to the
lubrication system.
Check with NIRO-SOAVI Customer Service for the type of lubricant
suitable for the specific local conditions.
Once all preliminary checks have been completed, the machine can be started
following the procedure below.
Open all on/off valves on utility lines (water, air, steam) and regulate the flow
rates if necessary.
Feed the machine with product at the required flow rate and pressures as
indicated in Section 1 TECHNICAL SPECIFICATIONS.
WARNING: Feeding pressures lower than the limits given will cause
CAVITATION in the machine, recognized by the typical noise produced by
the head, which will seriously damage the whole machine. NIRO SOAVI
shall not be libale for breakages, malfunctions or damage to the machine
caused by CAVITATION even if this occurs during the 12 month guarantee
period.
3C001E0C.DOC 3.3.3
Niro Soavi S.p.A
Give power using the main switch on the electric power board
Press the start push-button. In case the control board has been supplied by
NIRO-SOAVI, this operation allows to start the machine according to the
correct sequence, depending on the type of machine and optionals provided:
- opening of any utility solenoid valve (optional)
- start of the oil motor-driven pump (if this type has been provided)
- start of electric fans (if provided)
- start of main motor.
In case the control board is supplied by the Customer, the correct operating
sequence is provided (see Section 1 TECHNICAL SPECIFICATIONS), and
should be observed strictly.
To identify the machine configuration refer to Section 1 TECHNICAL
SPECIFICATIONS.
3C001E0C.DOC 3.3.4
Niro Soavi S.p.A
Once the machine has been started, before increasing the homogenizing
pressure, check that the machine itself is operating normally, with a particular
attention paid to the feed pressure, establishing it is stable and within limits as
prescribed in Section 1 TECHNICAL SPECIFICATIONS.
Then it is possible to operate the control devices in order to increase the
homogenizing pressure up to the desired process value.
If your machine is equipped with a second stage homogenizing valve, refer to
paragraph 3.4.2.
Once the homogenizing pressure has been set to the desired value, lock the
reducer knob (B) by pressing it.
If the set pressure is the one used normally during production, the
homogenizing pressure can be applied or released by operating ONLY the
pneumatic selector (A), with the reducer left on the adjustment position.
3C001E0C.DOC 3.4.1
Niro Soavi S.p.A
2
C
1
A
FIGURE 3.4.1
3C001E0C.DOC 3.4.2
Niro Soavi S.p.A
Once the homogenizing pressure has been set to the desired value, block the
reducer knob (B and D) by pressing it.
If the set pressure is the one used normally during production, the
homogenizing pressure can be applied or released by operating ONLY the
pneumatic selector (A and C), with the reducer left on the adjustment position.
3C001E0C.DOC 3.4.3
Niro Soavi S.p.A
3C001E0C.DOC 3.4.4
Niro Soavi S.p.A
CAUTION: Even with remote control, if the system has two stage the
intended pressure value should be set FIRST on the second stage, THEN
on the first stage to reach the total desired pressure.
A different operative sequence may result in SERIOUS RISK because the
machine may inadvertently reach higher pressure values than those
designed for the machine.
3C001E0C.DOC 3.4.5
Niro Soavi S.p.A
S RGE
E N
M C
E Y
S T OP
FIGURE 3.5.1
3C001E0C.DOC 3.5.1
Niro Soavi S.p.A
3.6. CLEANING
WARNING: The products used for cleaning and rinsing of the equipment
should contain only the substances specified in Table 3.6.A.
The presence of CHLORINE and IODINE ions - including simple traces - is
very harmful to the materials used in the construction of the machine, as
it may lead to stress corrosion phenomena which may cause the
compression block failure in a short time and unpredictably.
3C001E0C.DOC 3.6.1
Niro Soavi S.p.A
TABLE 3.6.A
3C001E0C.DOC 3.6.2
Niro Soavi S.p.A
3C001E0C.DOC 3.7.1
Niro Soavi S.p.A
3.7.1.1 OPERATION
The valve consists of a ball maintained in place in its seat by a spring, which
allows it to open when the calibration set point is exceeded.
The spring loading should not be changed as this would modify the valve
opening value and cause the immediate forfeiture of the safety conditions
established by NIRO-SOAVI and the guarantee. Therefore a seal has been
applied to the spring load adjustment nut.
In the event the calibration setting is exceeded, the valve opens automatically
and lets the product flow out of the discharge pipe; it closes again when
pressure reduces below the opening value. This can be achieved by adjusting
the pressure regulating device until the valve is closing, or reducing the pump
speed in case of high pressure pumps.
Once the valve has closed again, normal operating pressure can be re-
established, provided the machine has not been damaged and the cause of
overpressure has been addressed.
3C001E0C.DOC 3.7.2
Niro Soavi S.p.A
3.7.1.2 CLEANING
The part in contact with the product is normally cleaned during the machine
washing (C.I.P.).
CAUTION: Do not disassemble the valve body and do not remove the
plastic cap. Changes to the safety valve setting are not allowed and shall
invalidate the guarantee and affect protection of the machine, of its
components and of the operators, unless a written authorization has been
obtained from Niro Soavi.
3C001E0C.DOC 3.7.3
Niro Soavi S.p.A
WARNING: The machine should not be used if the guard is not correctly
secured in place.
3C001E0C.DOC 3.7.4
Niro Soavi S.p.A
3.8. TROUBLESHOOTING
This chapter lists the most frequent problems which are likely to be encountered
during the machine operation, their possible causes and remedies in order to
restore normal working conditions.
If the failure persists, or does not appear among those listed below, our Service
Department will be pleased to give you the advice and means required to
achieve the best possible results.
1. The machine does main motor does not check the electrical
not run start wiring, fuses, automatic
switches
3C001E0C.DOC 3.8.1
Niro Soavi S.p.A
3C001E0C.DOC 3.8.2
Niro Soavi S.p.A
3C001E0C.DOC 3.8.3
Niro Soavi S.p.A
3C001E0C.DOC 3.8.4
Niro Soavi S.p.A
3C001E0C.DOC 3.8.5
Niro Soavi S.p.A
15.White foam in the Water into the oil Stop the machine for
lubricating oil at least 1 hour and drain
water from lowest point
(Section 4
MAINTENANCE)
3C001E0C.DOC 3.8.6
Niro Soavi S.p.A
3C001E0C.DOC 3.8.7
Niro Soavi S.p.A
BLANK PAGE
SECTION 4
MAINTENANCE - INDEX
4.1. GENERAL INFORMATION
4.2. ORDINARY MAINTENANCE
4.3. TIGHENING BOLTS AND STUDS
4.4. COMPRESSION HEAD
4.5. HOMOGENIZING GROUP
4.6. OVERPRESSURE VALVE AND PRESSURE GAUGE
4.7. TRANSMISSION
4.8. POWER END - CRANKCASE
4.9. LUBRICATION
4.10. PNEUMATIC PLANT
4.11. ASEPTIC PLANT
4c00se0c.doc 4.0.1
Niro Soavi S.p.A
4.1. GENERALS
CAUTION: For the personnel safety, any check and maintenance operation
should be carried out with the MACHINE STOPPED and with the isolator
switch LOCKED (with the appropriate padlock) in the OPEN POSITION.
CAUTION: The only operations allowed are the ones described in this
INSTRUCTION MANUAL; for extraordinary work on the machine please
contact our Service Department.
4c010e0c.doc 4.1.1
Niro Soavi S.p.A
Here below are the tables showing the periodical maintenance required by the
machine to operate efficiently and safely.
Values shown refer to a normal use of the machine; heavy-duty conditions or
particularly abrasive/aggressive products may reduce sensibly the life of some
parts, which should therefore be checked more frequently.
All the operations listed here below are described with detailed procedures in
the following paragraphs.
Execute carefully all the checks prescribed in these tables and note
scrupulously the DATE, MACHINE HOURS, OPERATOR in the Tables for the
checks to be performed every 1500 HOURS - 6 MONTHS and every 3000
HOURS - 12 NONTHS. In this way the machine will be maintained in the best
conditions of running and safety, and a track will be kept of the maintenance
operations actually completed.
As additional tool for ordinary maintenance of the machine, please refer to the
form CHECKLIST FOR MACHINE INSPECTION at Section 5 SPARE
PARTS LIST.
4c010e0c.doc 4.2.1
Niro Soavi S.p.A
4c010e0c.doc 4.2.2
Niro Soavi S.p.A
4c010e0c.doc 4.2.3
Niro Soavi S.p.A
4c010e0c.doc 4.2.4
Niro Soavi S.p.A
4c010e0c.doc 4.2.5
Niro Soavi S.p.A
All the studs used in the compression head are subject to vibrating stress so, in
addition to being made of special, highly resistant material with an accurate
processing cycle, they require specific tightening in accordance with the values
shown in Table 4.3.1.
It is also necessary to frequently check screwn and nuts to make sure that they
do not become loose.
NIRO SOAVI supplies a Maintenance box with the wrenches needed for the
nuts fitted on their machines; we suggest you use a dynamometric wrench (not
included) to check tightening torques as specified in the table below.
M8 8 10 6 8
M 10 15 20 11 15
M 12 25 30 19 22
M 16 60 70 44 52
M 20 120 140 89 104
M 24 210 230 155 170
M24x2 235 260 174 192
M 27 310 340 229 251
M27x2 350 390 258 288
M 30 410 450 304 332
M 33 560 600 413 445
M33x2 635 680 469 502
M39 880 960 650 709
TABLE 4.3.1
4c010e0c.doc 4.3.1
Niro Soavi S.p.A
4c010e0c.doc 4.3.2
Niro Soavi S.p.A
4C042E0C.DOC 4.4.1
Niro Soavi S.p.A
4C042E0C.DOC 4.4.2
Niro Soavi S.p.A
4.4.1.1 DISASSEMBLING
Ceramic pistons (figure 4.4.1) are fixed by a clamp (B): to remove them first
unscrew the clamps retaining screws (A) and move the plunger away from the
extension (C). To open the clamp it may help to insert one of the screws in the
middle bore of the clamp to expand it.
To pull the plunger away from the extension of the guide plunger you need to
rotate the crankshaft; to do this open the right side panel and rotate the
flywheel: follow the instructions and safety rules described in chapter 4.1 and
4.7.
FIGURE 4.4.1
4C042E0C.DOC 4.4.3
Niro Soavi S.p.A
In the VHP high-pressure head the plunger gaskets are housed inside
removable flanges which can be accessed from the read of the head, inside the
water sump.
For complete disassembly instructions see paragraph 4.4.2.
4.4.1.2 ASSEMBLING
Once the flange which contains the packing and the plunger has been fixed on
the studs and on the special centering dowels, it is possible to fix each plunger
to its guide plunger, using a clamp (item. B, figure 4.4.1) and correctly tightening
the retaining screws. (tightening torque 78 N*m).
Take care not to bend the ceramic plungers as you risk breaking them.
CAUTION: Plungers must be mounted one by one, starting with the outer
and leaving the middle one(s) last for easier access.
Once all the nuts of the packing flanges have been tightened (see details in
paragraph 4.4.2) proceed as follows (figure 4.4.1):
Insert the clamp (B) onto the end of the guide plunge extension (C) or on the
part of the plunger which protrudes from the packing flange
Move the guide plunger extension completely forward, by rotating the
flywheel manually, until the plunger is right against the extension (C)
Move the clamp into position, against the diameter enlargement of the
extension, then tighten the clamp with the screws (A), by applying a 78 N*m
tightening torque.
Repeat this procedure for every plunger, starting with the outer ones.
4C042E0C.DOC 4.4.4
Niro Soavi S.p.A
CAUTION: During assembly make sure that the plunger and clamp are
fixed in the correct position, and that the various clamps do not interfere
with one another during alternating plunger movements. We therefore
suggest that you rotate the drive pulley by hand to verify that plunger
movement is correct.
FIGURE 4.4.2
4C042E0C.DOC 4.4.5
Niro Soavi S.p.A
4C042E0C.DOC 4.4.6
Niro Soavi S.p.A
4.4.2.1 DISASSEMBLING
Plunger gaskets are housed inside the flanges located in the rear part of the
head, so disassembly must be carried out through the part of the sump behind
the head.
4C042E0C.DOC 4.4.7
Niro Soavi S.p.A
FIGURE 4.4.3
FIGURE 4.4.3
4C042E0C.DOC 4.4.8
Niro Soavi S.p.A
4.4.2.2 ASSEMBLING
For assembly refer to figure 4.4.4, which shows how to assemble the elements
which make up the plunger packing:
prepare the rings (H) which are supplied ready cut and preformed
insert the rings in the flange which contains the packing (F) as specified
below
insert the plastic ring (R) to the bottom of the flange
insert, one at a time, the rings (H) which make up the seal packing, taking
care to stagger the joints regularly (for exambple by 120). If the packing is a
standard type with multiple V rings or a single plastic piece, insert it all in one
go.
Insert the plunger to give the rings the required shape
Insert the double conic washer (M) as shown in the picture, making sure that
the direction of assembly is the one shown in the cross section
Insert the packing washer (L); in some cases this washer can be made up
by two separate washers (L1, L2) made with both plastic and metal material.
Lay the retaining flange (E) against the rear part of the flange which contains
the packing (F)
FIGURE 4.4.4
4C042E0C.DOC 4.4.9
Niro Soavi S.p.A
Install the o-ring (P figure 4.4.3) or, where used, the antiextrusion (R) ring
on the front of the flange (F)
Insert the pre-assembled packing on the studs, check position against
centering dowels
Tightent the nuts diagonally (N)
Mount the plunger as described in paragraph 4.4.1
For the replacement procedure of the valve assembly see here below; follow the
specific assembly drawings in Section 5 SPARE PARTS CATALOGUE.
4.4.3.1 DISASSEMBLING
4C042E0C.DOC 4.4.10
Niro Soavi S.p.A
FIGURE 4.4.5
Once the manifolds have been removed, the valve assemblies for suction and
delivery are the same, with the configuration shown in figure 4.4.5 or 4.4.6.
Bear in mind that the seat (E) made of special wear-resistant material is forced
into the seat housing (A) so in case of replacement it must be removed with the
help of a press.
4C042E0C.DOC 4.4.11
Niro Soavi S.p.A
P
N
H
L
FIGURE 4.4.6
4.4.3.2 ASSEMBLING
To mount the valve assemblies refer to figures 4.4.5 and 4.4.6 (as an
alternative).
Carefully place the o-rings (H + N + F) and the relative anti-extrusion rings (L
+ P + G) in the slots provided, if necessary use food-grade vaseline to hold
them in position
For delivery valve assemblies, position the seat housing (A), and the guide
(M) where present, using the existing studs as guides
For suction valve assemblies, the seat housing (A), and the guide (M) where
present, must be placed on the bottom support flanges or on the suction
manifold itself, if made as one single element (depending on machine model)
Insert the inner components: ball (D), spring (C) and valve cap (B), making
sure that the position of the spring is correct
If necessary check that the ball (D) can be lifted, by pushing it from
underneath
4C042E0C.DOC 4.4.12
Niro Soavi S.p.A
Position the delivery manifold, and tighten the nuts using the torque values
specified in table 4.3.1. When tightening proceed gradually through ALL the
nuts and tighten them in circle with all the other parts of the head in place.
Position the retaining flanges of the suction valve assemblies, or the
complete suction manifold if made as one single elements (depending on
machine model), and tighten all the nuts using the torque values specified in
table 4.3.1
Mount the suction manifold
WARNING: when tightening the head nuts observe the tightening torques
shown in chapter 4.3, Table 4.3.1; use a torque wrench (not provided).
CAUTION: The tools used for removing the valve seats are NOT included
in the maintenance box. Tightening of the head nuts must be made using
the torque values indicated in chapter 4.3, Table 4.3.1.; use a torque
wrench (not supplied).
4C042E0C.DOC 4.4.13
Niro Soavi S.p.A
B S1 S2
A
C
B
C
S3 S4
FIGURE 4.5.1
4c053e0c.doc 4.5.1
Niro Soavi S.p.A
When the grooves reach the external diameter, the homogenizing efficiency
collapses, therefore the component should be replaced either when the grooves
cover nearly 3/4 of the useful surface or whenever a reduced homogenizing
efficiency is noticed.
In some cases, because of extreme wear of the parts, the homogenizing
pressure cannot be achieved anymore, therefore the complete homogenizing
valve must be replaced.
Some local cavitation effects may sometimes create some craters or strong
wear path on the valve surface, therefore it is necessary to proceed with
replacement of the parts.
As far as the impact ring (figure 4.5.1 pos. C), it has the dual function of
completing the homogeneization by impact and protecting the body of the
homogenizing assembly from erosion.
Due to wear, a groove (S4) is produced on its internal surface, and good
performance is undermined.
We recommend replacing the ring when the groove is approximately 1 mm
deep.
CAUTION: the impact head and the passage head are manufactured from
a material whose hardness is suitable to withstand the abrasive action of
the product handled for a long time.
Whenever wear signs appear that may jeopardize the homogenizing
efficiency, working surfaces can be rectified to remove max 1 mm of
material: this can be done either at NIRO-SOAVI or at properly equipped
workshops.
4c053e0c.doc 4.5.2
Niro Soavi S.p.A
Follow the below listed instructions for the ordinary maintenance of the
pneumatic actuated homogenizing group.
DISASSEMBLING
CAUTION: oil dripping may occur when disconnecting the pipes of the
pneumatic-hydraulic system: provide a container to collect such oil and
dispose as prescribed by the local regulations.
4c053e0c.doc 4.5.3
Niro Soavi S.p.A
FIGURA 4.5.2
Disassemble from the bottom the valve group parts (see details in picture
4.5.3): passage head spacer (Y), passage head (V) and impact ring (U)
The above mentioned items are assembled into an housing (D)
Remove also all the Oring gaskets (Z, W, E, F) and the antiextrusion rings
(A, C) if installed
Remove the guide (T) of the impact head (G) and check its inner surface; if
wear marks are present or there is excessive play between the guide (T) and
the impact head (G) it is necessary to replace it
4c053e0c.doc 4.5.4
Niro Soavi S.p.A
ASSEMBLING
FIGURA 4.5.3
Put the homogenizing valve chamber (B) on its side and insert the impact
head guide (T)
Put inside the impact head (G) and make sure this is not coming out of its
guide (T)
Assemble the impact ring (U)
Put the homogenizing valve chamber on the studs and push it towards the
compression head
Assemble the impact ring (U) and the passage head (V) inside the housing
(D), including the Orings (E, F), then put all the parts inside the valve
chamber (B)
4c053e0c.doc 4.5.5
Niro Soavi S.p.A
Insert the spacer (Y) complete with Oring gaskets (Z, W) and antiextrusion
rings (C, A), if present
Slide the homogenizing chamber on the studs towards the compression
head, taking care of the Oring (Z) and of the antiextrusion ring (A) to avoid
they can come out of position
Prepare for assembling the impact head shaft (S) and its guide (H) (figure
4.5.2):
Insert from the top the plastic bushings (J) inside the guide (H); this is usually
not required if the bushings are not removed from their location or are not
damaged
Place the gaskets (P) and (R) into their grooves
Put from the top the impact head shaft (S) into the guide (H) being careful not
to damage the gasket (P)
Check the smooth sliding of the impact head shaft (S) into the guide (H)
The above indications are valid for both homogenizing valves, on machines
supplied with second stage homogenizing valve (available as option).
4c053e0c.doc 4.5.6
Niro Soavi S.p.A
FIGURE 4.5.4
4c053e0c.doc 4.5.7
Niro Soavi S.p.A
The pneumatic actuator cylinder, used to close the homogenizing valve and
achieve homogenizing pressure, is connected in the bottom part to an
hydraulic/pneumatic system for dampening pulsations.
The presence of air in the bottom part of the pneumatic cylinder may cause
incorrect operation of the dampening system resulting in abnormal noise level
and vibrations of the homogenizing valve, particularly if the machine operates
with two homogenizing stages.
In this case you need to eliminate the air by pressing the pneumatic switch 3 or
4 times to apply and release pressure.
The homogenizing assembly used in the aseptic version is the same as the one
used in the sanitary version in terms of functional features; the only difference is
that the impact head shaft is flushed with sterile condensate used as barrier
fluid.
The homogenizing chamber body has all the connections with the system for
distributing sterile condensate, and the guide of the impact head shaft has
outlets for the condensate with relative gaskets, as shown in figure 4.5.7.
FIGURE 4.5.7
4c053e0c.doc 4.5.8
Niro Soavi S.p.A
Make sure you do not lose the ball (E), as the valve cannot work without it; we
recommend you always keep a spare seat and ball in case you need to replace
them.
Valve maintenance does NOT require replacing the spring; to avoid sudden
release of the springs preloading DO NOT remove the elastic ring (L)..
Carefully clean the seat (B) from any product residues but take care not to
damage the sealing area.
If the sealing area between the seat (B) and the ball (N) is damaged or worn
out, there can be product leaks and the valve can be triggered at a pressure
value lower than the valve setting; we therefore recommend you replace the
seat and, if required, the ball.
4c063e0c.doc 4.6.1
Niro Soavi S.p.A
- the flange (F) will normally be separate from the beat due to the spring
preloading; to disassemble it you need to gradually loosen the nuts (G)
on the studs (H) until the valve is fully locked
4c063e0c.doc 4.6.2
Niro Soavi S.p.A
FIGURE 4.6.1
4c063e0c.doc 4.6.3
Niro Soavi S.p.A
For instruments provided with electric equipment refer to the wiring diagram,
which also indicates the setting range of the instrument.
4c063e0c.doc 4.6.4
Niro Soavi S.p.A
Refer to figure 4.6.2: to disassemble the pressure gauge (or pressure gauge
with transmitter, or pressure transducer) you need to loosen the nuts (G) and
pull out the pressure gauge complete with flange (F).
The pressure gauge (A) and flange (F) can be separated once the semi-rings
(D) have been removed.
Figure 4.6.3 shows the analog configuretion for disassembling the pressure
transducer.
FIGURE 4.6.2
4c063e0c.doc 4.6.5
Niro Soavi S.p.A
- insert the anti-extrusion ring (C), if used, on the manometer; this ring is
used in high-pressure versions from 600 bar upwards
- insert the flange (F) on the pressare gauge body (A) and fit the two semi-
rings (D) to hold the flange in position
- insert the pressure gauge prepared in this way into its housing, and place
the flange (F) on the studs (H)
- screw the nuts on (G) by hand before tightening them fully.
FIGURE 4.6.3
4c063e0c.doc 4.6.6
Niro Soavi S.p.A
FIGURE 4.6.4
For disassembly, unscrew the ring (D) and pull the instrument out; remove also
the gasket (B) and anti-extrusion rings (A, C) from their housing.
4c063e0c.doc 4.6.7
Niro Soavi S.p.A
The digital pressure gauge (M) will switch off automatically after a few
minutes if no pressure is measured, to preserve the internal battery.
To start the pressure gauge simply press the front ZERO/ON push-button;
keep this button pressed for a few seconds to reset the instrument to ZERO
if the reading given is NEGATIVE.
If the display reads BATT it means that the battery is down and needs to
be replaced.
Disassemble the pressure gauge and, on a dry surface, remove the rear
screws to lift off the cover on the battery housing. The battery used is a long
life 9V lithium battery, size PP3; in special circumstances a standard 9V
alkaline battery may be used.
4c063e0c.doc 4.6.8
Niro Soavi S.p.A
4.7. TRANSMISSION
The machine is equipped with a direct trapezoidal belt drive system which uses
pulleys on the motor shaft and crankshaft.
The elements of the drive system usually require only a visual inspection, carried
out with the machine not in operation, to check for possibile lubrication oil leaks
and, more importantly, for loosening of nuts, bolts, belt tensioning components
and reduction gear support parts.
Excessive movement of drive components, due to loosening of locking elements
caused by vibrations, can result in slack couplings and consequent breakage of
elements during machine operation.
4c072e0c.doc 4.7.1
Niro Soavi S.p.A
Worn pulleys significantly reduce the life of belts, which can touch the bottom of
the groove causing slipping which provokes wear and superficial burning.
If the sides of the groove are hollow, the contact between the sides of the belt
and the pulley is not uniform, and the lower part of the pulley causes wear of the
lower edge of the belt, causing it to break prematurely.
Thus, it is necessary to check the state of wear of the pulleys and remove any
rust, grease or oil that may be present.
ALIGNMENT CHECK
FIGURE 4.7.2
4c072e0c.doc 4.7.2
Niro Soavi S.p.A
SELECTION OF BELTS
Use at the same time belts of the same make, of the same type and of the same
lot, since there may be differences both in size and in performance.
Moreover, it is essential not to use new belts with others that have already been
used, because of a different extension, adjustment to the grooves of the pulleys,
and differences in performance, which would considerably affect the duration of
the drive train.
In order to ensure correct operation and avoid premature breaking, the belts must
be stored without any noticeable bends and must not be exposed to
temperatures that are too high or too low, or to a high degree of humidity.
On NIRO SOAVI machines equipped with direct V-belt drive the motor unit which
carries the driving pulley is mounted on a mobile support.
An adjustable tie rod makes it possible to change the distance between the
driving pulley and the driven one to allow installation and tensioning of the driving
belts.
During installation belts must never be forced with a tool into the pulleys grooves
to avoid the risk of damaging both thus reducing the life of the drive.
To make this operation easier simply reduce the distance between the pulleys.
Fit the belts into the grooves and rotate the pulley to facilitate insertion and
prevent damage.
4c072e0c.doc 4.7.3
Niro Soavi S.p.A
FIGURE 4.7.3
4c072e0c.doc 4.7.4
Niro Soavi S.p.A
WARNING: Control and servicing operations must be carried out WITH THE
MACHINE NOT IN OPERATION and with the sectioning switch of the imput
line LOCKED (by means of a lock) IN OPEN POSITION for the safety of the
personnel.
The ideal stretch is the lowest at which the belts do not slip under maximum load.
During the first 24-48 hours of running-in, check the stretch frequently; remember
that excessive stretch reduces the life of the belts and of the bearings that
support the drive.
Arrange for the stretch to be tightened as soon as any slipping occurs.
Belt slipping can cause overheating and create hazard particularly if the machine
is designed for operation in danger zones (explosion-proof version).
The following are two methods to identify the correct degree of stretching of the
belts; the first, which is easier, can be used when a new train of belts is installed,
or after loosening them completely; the second allows stretch to be checked even
during normal operations of servicing and control. The procedures of the
operations are described in paragraph 4.7.1.
4c072e0c.doc 4.7.5
Niro Soavi S.p.A
Before stretching the belts assembled on the pulleys, trace two fine marks across
the back of one belt and measure the distance between them; they should be as
far from each other as possible but must remain on the straight-line of the belt.
Stretch the belts gradually after having them rotate for approx. 1 minute in
successive stages; at each stage, tighten the belts so that the distance between
the two marks has a percentage increase as shown in table 4.7.4, considering
the case of medium diameter pulleys.
TABLE 4.7.4
Measure the length of the free section "t" (figure 4.7.5) and apply to its half-point
a force P perpendicular to the belt, that causes a deformation of 1.6 mm every
100 mm. of free length:
The intensity of the force, in Newton, should be in the interval of values shown in
table 4.7.6; it is measured by means of a special dynamometer which is not
supplied.
In order to calculate the peripheral speed value it is sufficient to use the formula:
V = 0.052 X n X d (m/s)
4c072e0c.doc 4.7.6
Niro Soavi S.p.A
FIGURE 4.7.5
TABLE 4.7.6
4c072e0c.doc 4.7.7
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OVERLOADS
Any overload shortens the life of the belts.
Check that operation is taking place under the initial project conditions, and that
no overloads occur due to wear or slipping and superficial burning.
PROTECTIONS
The drive should always be protected by a suitable guard, which not only protects
the operators but also protects the parts from dust or dirt and contact with foreign
objects which may cause serious damage to the system.
4c072e0c.doc 4.7.8
Niro Soavi S.p.A
TENSIONING
Check and maintain the correct stretch of the belts, to prevent irregular
vibrations.
EXPOSURE TO HEAT
Check that the belts are not exposed to sources of heat; an exposure to
temperatures greater than 60C will shorten their life.
WEAR
Check the condition of the sides of the belt: an anomalous wear may cause
slipping or excessive wear of the grooves of the pulleys.
4c072e0c.doc 4.7.9
Niro Soavi S.p.A
Drive pulleys are usually mounted both on the crankshaft drive end and on the
motor shaft using a Taper-Lock conical bushings.
With reference to figure 4.7.6, the procedure for disassembly is the following:
FIGURE 4.7.6
Assembly procedure:
- clean bush and shaft thoroughly
- insert Taper-Lock bush into pulley
- partially insert threaded screws into bores (A)
- mount the pulley on the shaft
- align the pulleys
- tighten screws A fully
If the motor pulley is not fitted with a Taper-Lock bushing, to install or remove
the pulley use a suitable pulley extractor and threaded rod for mounting the shaft,
using the threaded bore on the end of it.
4c072e0c.doc 4.7.10
Niro Soavi S.p.A
FIGURE 4.8.1
The type of construction, the high-quality materials used and the careful
assembly by highly-qualified personnel are a guarantee of excellent reliability and
durability.
Correct lubrication is fundamental for the life of the drive body and of its
components, so it is absolutely necessary to comply with the instructions given in
terms of recommended change frequency (Chapter 4.2), filter cleaning, level and
type of lubricant used (Chpater 4.9).
Under normal conditions the power end does not require servicing. Should you
notice abnormal noise levels, irregular machine operation or low pressure of
lubrication oil triggering the pressare switch, contact NIRO SOAVIs Customer
Service to request technical service.
4c081e0c.doc 4.8.1
Niro Soavi S.p.A
4c081e0c.doc 4.8.2
Niro Soavi S.p.A
Before removing the flanges you need to drain out, at least partially, the oil
inside the body to prevent accidental spillage.
Refer to figure 4.8.2 for the assembly and disassembly procedures described
below.
FIGURA 4.8.2
DISASSEMBLY
remove the plunger following the procedure described in Charter 4.4
loosen the screws (K) and extract the flange (M) from the guide plunger (Q)
remove the scraping ring (L) and the seal gasket (J)
ASSEMBLY
fit the scraping ring (L) and gasket (J) inside the flange (M), in the seat.
check and clean the plunger stem, if the surface is badly scored or the chrome
plate damages the whole plunger must be replaced. The guide plunger stem
cannot be supplied separately as spare part
insert the complete O-Ring flange (H) onto the guide plunger (Q) as far as the
edge. During assembly take care not to damage the sealing lip of the gaskets;
use lubrication grease for easier assembly
- tighten the screws (K).
4c081e0c.doc 4.8.3
Niro Soavi S.p.A
In some models a rubber bellows is installed to protect the guide plunger stem. In
this case the bellows must be removed to replace the gaskets, and then inserted
onto the guide plunger stem (Q) and snapped on locked against the flange (M) in
the seat provided.
4c081e0c.doc 4.8.4
Niro Soavi S.p.A
4.9. LUBRICATION
For topping-up and replacement use ONLY the oils shown in Table 4.9.1; table
4.9.2 indicates the capacity of the lubrication system for the various models.
4c092e0c.doc 4.9.1
Niro Soavi S.p.A
TABLE 4.9.1
4c092e0c.doc 4.9.2
Niro Soavi S.p.A
Splashing of oil due to moving parts allows to lubricate the various points for
which lubrication is required to avoid seizing or damage.
Splash lubrication is very simple because there are no mechanical parts to be
checked, but is always required to verify the oil level carefully to keep its
efficiency.
This system is not suitable for machines arranged for variable speed operation,
as at low speed slash lubrication cannot allow the sufficient lubricating effect on
moving parts in slow motion.
The machine is not provided with oil pressure gauge as there is no oil pressure
circuit with splash lubrication.
4c092e0c.doc 4.9.3
Niro Soavi S.p.A
The oil level needs to be checked every day, before the machine is started; the
oil should reach the mid level indicated on the sightglass located or inside the
machine on the crankcase or on the machine front panel. The oil level must be
checked with the machine stopped for at least 1 hour.
See for reference figure 4.9.3.
FIGURE 4.9.3
It is normal at the start of the machine to observe a lowering of the oil level on
the sightglass.
If oil drops below the required level top it up through the orange filler located
inside the machine on the crankcase lid.
To reach the fill you need to remove the side panel of the machine.
4c092e0c.doc 4.9.4
Niro Soavi S.p.A
OIL CHANGE
The frequency of oil change intervals is given in the "Tables for Regular
Servicing" at Chapter 4.2.
Use only oil as specified in Table 4.9.1.
To change the oil (see figure 4.9.1):
- prepare a reservoir to collect the oil, and of a size that is suitable to contain
the amount of oil found in the machine according to table 4.9.2;
- open the filling tap on the crankase cover
- open the bottom drain plug and let the oil drain out.
- once the oil has drained out completely, close the bottom plug and pour in
the new oil through the filler plug
- check the oil level through the sightglass.
The condensate drain can be done when the machine is stopped for at least 4
hours.
To drain the condensate:
- Prepare a basin for collection and open the bottom drain valve
- Water is heavier than oil, therefore it is collected at the bottom of the oil
tank; once the oil starts to pour out, close again the drain valve
- Check the oil level again and, if necessary, top it up through the filler plug
Presence of water into the oil may be caused by cooling water entering trough
the crosshead seals; it is recommended to check the surface of crosshead
extensions for scratches, and to replace the crosshead seals in case of oil
leakage or oil into the water, according to what is mentioned in paragraph 4.8.1.
4c092e0c.doc 4.9.5
Niro Soavi S.p.A
The force required to close the homogenizing valve and consequently achieve
the homogenizing pressure is applied through a pneumatic actuator using
compressed air on its upper part; the lower part of the actuator is connected
with the pressurized oil dampening system.
The dampening system is not installed on the machine when the pneumatic
valve installed is type NanoValve.
The pneumatic actuator does not requie any periodical maintenance but it is
recommended to protect it from extreme temperatures (which may damage the
gaskets) and corrosive fluids, as its body is made with Aluminium alloys and not
in stainless steel.
In case the pneumatic actuator is not working properly we recommed its
replacement; its anyway available upon request to Niro Soavi Spare Parts
Dept. the complete gaskets spare kit.
The scheme of the plant actually installed on the machine is given in Section 5
SPARE PARTS CATALOG with components list; you can also check the Flow-
sheet (P&ID) given in Section 1 TECHNICAL SPECIFICATIONS.
4c101e0c.doc 4.10.1
Niro Soavi S.p.A
FIGURE 4.10.1
4c101e0c.doc 4.10.2
Niro Soavi S.p.A
- Close the upper plug and connect a compressed air source to the quick
connection (M) to restore the pressure of 0,5 bar inside the damper tank
- Open the valve (J) and check if the air pressure is still at the set value of 0,5
bar
Pressure inside the camper tank cannot be higher than 0,6 bar when the
machine is stopped.
Oil into this circuit does not requie any change but only refilling in case the level
is low.
If during the above mentioned procedures of filling up, or during the
homogenizing valve maintenance some air bubbles are present into the plastic
pipes, it is possible toeliminate the same by application and release of the
pressure to the actuator through the pneumatic switch (C), with machine
stopped and with the manual pressure regulato set to allow some air to go
through (not at zero).
The presence of air bubbles, anyway, cannot prevent the system to work
properly, even if the dampening effect may be sometimes reduced.
The adjustment of the throttle valve (E, H) allows to regulate the speed of the
homogenizing pressare raise.
Usually the setting of this valve is made during the machine test, in order to
avoid a sudden raise of the homogenizing pressure which may cause the
opening of the overpressure relief valve.
Before making any modification to the setting, please tae note of the original
setting on the scale in order to recover the original setpoint in case of need.
As general information the closing of the valve (H) is slowing down the pressure
raise, its opening is making it faster.
4c101e0c.doc 4.10.3
Niro Soavi S.p.A
Class: ISO VG 32
DIN 51524-2-HLP
TABLE 4.10.2
The pneumatic plant for local and manual pressure adjustment allows to adjust
the homogenizing pressure from the machine front panel through a pneumatic
regulator and pneumatic switch.
No maintenance is required on these components, and in case of evident
malfunctioning replacement of faulty parts is recommended.
4c101e0c.doc 4.10.4
Niro Soavi S.p.A
FIGURE 4.10.3
4c101e0c.doc 4.10.5
Niro Soavi S.p.A
The proportional valve is tested and calibrated durino the machine test run. The
setting is related to the range of pneumatic signal output related to the electrical
signal input; in case of need it is possible to modify the factory settings by
adjusting the ZERO and SPAN screws located on the proportional valve
body under a protection cover (see figure 4.10.4).
The proportional valve is installed inside the machine cabinet, on left hand side,
and it is possible to access to it by removing the left side panel of the machine.
FIGURE 4.10.4
4c101e0c.doc 4.10.6
Niro Soavi S.p.A
4c112e0c.doc 4.11.1
Niro Soavi S.p.A
SECTION 5
SPARE PARTS CATALOGUE - INDEX
5C001E0C.DOC 5.1.0
Niro Soavi S.p.A
5C001E0C.DOC 5.1.1
Niro Soavi S.p.A
Spare parts can be ordered directly from NIRO SOAVI, Service Department, or
through your local NIRO SOAVI agent or Authorized Dealer, who can provide
useful advice and forward your request immediately.
To order spare parts or request quotations for spare parts, copy the standard
form below and send it by fax.
5C001E0C.DOC 5.2.1
Niro Soavi S.p.A
Model:
Serial No.
Shipping Specs.
5C001E0C.DOC 5.2.2
Niro Soavi S.p.A
.
In order to limit the number of shutdowns during production, and the time
required for maintenance of the machine, we recommend you stock a set of
spare parts to replace elements which are normally subject to wear.
The number of spare parts to be stocked will depend on production needs and
on how important it is to avoid long shutdowns due to unavailable spare parts.
In specific, in case of homogenizing valves, the replacement at due time allows
to keep the homogenizing efficiency and consequently the quality of the
processed product.
NIRO SOAVI cannot guarantee that a given spare part will be in stock either at
their central warehouse or at the Dealers due to problems with material
availability or to special requirements for dispatch.
Please note that shipment is no guarantee of successful delivery and that
delays may occurr due to customs problems or miscarriage.
In any case NIRO SOAVI shall not be responsible for delays occurring due to
the shipment of spare parts.
5C001E0C.DOC 5.3.1
Niro Soavi S.p.A
Notes:
5C001E0C.DOC 5.3.2
Niro Soavi S.p.A
5C001E0C.DOC 5.3.3
Niro Soavi S.p.A
The machine is supplied complete with a set of spanners and tools to be used
during ordinary maintenance; they include special tools for installing or
removing plungers and packings, where required.
The set of spanners DOES NOT INCLUDE a Torque Wrench, which is
recommended for correct tightening of nuts and studs to the torque values given
in Section 4 - MAINTENANCE.
The maintenance box includes a basic set of spare gaskets.
Please find attached a list of the tools supplied for ordinary maintenance.
5C001E0C.DOC 5.4.1
Niro Soavi S.p.A.
Item Description Description Qty Part Code
- CHIAVE COMB 24X24 MIXED WRENCH 24X24 1 810224
- CHIAVE COMB 30X30 MIXED WRENCH 30X30 1 810230
- CHIAVE COMB 19X19 MIXED WRENCH 19X19 1 810219
- CHIAVE ESAGONALE AD " L " 8 EXAGONAL KEY " L " 8 1 810308
- GIRAVITE A CROCE 8X150 SCREWDRIVER 8X150 1 810010
- CHIAVE UNIFAST UNIFAST KEY 1 350229
- FONDELLO PIEDE FOOT BASE 4 350457
- MOLLA SPRING 6 0124804-1
- RONDELLA WASHER 6 0133563
- PACCHETTO PACKING 3 150101CX
- ORING ORING 18 140205PU
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 18 0130254
- ORING ORING 1 140027PU
- ORING ORING 1 140022PU
- ORING ORING 1 140030PU
- ORING ORING 1 140035PU
- ORING ORING 1 140026PU
- ORING ORING 1 140330PU
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130176
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130982
- ORING ORING 1 140013PU
- ORING ORING 3 140030PU
- ORING ORING 1 130031S
- ORING ORING 1 130027PU
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0127432
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130175
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0124748
- ORING ORING 1 140022PU
- ORING ORING 1 140205PU
- GUARNIZIONE GASKET 2 140358
- GUARNIZIONE GASKET 1 140353
You will find attached assembly drawings and a list of components and spare
parts.
The first code of each spare parts list indicates the assembly drawing which the
components refer to.
5C001E0C.DOC 5.5.1
Item Description Description Qty Part Code
\ ASS. TESTATA DI COMPRESSIONE COMPRESSION HEAD ASS. DRW. 1 0130237-2
2 PIASTRA PLATE 1 0131376-10
3 PACCHETTO PACKING 3 150101CX
4 RONDELLA WASHER 6 0133563
5 FLANGIA FLANGE 3 0129632-9
6 PRIGIONIERO STUD 12 0122926
7 DADO NUT 12 760006
8 PRIGIONIERO STUD 4 0131063
9 DADO NUT 4 760006
10 PRIGIONIERO STUD 8 0130852
11 DADO NUT 8 760008
12 TESTATA COMPRESSION HEAD 1 0133288
13 ORING ORING 3 140205PU
14 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 3 0130254
15 GRUPPO VALVOLA VALVE GROUP 3 DRW.29112
16 GRUPPO VALVOLA VALVE GROUP 3 DRW.29112
17 PRIGIONIERO STUD 8 0131067
18 DADO NUT 8 760008
19 PRIGIONIERO STUD 8 0131068
20 DADO NUT 8 760008
21 ASSIEME ASSEMBLY DRAWING 3 0201BKB7
22 COLLETTORE MANIFOLD 1 0133689-2
23 COLLETTORE MANIFOLD 1 0133283-2
SECTION 6
ELECTRICAL DIAGRAMS - INDEX
6C001E0C.DOC 6.1.0
Niro Soavi S.p.A
In the following pages it is possibile to find the wiring diagrams of the electrical
devices installed on-board the machine, or as an alternative, the complete
electrical diagram of the Electric Power Board if the same or its engineering is
supplied by Niro Soavi.
We recommend to check carefully the wiring diagrams to proceed with correct
connection of the machinhe and its components.
The wiring of the machine and its components must be done by qualified
personnel who must be able to understand properly the supplied electrical
documentation and wiring diagrams.
6C001E0C.DOC 6.1.1
Niro Soavi S.p.A
SECTION 7
SUPPLIERS CATALOGUE - INDEX
7C001E0C.DOC 7.1.0
Niro Soavi S.p.A
7C001E0C.DOC 7.1.1