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Somat SPC-50S Operation Manual Download Page 46

46 

 

 

Heavy flow from 
overflow pipe.

 

1.   Excessive foaming

 

1.   Add a de-foamer.

 

2.   Blockage of return line.

 

2.   Check individual cleanouts to locate 
blockage.

 

3.   Improper Return water 
flow.

 

3.   Readjust throttling valves.

 

Excessively wet 
pulp discharge 
from Hydra-
Extractor®.

 

1.   Blockage of screen.

 

1.   Clean the Hydra-Extractor screen.  Refer 
to Hydra-Extractor Maintenance Section of 
the manual.

 

2.   Worn screw and         
brush.

 

2.   Remove and replace. Refer to Hydra-
Extractor Maintenance Section of this 
manual.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for SPC-50S

Page 1: ...SO1000 11 20 Operation Manual SPC50 SPC75 Close Coupled Pulping Systems 165 Independence Ct Lancaster Pa 17601 Ph 800 237 6628 service somatcompany com ...

Page 2: ...umber Rep Dealer Rep Dealer Phone number Somat Service Dept 800 237 6628 x176 Somat Parts Visit SomatCompany com for an authorized parts distributor To expedite service or parts please have the above information available before you call The serial number of your equipment is located inside of the main electrical control panel of your Somat equipment ...

Page 3: ...ct tort strict liability or under any warranty or otherwise shall not exceed the purchase price received by it and shall in no event include any consequential incidental punitive or other special damages No change in this warranty and limitation of liability and substitute therefore whether incorporated in a purchase order or otherwise shall be effective unless specifically set forth in a written ...

Page 4: ...turn Piping for Units with a Trough Electrical Installation 21 22 Panel Optional Remote PBS Mounting Supplying Som A Trol with Power Remote Push Button Station Start up 23 Warranty Registration Form 25 Operation 26 Typical Operating Procedure 27 Shutdown Procedures 28 Light Codes 29 Special Operating Procedures 30 Cleaning Your System 31 Cleaning Instructions 32 Cleaning the Pulper 32 Cleaning the...

Page 5: ...CE ADJUSTMENTS OR CLEANING OF THE UNIT BEFORE STARTING BE SURE ALL PERSONNEL ARE CLEAR OF MOVING PARTS KNOW LOCATION AND FUNCTIONS OF ALL START STOP BUTTONS AND SAFETY SWITCHES DURING PERIODIC MAINTENANCE CHECK ALL SAFETY SWITCHES TO BE SURE THEY ARE OPERATING PROPERLY DO NOT REMOVE OR ALTER GUARDS DO NOT REMOVE SAFETY LABELS IF LABELS ARE MISSING OR DESTROYED CONTACT FACTORY FOR REPLACEMENT DO NO...

Page 6: ... or serious injury can occur if warnings are not followed This equipment has moveable lids protecting you from moving parts Do not alter safety devices or guards Do not reach into any part of the unit with the power turned on This equipment uses High Voltage Only trained and authorized personnel should perform maintenance on the electrical components of this machine This equipment has moving parts...

Page 7: ...achine s Keep these items out of the machine s to avoid component failure and unwanted downtime When in doubt keep it out of the machine s Glass Bottles Jars Cans Silverware Metal of any kind Pans China Wood Towels Rags Scrub Pads Always turn the power off before servicing the pulper ...

Page 8: ...ed to pulp all forms of paper plastic cardboard and food waste The waste material is fed manually or automatically to the Pulper The continual down flow of water and the rotation of the Pulper impeller create a strong vortex action which pulls the waste down against the cutting blades of the impeller The resultant slurry is then forced through a perforated stainless steel Sizing Ring surrounding t...

Page 9: ...area are called the plug This plug is broken up at the Hydra Extractor discharge opening by a cutter and the pulp then falls out of the discharge chute This system can reduce the volume of average non compacted waste by approximately 80 percent The system is powered by electric motors with the associated controls housed in Som A Trol electric control panels Since in the course of operation some wa...

Page 10: ...er has been extracted 4 Som A Trol Electrical control panel including motor starters and sequencing controls for automatic operation of the SOMAT system 5 Slurry Pump Specially designed pump used to transport slurry from a SOMAT Pulper to Hydra Extractor 6 Return Pump Specially designed pump used to return water from Hydra Extractor to SOMAT Pulpers 7 Water Level Control a PLC controlled function ...

Page 11: ...nd permits water to drain off by gravity 2 Screen Mesh screen that surrounds the screw through which water drains off 3 Plug Mass of pulp extending beyond last helix of the screw The force required to extrude the plug squeezes additional water from pulp 4 Brush Nylon brush attached to edge of screw helix which serves to clean the screen 5 Plug Cutter Assists in breaking apart waste to discharge do...

Page 12: ...12 Installation ...

Page 13: ...KING The crate containing your SOMAT Pulper will contain the following items 1 Pulper 2 Tray if so equipped 3 Som A Trol Panel Misc parts box containing ALL UNITS Anti Vibration Pads Installation Drawings 2 1 3 ...

Page 14: ...nless Steel Adapter Unless shipped directly to table manufacturer 3 UDT Gasket on unit TRAY ONLY 1 Return Water Assembly TROUGH ONLY 1 Trough Gasket Hardware 2 Trough Nozzles Throttling Gate Valves See Installation Drawing for quantity 1 1 2 3 1 2 ...

Page 15: ...15 OPTIONAL EQUIPMENT 1 Remote Push Button Station 2 Trough Magnet Hardware 3 Tray Feed Hood 1 2 3 ...

Page 16: ...n Pads under each leg of the Pulper and Hydra Extractor 3 TRAY FEED UNITS ONLY Install the tray to the Pulper if it was not already installed at the factory using the provided gasket material and hardware 4 TROUGH FEED UNITS ONLY Install the provided trough gasket between the Pulpers inlet and the trough outlet and secure with the provided hardware ...

Page 17: ...ition 4 Place the anti vibration pads under each leg of the Pulper and Hydra Extractor 5 Adjust the Pulper and Hydra Extractor legs so that the unit sits level and the rubber UDT gasket provides a watertight seal with 2 clearance between Pulper top and the underside of the table 6 Install the provided trough gasket between the Pulpers inlet and the trough outlet and secure with the provided hardwa...

Page 18: ... 32 diameter holes into the trough as shown below Seal the heads of the provided screws with silicone and attach the magnet RECOMMENDED POSITION OF THE GRABBER MAGNETS MOUNTING DETAIL OF TROUGH 12 TROUGH DETAIL 9 TROUGH DETAIL Holes in Pulper Trough Connection to be Drilled in the Field not done by the FACTORY ...

Page 19: ...be exerted on Somat equipment 7 Protect all Somat equipment and piping from freezing and condensation 8 All piping to be in accordance with state and local plumbing codes 9 F furnished by Somat NF not furnished by Somat FRESH WATER NOTE Check local codes regarding the proper backflow prevention devices to be installed 1 Bring a 1 2 cold water line for the Pulper to the pre piped freshwater assembl...

Page 20: ...ded tubing over to the return water elbow on the feed tray and the other side onto the pump return water assembly if not already factory installed 2 Install the provided hose clamps at each connection RETURN PIPING FOR UNITS WITH A TROUGH Pipe from the return pump to the supplied trough end flush nozzle and silver saver connections as well as to the optional trough nozzles as shown in the trough d...

Page 21: ...ional electric code specifications 6 Integral pushbuttons are in panel door and pre wired at factory Optional remote push button station if supplied to be mounted wired at workstation by electrician Bracket Required by Customer PANEL OPTIONAL REMOTE PUSH BUTTON STATION MOUNTING 1 Mount the Som A Trol electrical control panel in a suitable location see installation Drawings so that the bottom of th...

Page 22: ...es and control wires through these conduits separately and do your final wire terminations matching numbers from panel to pre wired junction box REMOTE PUSHBUTTON STATION Mount the remote pushbutton station run the conduit from the remote pushbutton station to the pre wired junction box or panel then pull the wires from the remote pushbutton station to the pre wired junction box and do your final ...

Page 23: ...23 Start Up ...

Page 24: ... up Checklist which is sent from Somat Installation Errors If the equipment is not ready for start up due to installation errors or incomplete installation the technician may have to schedule an additional start up visit at the owner s expense Somat equipment carries a 1 year warranty from date of start up To accurately track this information we ask that you fill out the Warranty Registration Shee...

Page 25: ... Customer Name Address City State Zip Contact Name Contact Number Email Service Company City State Zip Please email to Somat Company Service Department service somatcompany com OR send with startup paperwork WARRANTY REGISTRATION FORM ...

Page 26: ...26 Operation ...

Page 27: ... a continuous flow of return water before feeding waste to the Pulper either manually or by starting waste down the flushed trough if so equipped PULPER FEEDING Best results are obtained if the Pulper is fed waste at a UNIFORM RATE Under normal conditions waste may be fed to the Pulper if a strong vortex is maintained in the tank If waste is fed too fast the vortex will diminish to a point where i...

Page 28: ...gage spray rinse system system will then time out on its own The Pulper will stop when the shutdown timer has timed out 3 Press DRAIN EMPTY pushbutton on panel door to drain the pulping system This pushbutton will DRAIN all water in the system 4 Turn power off to perform any cleaning or maintenance 5 Refer to the applicable Pulper and Hydra Extractor maintenance sections of this manual for daily w...

Page 29: ...ed and secure system is ready to run Flashing Green System is in timed stop mode extractor will spray after less than 10 minutes system will shut down Slow flashing Green Unit drain is open press Green pushbutton to close drain Two Green flash pause and repeat All safeties are latched and secure tank is filling Solid Red One of systems 3 motors is overloaded and must be reset Flashing Red Lid swit...

Page 30: ...ten used where equipment is exposed 4 Non Pulpables The SOMAT Pulper is designed to handle a limited amount of non pulpable material The lighter items are eventually ground and the heavier material is discharged into the junk box Occasionally the amounts of non pulpables may become excessive and the processing rate may begin to decrease Safely stop the Pulper scoop out the non pulpable matter and ...

Page 31: ...31 CLEANING YOUR SYSTEM ...

Page 32: ...e brush detergent and deodorant or other cleaning solution Exercise care in cleaning the underside of the upper shell flange Wipe down the equipment exterior 4 Leave lid open if allowed to let machine air out and reduce odors CLEANING THE HYDRA EXTRACTOR With a hot water high pressure hose wash down screens and interior walls of Hydra Extractor housing If necessary a long handled brush can be used...

Page 33: ... The ideal cleaning products for use with SOMAT equipment combine four important functions detergency disinfection pH buffering and odor counter action To simplify this selection SOMAT offers products to maintain a clean system SOMAT NEUTRO PLUS 72000 Designed for use in the SOMAT System to keep it clean to deodorize and to reduce grease build up This is an industrial strength product The surfacta...

Page 34: ...34 MAINTENANCE ...

Page 35: ...e adequate lead time when ordering spare parts minimizing unnecessary and costly equipment downtime PULPER DAILY WEEKLY MONTHLY QUARTERLY 1 GENERAL a Check shell and slurry chamber for wear X b Check exterior finish for corrosion X 2 IMPELLERS a Check impeller blades for wear X b Check stationary blades for wear X c Check impeller for wear X d Check security ring for wear X 3 DRIVE a Check seal fo...

Page 36: ...ge X b Check bushing and bottom pin X Lubrication Chart FREQUENCY TYPE OF FITTING LUBRICANT Hydra Extractor speed reducer 6 months to 1 year Oil fill plug Amer Worm Gear Oil Gear Oil 629 Mobil Return Pump DAILY WEEKLY MONTHLY QUARTERLY 1 GENERAL a Check exterior finish for corrosion X b Check pump casing for wear X c Check impeller for wear X 2 DRIVE a Check seals for leakage X b Check bearings fo...

Page 37: ...er assembly by removing four machine screws MECHANICAL SEAL REMOVAL 1 Remove spring and upper seal ring prior to removing motor 2 With motor removed push upward on Ni Resist Seal until it can be removed MECHANICAL SEAL INSTALLATION 1 Clean the seal cavity and moisten the O ring of the Ni Resist Seal with soapy water 2 Tap the Ni Resist Seal in the cavity with seal installation tool The cut out on ...

Page 38: ...n stationary blocks and rotating blades Do not over tighten IMPELLER REMOVAL 1 Remove impeller hold down bolt 1 and washer 2 carefully remove the impeller assembly from the motor drive shaft with an impeller puller Somat P N 84150 To use Impeller Puller 3 Tighten the two fastening screws 4 to secure puller to impeller Next turn center setscrew 5 to lift impeller out of security ring Remove key ...

Page 39: ...e impeller as described above Remove attaching hardware for cutting ears Using a gloved hand firmly grasp blade and with an angle grinder grind a new edge on interior of blade only Interior of blade will face center bolt of impeller The picture below has the edge to be resurfaced highlighted in black DO NOT grind on opposing side of blade as this will reduce or impair any cutting ability Grind onl...

Page 40: ...ly 6 lift head with screen 7 and screw assembly 8 attached from the Hydra Extractor shell 9 2 Remove the screw assembly from the screen assembly by pulling the screw assembly through the bottom opening of the screen while turning bottom of screw counterclockwise with a pipe wrench 3 After removing the screw assembly remove two button head machine screws 10 from the screen and slip the screen from ...

Page 41: ...eramic disc into adapter seat bore with polished side up Take extreme caution to not damage polished side as this will cause immediate leaks Ensure seal is seated to bottom of adapter seat bore If needed use a wooden dowel and gently tap into place to ensure tight seat into bore 8 Replace impeller assembly back onto motor shaft Use a light coating of anti seize on motor shaft to ensure smooth seat...

Page 42: ...eve to motor shaft 5 Remove impeller with drive sleeve as an assembly taking care not to damage mechanical seal or pumping vanes 6 Remove 4 3 8 16 x hex head screws from adapter plate to motor 7 Remove adapter unit from motor 8 Replace motor as required properly wiring unit Ensure that wiring is for correct voltage 9 Replace pump pak as described in MECHANICAL SEAL REMOVAL SECTION s 8 14 ...

Page 43: ...43 TROUBLESHOOTING ...

Page 44: ... is burned out replace with a new valve Too much water in Pulper 1 Trough valve open too far 1 Throttle down valve to decrease water in pulper and increase water in extractor more overflow 2 Misadjusted PLC POT setting 2 The PLC controls the circuit to the solenoid valve Too high a setting would tend to hold the solenoid valve open too long letting too much water into the Pulper See Display Module...

Page 45: ...t procedure 3 Worn or missing stationary blades 3 Adjust or replace blades in accordance with Pulper maintenance section of manual 4 Excessive foaming 4 Add a de foamer or any other suitable commercial preparation 5 Sluggish vortex a See Previous section b Overload of waste b Revise waste feeding rate see Feeding Instructions Section 4 6 Clogged or worn pump 6 See pump section for require correcti...

Page 46: ...blockage 3 Improper Return water flow 3 Readjust throttling valves Excessively wet pulp discharge from Hydra Extractor 1 Blockage of screen 1 Clean the Hydra Extractor screen Refer to Hydra Extractor Maintenance Section of the manual 2 Worn screw and brush 2 Remove and replace Refer to Hydra Extractor Maintenance Section of this manual ...

Page 47: ...47 Display Module Instructions ...

Page 48: ...up water during operation seconds 0 30 second span D2 Timed Stop duration seconds 0 1 200 second span D3 Return Pump Start Delay seconds IF APPLICABLE 0 20 second span D4 Auxiliary Fill Duration Optional with auxiliary pump IF APPLICABLE D5 Pulper Hours of Operation D6 Pulper Minutes of Operation D7 Pulper seconds of Operation displayed in 1 10ths of seconds ...

Page 49: ...49 SP SPC 50 Water Control Module Settings Factory settings D0 120 seconds D1 6 seconds SP SPC 75 Water Control Module Settings Factory settings D0 120 seconds D1 4 seconds ...

Page 50: ...LC If the date time is displayed on the DM Module then you are ready to proceed If not push the ESC button to display the date time Then press the OK button twice to display the D register s From the Date Time screen after pushing the OK button twice the DM Module will go to the last D register that was modified The D number is displayed on the bottom of the DM Module screen The value of that D nu...

Page 51: ... for remote machines press the button once if D4 D14 for remote machines press the button twice 10 To change the Timed Stop Duration D2 press OK once then enter value found in table above 11 To verify all changes drain the pulper and follow restart procedure Verify how many seconds the freshwater solenoid remains on while the pulper is in operation ...

Page 52: ...52 165 Independence Ct Lancaster Pa 17601 Ph 800 237 6628 service somatcompany com ...

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