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Initial Commissioning

Safety instructions for initial commissioning

2007-9015-001
03-2014

71 / 108

Initial Commissioning

6.1

Special personnel qualification required for initial commissioning

Initial commissioning may only be performed by specially qualified personnel in
accordance with the safety instructions.

6.2

Safety instructions for initial commissioning

Caution!

Always open 2 ball valves under the hydraulic power unit before
operating the equipment. Operating the hydraulic power unit with
closed ball valves will result in failure and/or injuries due to excess of
pressure in the oil filter.

To prevent damage to property and/or life-threatening injury to personnel
always follow these instructions:

● Before starting for the first time, check that all tools and other parts have

been removed from the danger area.

● Make sure all electrical connections and safety devices are properly

installed to meet local and national regulations.

● Check the direction of rotation of the motor before commissioning.

Содержание Futuro

Страница 1: ...Futuro Underground Manure Pumps Instruction Manual Installation Instructions Original instructions 2007 9015 001 03 2014 engineering for a better world GEA Farm Technologies...

Страница 2: ...for transportation 39 4 4 Lifting and moving the pump 40 4 5 Lifting and moving the hydraulic power unit 40 4 6 Storage conditions 40 4 7 Information on disposing of packing material 40 5 Installation...

Страница 3: ...8 3 Troubleshooting possible faults 84 9 Maintenance 87 9 1 Special personnel qualification required for maintenance work 87 9 2 Safety instructions for maintenance 87 9 3 Scheduled maintenance respo...

Страница 4: ...cialist terminology are explained in more detail in the Appendix These instructions are part of the supply They should be kept close at hand and remain with the equipment even if the equipment is sold...

Страница 5: ...cate the language as follows language language language 9000 German 9013 Dutch 9032 Serbian 9001 English United Kingdom 9015 English North American 9034 Slovakian 9002 French France 9016 Polish 9035 C...

Страница 6: ...lease contact your nearest authorized technical dealer There is a comprehensive dealer Internet search function on our website at the following address www gea farmtechnologies com European Contact In...

Страница 7: ...ines and specifications EN ISO 13857 2008 06 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs EN ISO 14121 1 2007 12 Safety of machinery Risk assessm...

Страница 8: ...T THAT THE EQUIPMENT IS SOLD OR OTHERWISE TRANSFERRED 1 5 2 Condition of the limited warranty The Company through its GEA authorized dealers only hereinafter referred to as Dealer reserves the right t...

Страница 9: ...ditions including without limitation damages caused by fire lightning flood or other natural disaster damages caused by the use of sand litter or other abrasive or inadequate material including withou...

Страница 10: ...AL PUNITIVE OR EXEMPLARY DAMAGES IN ANY KIND OR CHARACTER INCLUDING INDIRECT COSTS LOSS OF PRODUCTION LOSS OF REVENUES OR PROFITS AND OTHER DISBURSEMENTS WHICH MAY OCCUR Some states or jurisdictions d...

Страница 11: ...compacted sand bed on the bottom of trench before installing the Steel Evacuation Line 1 6 2 Prorated Warranty Against Corrosion The Steel Evacuation Line is warranted against perforation due to corro...

Страница 12: ...s and warnings A Danger TOXIC GASES sign is posted at the eye level at the entry of the pit area Make sure this sign remains visible at all times No one must enter into a manure pit at any time except...

Страница 13: ...or the farm These must be especially adapted to the conditions of the business once again expressly taking account of safety aspects The product is only used for its intended purpose should only be op...

Страница 14: ...he indication Danger signals immediate danger to life or health of personnel Death or serious injury will result if the danger is not avoided Warning The indication Warning signals danger to life or h...

Страница 15: ...ional Safety and Health Administration www osha gov In European Union European Agency for Safety and Health at Work www europe osha eu int Danger As manure produces toxic gases that may cause death it...

Страница 16: ...n livestock farms has inherent risks Read and follow the instructions carefully especially the section on Safety to ensure your own safety The chapter on Technical data gives the permissible working c...

Страница 17: ...be performed by qualified personnel only in accordance with slinging techniques Any work in a reservoir must only be carried out by qualified personnel having knowledge on safety procedure in confine...

Страница 18: ...99 4721 000 Warning American model Always turn off main power before maintenance and service Never adjust the equipment while it is running Keep all shields and guards in place Keep hands and loose cl...

Страница 19: ...arting the pump American model Never operate the pump without manure part no 2099 4724 010 Make sure that both valves under the tank are opened before operating the power unit American model Change th...

Страница 20: ...trical motor on the equipment which does not match the motor technical specifications provided in this manual The equipment is not designed to use any other type of motor than those listed Improper mo...

Страница 21: ...ety reasons do not carry out any unauthorized modifications Planned changes must be approved by the manufacturer in writing Any unauthorized modifications to the product will invalidate the warranty a...

Страница 22: ...oses and the intake flapper opens to fill the evacuation chamber with slurry During the evacuation cycle down stroke the intake flapper closes and the discharge flapper opens to move the slurry from t...

Страница 23: ...Pump 1 2 3 4 5 6 7 8 9 10 11 Legend 1 Hydraulic cylinder 2 Grease lines 3 Manual lever guillotine valve 4 Reversing mechanism 5 Pumping Tube 6 Discharge guillotine valve 7 Spring housing 8 Access door...

Страница 24: ...Description Main View 2007 9015 001 03 2014 24 108 Legend 1 Intake flapper valve 2 Flapper door seal 3 Downstroke lever 4 Piston 5 Discharge flapper valve 6 Discharge valve spring...

Страница 25: ...Main View 2007 9015 001 03 2014 25 108 3 5 2 Hydraulic Power Unit 2 3 4 4 1 7 6 5 8 Legend 1 Oil reservoir 2 Reservoir cap 3 Oil sight gauge 4 Ball valve 5 Oil filter 6 Motor 7 Chain joint guard 8 Hyd...

Страница 26: ...he length of the suction pipe is limited and based upon the consistency of the manure slurry The suction pipe elbow may be position up or down depending on the relationship between the elevation of th...

Страница 27: ...gate valve must be installed to prevent manure flow into the air line 1 5 6 2 3 4 Legend 1 Air valve 2 50 mm 2 Relief valve 6 mm 3 Cap 6 150 mm 4 Gate valve 6 150 mm 5 Air flush riser 6 Flow direction...

Страница 28: ...305 cm valve 16 406 cm valve Dimensions do not include lever extensions If lever extensions are used add the extension length to these dimensions Manual lever and lever extension 12 305 mm or 16 406...

Страница 29: ...ow back as long as manure remains consistent enough to seal the flapper The flapper valve may leak if manure becomes watery or if a piece of material gets stuck between the flapper and the valve housi...

Страница 30: ...m Maximum evacuation line length Varies based on manure consistency Maximum length of suction pipe Varies based on manure consistency Pump without intake or discharge accessories Perform a manure cons...

Страница 31: ...iption Technical Data 2007 9015 001 03 2014 31 108 12 315 mm steel elbows 15 Elbow 30 Elbow 45 Elbow 60 Elbow 75 Elbow 90 Elbow 16 406 mm steel elbows 15 Elbow 30 Elbow 45 Elbow 60 Elbow 75 Elbow 90 E...

Страница 32: ...1 22 m X 15 15 4 57m needle 20 6 1m needle A 180 4 57 m A 240 6 1 m B 37 93 99 cm and less B 53 1 35 m and less C 48 1 22 m C 48 1 22 m X 15 X 15 75 long radius elbow with rising pipe 15 X 5 long 75 l...

Страница 33: ...less D 24 61 cm and more D 24 61 cm and more X 15 X 15 75 Flapper valve with rising pipe 15 X 5 long 75 Flapper valve with rising pipe 15 X 10 long A 108 2 74 m A 168 4 27 m B 32 81 3 cm and less B 48...

Страница 34: ...pressure 54 PSI 1200 PSI in hydraulic circuit Noise level 62 dBA Pump without intake or discharge accessories Perform a manure consistency test Metric chart Slurry consistency Maximum evacuation dist...

Страница 35: ...kW 50 Hz 1450 PLP 20 14 5 5 20 7 1800 124 1 PLP 20 16 6 3 24 1440 99 3 PLP 20 20 8 30 3 1200 82 7 5 HP 60 Hz 1740 PLP 20 14 6 6 24 8 1500 103 4 PLP 20 16 7 6 28 8 1200 82 7 PLP 20 20 9 6 36 3 1000 68...

Страница 36: ...rent No special requirements Efficiency min 80 Power Factor No special requirements General data Standard specifications NEMA IEC Frame sizes required 184T 213T 215T 112 132 Type of construction B3 We...

Страница 37: ...ff switch meet all motor specifications provided in this manual meet local electrical requirements Special specifications The control panel protection devices must be designed to avoid any unexpected...

Страница 38: ...6 7 Bolt torque chart Bolt Mat Bolt diametre 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 SAE 2 LCS 8Nm 6ft lb 16Nm 12ft lb 27Nm 20ft lb 44Nm 32ft lb 64Nm 47ft lb 94Nm 69ft lb 130Nm 96ft lb 210Nm 155ft l...

Страница 39: ...d support points for transport Also read the chapter on Safety Special transport hazards Sharp edges may cause injuries Suspended loads can fall resulting in severe injuries or even death If load susp...

Страница 40: ...hydraulic power unit Using a fork lift Insert forks under the power unit motor base to lift it 4 6 Storage conditions Attention Risk of corrosion When storing the goods supplied the location must pro...

Страница 41: ...n Before installation look for any damage caused during transport Do not use damaged components Use only the special tool indicated for assembly Special hazards during installation Injury can be cause...

Страница 42: ...trical wiring diagrams Foundation plan Special tools Description Purpose Fork lift truck To lift the equipment Chain hoist To lift the equipment Safety chains To lift the equipment Hammer drill To mak...

Страница 43: ...al purchased items Provided by the owner Safety fences installed around the equipment reservoir to prevent fall PVC pipe rated at 150 psi 10 3bar minimum An electric motor meeting technical specificat...

Страница 44: ...ns of the pit do not include a stairway for pump maintenance Refer to your engineer or architect in order to design a stairway that gives access to the pit Note Evacuation pipe must be installed throu...

Страница 45: ...r pump with a hopper and with an air riser Refer to section on Installing a 6 15 cm riser for air flush The length of pit is applicable to all configurations of intake and discharge adaptors with or w...

Страница 46: ...preparations 2007 9015 001 03 2014 46 108 Pit for pump with a suction pipe and without an air riser The length of pit is applicable to all configurations of intake and discharge adaptors with or with...

Страница 47: ...with an air riser Refer to section on Installing a 6 15 cm riser for air flush The length of pit is applicable to all configurations of intake and discharge adaptors with or without guillotine valve...

Страница 48: ...e Technical Data Section on Concrete Anchor Bolt To tighten bolts adequately refer to the Technical Data Section on Bolt Torque Chart 5 5 1 Positioning the pump Lift the pump and position it in the pi...

Страница 49: ...impeded lever movement and operator convenience Lever extension The pump pit can be covered for added safety and convenience In this case the valve levers are raised above the floor by using a lever e...

Страница 50: ...st be turned down with hydraulic agitation option added to prevent plugging Refer to section on Minimum pit dimensions for installing the pump in a service pit The maximum length of the suction line i...

Страница 51: ...g the hydraulic agitator use a lifting equipment having a minimum capacity of 200 lbs 90 kg to hold the hydraulic agitator Using 2 U bolts 7 16 x 3 5 x 4 375 round U bolts install the agitator on supp...

Страница 52: ...ll scratches with tar to protect from corrosion Attention Pipes must be surrounded with sand and carefully backfilled under the frost level Attention All gate valves with insulated rod and PVC elbows...

Страница 53: ...must refer to local authorities for proper specifications regarding the size the orientation and the spacing of the blocks C A B A Evacuation line inlet B Insulated gate valve C Concrete thrust block...

Страница 54: ...female PVC Male steel to male PVC A G B C G Male steel to male steel Male steel to female steel C D G D G Male PVC to female SS Male steel to female SS B E F G E F G Legende A PVC pipe collar G Thread...

Страница 55: ...f the evacuation line Refer to section on Dimensions of GEA Houle steel components prior to install the discharge pipe Install the discharge pipe in the bottom of the manure storage pit according to t...

Страница 56: ...o seal the flapper The flapper valve may leak if manure becomes watery or if a piece of material gets stuck between the flapper and the valve housing Manure storage pit In a sand bedding operation if...

Страница 57: ...the evacuation line 2007 9015 001 03 2014 57 108 Remove the filling cap of each insulated gate valve and fill the tube with hydraulic oil to protect it against frost and to prevent corrosion Then put...

Страница 58: ...flush sand from the evacuation line using air pressure and a straw bullet Evacuation line Air riser One riser is required every 200 60 m Note Some evacuation lines require extra risers where potentia...

Страница 59: ...ume of compressed air Refer to the table below to find appropriate air tank size required to flush the full length of evacuation line 12 3 4 315 mm evacuation line Air Pressure Length of evacuation li...

Страница 60: ...79 m 290 88 m 320 98 m 350 107 m Minimum size of air tank 125 psi 8 6 bar 210 g 790 L 335 g 1263 L 460 g 1739 L 585 g 2211 L 710 g 2684 L 835 g 3160 L 960 g 3633 L 1085 g 4105 L 1210 g 4581 L 1336 g 5...

Страница 61: ...long the buried line The following instructions prolong the life of the steel equipment significantly Each steel pipe must be free of scratches on its coating Scratches greatly amplify the corrosion p...

Страница 62: ...or indirectly to the equipment protected For example if the concrete floor wire mesh the stalls and the evacuation line are linked together to the same ground wire sacrificial anodes will have to pro...

Страница 63: ...equired to make a single loop around the bolt Hook the stripped wire to the bolt between 2 washers Do not overlap the wire since it may cut itself when tightening the nut copper wire of the sacrificia...

Страница 64: ...owder in the cardboard tube must be saturated with water before burying the sacrificial anode Using a knife make a cut in the plastic cap and fill the tube with water The cardboard will disintegrate w...

Страница 65: ...e from a supplier other than the manufacturer it is mandatory to verify components compatibility Make sure motors and or control panels match the equipment specifications Refer to the Technical Data s...

Страница 66: ...n motor shafts as shown below Using the appropriate bolt pattern install the motor on the support Position the motor shaft in line with the pump shaft and tighten motor bolts Install the chain to main...

Страница 67: ...square cut The saw must be equipped with a blade capable of cutting through the wire reinforcement layers Attention Dirt is the worst enemy of any hydraulic system To prevent dirt from entering into t...

Страница 68: ...be protected from freezing temperatures Choose a location that will minimize the length of hydraulic lines required Allow sufficient clearance around the hydraulic unit to permit service and routine m...

Страница 69: ...ate energy when under pressure If the hose is too tight a tension will be apply to the fitting and connection point Where a hose must be bent into a curve the curve must be smooth with no twists in th...

Страница 70: ...ically bloc the potential stray voltage transfer between the hydraulic power unit and the equipment Note Some installation may require to use hydraulic hose extensions In this case keep the orange hos...

Страница 71: ...revent damage to property and or life threatening injury to personnel always follow these instructions Before starting for the first time check that all tools and other parts have been removed from th...

Страница 72: ...ully read understand and act in accordance with the instructions All stationary components are securely anchored to the floor All grease zerks have been lubricated All guards and covers are in place A...

Страница 73: ...ted and secured Pump Clean and lubricate the reversing mechanism with fine oil Make sure the distance between the adjustable finger and the bottom finger does not exceed the maximum Adjust finger if n...

Страница 74: ...nt the springs must force the trigger to complete its down stroke If the trigger does not complete its stroke automatically repeat the first step Evacuation cycle Siphoning cycle Spacers Bolts Piston...

Страница 75: ...on on Lubricant specifications Check the oil level in the hydraulic power unit Inspect all hydraulic fittings for leaks If the oil level has dropped check for leaks Defective parts may need to be repa...

Страница 76: ...personnel always follow these instructions Only fit or use the product for its intended purpose Also read the chapter on Safety Special dangers involved in operation Incorrect use may lead to serious...

Страница 77: ...re are no unnecessary object or material is located in the working area Check and make sure that the working area has been cleaned from oil grease parts Make sure the hydraulic circuit of the hydrauli...

Страница 78: ...lose the valve Open Closed Lever lock To lock the valve in the open position raise the lever and swing the lock bar down and rest it on top of the cylinder This will prevent the valve from accidentall...

Страница 79: ...en the handle is far from the line The gate valve is only installed if the elevation of the top of the manure storage reservoir is higher than the cap on the air flush riser Gate valve 6 152 mm Relief...

Страница 80: ...and stop the pump Note It is recommended to close and open valves periodically to make sure they are in good condition and installed as a safety measure in case of emergency Open the hydraulic guillo...

Страница 81: ...e pressure is relieved completely before removing the cap The compressed air inside pipes would propel the cap with force Before removing the cap open the ball valve to relieve pressure Note If you ar...

Страница 82: ...y required to clear obstructions that have clogged the suction pipe Stop the pump and close the intake guillotine valve Open the air injection valve for 10 seconds Close the air injection valve Open t...

Страница 83: ...ing injury to personnel always follow these instructions First of all prevent the product from being restarted accidentally Secure the range of action of all moving parts Also read the chapter on Safe...

Страница 84: ...e evacuation line Suction line clogged Flush the suction line Intake and or discharge flapper valve not opening and closing properly Lubricate the valves Inspect the rubber seal on the flapper valves...

Страница 85: ...sists perform a fluid and filter change Hydraulic fluid is foamy or bubbly Pump is cavitating See symptom Pump cavitating Hydraulic pump Symptom Possible cause Remedy Pump cavitating Low fluid level i...

Страница 86: ...tem operated with burnt old or contaminated fluid Determine and eliminate the sources of contaminated fluid Never use used fluid or fluid from dirty unknown or open containers Pump cavitating See symp...

Страница 87: ...must be limited to qualified personnel that perfectly knows and follows safety procedures in confined spaces Permanent ventilation must be active in each structure surrounding the main storage to evac...

Страница 88: ...Note the special information in this manual for the individual components All warnings and warning signs must be present and legible Immediately replace components that are not in perfect condition A...

Страница 89: ...ants solvents can cause injury if they come into direct contact with the skin and could make the floor surface slippery which could result in dangerous fall Hydraulic hoses failures may cause unexpect...

Страница 90: ...il of hydraulic power unit Check Replace maintenance technician Every year Clean the equipment Clean Operator Check insulated gate valves oil level Check fill Operator Change oil of hydraulic power un...

Страница 91: ...e the oil above the pump piston is at proper level Add oil as needed Replace oil when it becomes dirty 2 5 cm 9 3 2 Every 50 hours or weekly Lubricate the equipment Note Use general purpose grease Ref...

Страница 92: ...ance responsibilities 2007 9015 001 03 2014 92 108 Use grease zerks to lubricate the flapper door pivot of the Futuro pump Grease zerks Operate gate valves Operate the gate valves to ensure they open...

Страница 93: ...ed Never let the fluid level drop to where it isn t visible in the sight gauge Look for changes in the appearance of the fluid i e dark cloudy etc Oil sight gauge Attention Wipe up any oil spills Safe...

Страница 94: ...ricant specifications Place a large container under the oil filter in order to recuperate oil more than 16 US gallons 60 litres Close 2 ball valves under the power unit reservoir A Remove the oil filt...

Страница 95: ...er when cleaning with a pressure washer Keep the pressure washer nozzle at least 12 30 cm from the surface to be cleaned Clean the Futuro pump with a pressure washer Clean the complete reversing mecha...

Страница 96: ...01 03 2014 96 108 Check insulated gate valve oil level Note Use hydraulic oil Refer to section on Lubricant specifications Remove the filling cap of the insulated gate valve Fill up the tube up with h...

Страница 97: ...e care when loosing the bolts The spring is under tension and can be expelled the housing cover with force Always wear proper eye protection Failure to do so may lead to injury Note In order to get ac...

Страница 98: ...issioning Leaking lubricants solvents could cause injury if they come into direct contact with the skin and could make the floor surface slippery which could result in dangerous fall Components which...

Страница 99: ...nt specifications Grease all parts labeled with Refer to section on Label position To prevent corrosion spread all moving parts with an environmentally friendly anti corrosion product 10 4 Final decom...

Страница 100: ...formed to find the viscosity of well agitated slurry Set a 24 60cm disc over a pail Slowly pour enough slurry to get overflow all around the disc After 1 minute of rest measure the thickness of slurry...

Страница 101: ...21 010 US D 2099 4724 010 US E US EU 2099 4701 240 F 2099 4725 190 EU G 2099 4725 130 EU H 2005 4703 560 US EU I 2099 4721 000 US J 2099 4724 030 US K 2099 4725 240 EU L EU 2099 4725 420 M 2099 4700 3...

Страница 102: ...Appendix Hydraulic diagrams 2007 9015 001 03 2014 102 108 11 3 Hydraulic diagrams 11 3 1 Futuro pump Reversing valve Pump cylinder...

Страница 103: ...Appendix Hydraulic diagrams 2007 9015 001 03 2014 103 108 11 3 2 Futuro pump with guillotine valve option Pump cylinder Guillotine valve cylinder Reversing valve Selection valve Guillotine valve...

Страница 104: ...9015 001 03 2014 104 108 Legend 1 Hydraulic reservoir 2 Shut off valves 3 Oil filter 4 Hydraulic pump 5 Selector valve 6 Reversing valve 7 Power unit 8 Optional cylinder on guillotine 9 Cylinder on g...

Страница 105: ...Appendix Hydraulic diagrams 2007 9015 001 03 2014 105 108 11 3 3 Futuro with optional hydraulic agitator Pump cylinder Reversing valve Hydraulic agitator motor...

Страница 106: ...temperature HT Heat Treated fax Facsimile LCS Low Carbon Steel ft Feet MCS Medium Carbon Steel gal Gallon MCAS Medium Carbon Alloy Steel GPM Gallons per minute NC National coarse thread Hp Horsepower...

Страница 107: ...Appendix Abbreviations 2007 9015 001 03 2014 107 108...

Страница 108: ...ur values Excellence Passion Integrity Responsibility GEA versity GEA Group is a global engineering company with multi billion euro sales and operations in more than 50 countries Founded in 1881 the c...

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