Lavapezzi clean it mod DS 750

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MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 1 I PREMESSA Nel ringraziarLa per la preferenza accordata, la Ditta CLEAN.IT è lieta di annoverarLa tra i suoi affezionati Clienti e confida che l’uso di questo macchinario sia per Lei motivo di piena soddisfazione. Il presente Manuale di Uso serve da riferimento per una guida corretta ed una rapida identificazione della macchina in tutte le sue parti. I disegni, le tabelle e quant’altro contenuto nel presente Manuale di Uso sono di natura riservata e, per questo, ogni informazione non può essere riprodotta né completamente né parzialmente e non può essere comunicata a terzi, senza l’autorizzazione della CLEAN.IT che ne è la proprietaria esclusiva. In base alla propria politica di continuo miglioramento della qualità la CLEAN.IT si riserva il diritto di apportare tutte le modifiche che riterrà opportuno in qualsiasi momento e senza preavviso. L’Azienda resta comunque a disposizione per ogni chiarimento tecnico o intervento di assistenza. GB PRELIMINARY STATEMENT In thanking You for Your preference, CLEAN.IT Company is glad to have You among its best customers, and feels sure this machine will fully satisfy You. This instruction manual is to be considered a reference for a correct guide and a fast identification of the machine in all its parts. The figures, the tables and all which is included in this instruction manual are reserved, and therefore no information can be completely or partially reproduced, and it cannot be communicated to third parties, without an authorisation by CLEAN.IT, which is its exclusive owner. According to its policy of continuous quality improvement, CLEAN.IT reserves the right to make all alterations which shall be considered appropriate, at all moment and without notice. The Company remains though at Your disposal for any technical explanation or assistance intervention. F AVANT-PROPOS Tout en vous remerciant de lui avoir accordé la préférence, la Maison CLEAN.IT est heureuse de vous compter parmi ses clients fidèles et espère que cette machine vous donnera entière satisfaction. Ce Manuel sert de référence pour un usage correct de la machine et une identification rapide de chacune de ses parties. Les dessins, les tableaux et tout ce qui y est contenu est strictement réservé. Par conséquent, aucune information ne peut être reproduite, entièrement ou partiellement, ni communiquée à tiers, sans l’autorisation de la Maison CLEAN.IT qui en est la propriétaire exclusive. Conformément à sa politique d’amélioration constante de la qualité, CLEAN.IT se réserve le droit d’apporter toutes les modifications qu’elle jugera nécessaires, à n’importe quel moment et sans préavis. L’entreprise reste néanmoins à votre disposition pour n’importe quelle information technique ou intervention du service après-vente. D VORWORT Die Firma CLEAN.IT dankt Ihnen für das bewiesene Vertrauen und freut sich, Sie zu ihren Kunden zählen zu können. Wir sind sicher, dafl Ihre neue Maschine Sie voll zufriedenstellen wird. Die vorliegende Betriebsanleitung dient als Hilfe für die korrekte und schnelle Identifizierung der Maschine in all ihren Teilen. Zeichnungen, Tabellen und alle anderen, in dieser Betriebsanleitung enthaltenen Angaben sind dem Anwender vorbehalten und dürfen folglich ohne die ausdrückliche Genehmigung des Alleininhabers Firma CLEAN.IT weder ganz noch auszugsweise reproduziert oder an Dritte weitergegeben werden. Im Rahmen der Unternehmenspolitik der ständigen Verbesserung behält sich die Firma CLEAN.IT das Recht vor, alle als angezeigt erachteten Änderungen jederzeit und ohne Vorankündigung vorzunehmen. Für jede weitere Klärung technischer Art oder Kundendienstleistungen steht die Firma jederzeit gerne zur Verfügung. DICHIARAZIONE DI CONFORMITÀ / DECLARATION OF COMPLIANCE MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 2 INDEX 1. PREFACE 4.8 Flashing and acoustic alarms 27 1.1 Aims and use of the manual 4 4.9 Rotation inverter 28 1.2 Manual updates 4 4.10 Emergency buttons 28 1.3 Safety regulations 4 1.4 Not permitted uses, anomalous use, 5. PREPARING FOR USE contraindications in use 5 5.1 Solvent loading 29 1.5 Instructions concerning the maintenance 5.2 Solvent transfer 30 and repair interventions 6 5.3 Thermostats and thermometers 30 1.6 Referring labels, symbols and abbre_ 5.4 Loading and unloading 31 viations used in this manual 7 5.5 Main motor 32 1.7 Preliminary notes 8 6. COMPONENTS OF THE UNIT 2. MACHINE DESCRIPTION 6.1 Base tank 33 2.1 Structural composition 9 6.2 Warm solvent tank 33 2.2 Technical features 11 6.3 First chips trap 33 6.4 Second chips trap 34 3. LAYOUT 6.5 Drying chamber 3.1 Moving and transportation 12 6.5.1 Fan motor 35 3.2 Loading, unloading and transport 12 6.5.2 Air heater 35 3.3 Unpacking and levelling 13 6.5.3 Air filter 35 3.4 Place of correct use 13 6.6 Destillator 3.5 Installation guideline 6.6.1 General rules 36 3.5.1 General informations 14 6.6.2 Safety valve 36 3.5.2 Positioning 14 6.6.3 Max level floating switch 36 3.5.3 Electrical supply connection 14 6.6.4 Working floating switch 37 3.5.4 Motors rotation 14 6.6.5 Diffuser 37 3.5.5 Steam connection 15 6.6.6 Failure signals 37 3.5.6 Compressed air connection 15 6.6.7 Sludge transferring 37 3.5.7 Water connection 15 6.6.8 Maintenance 37 3.5.8 Other connections 15 6.7 Sludge discharge 6.7.1 Components 39 6.7.2 Working 39 4. CONTROL PANEL GUIDELINE 6.7.3 Failure signals 39 4.1 Control panel 16 6.8 Cooling system 4.2 Computer 6.8.1 Components 40 4.2.1 Computer description 17 6.8.2 Sight glass 41 4.2.2 Push buttons 18 6.8.3 Filter 41 4.2.3 Functional buttons 19 6.8.4 High pressure pressostat 41 4.3 Working 6.8.5 Low pressure pressostat 41 4.3.1 Manual working 21 6.8.6 Pressostatic valve 41 4.3.2 Automatically working 21 6.8.7 High pressure manometer 41 4.4 Service operations 6.8.8 Low pressure manometer 41 4.4.1 Software version 22 6.9 Still condenser 42 4.4.2 Timers 22 6.10 Water separator and decanter 4.4.3 Memory Card copy 22 6.10.1 Description 42 4.4.4 Language on display change 23 6.10.2 Daily maintenance 43 4.5 Programming the computer 6.10.3 Periodical maintenance 43 4.5.1 New cycle 24 6.10.4 Failure signals 43 4.5.2 Existing cycle (change) 25 6.11 Activecarbon absorber 44 4.6 Visualizations of the display 6.11.1 Components 44 4.6.1 Total number of cycles 26 6.12 Vacuum Pump 45 4.6.2 Total cycle time 26 6.12.1 Components 45 4.7 Alarms 6.13 Ultrasonic 46 4.7.1 What to do 26 ELECTRICAL SCHEMATICS I 4.7.2 Alarms sheet 27 PNEUMATIC SCHEMATICS i MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 3 1. PREFACE 1.1 AIMS AND USE OF THE MANUAL This manual, based on the MACHINERY DIRECTIVE, has the aim of giving the operator and maintenance worker some easy to understand advice for each stage of the machine’s life, from the installation, the operation, through to maintenance and up to the scrapping of the machine. The manual wishes to emphasise the problem of “RISKS” involved in general, giving adequate information which will easily help to identify and avoid such risks. Therefore CLEAN.IT wishes to guarantee the operator a machine design and construction which ensure reliable and safe functioning, and at the same time protecting the operator and the environment. This manual must be preserved for the whole life of the machine. If the owner should ever trade the machine, the address of the new owner should be informed in order to be able to forward any additions to the manual. 1.2 MANUAL UPDATES The manual reflects the state of the machine at the moment it is commissioned. It may not therefore be considered inadequate if updating has been necessary due to new developments. CLEAN.IT reserves the right to upgrade its products and manuals, without obligation to upgrade previous products and manuals. CLEAN.IT will update this manual on the basis of modifications or notices which may be considered necessary, and therefore forward such modifications to the client or distributor. Any modification will become an integral part of the manual, substituting the previous one. 1.3 SAFETY REGULATIONS safety regulations to respect before, during and after the use of the unit. · The discharge of products or production waste or any pollutants into the sewers (from sinks, water closets, tanks, etc.) into water-courses, on the soil and into the environment, is severely prohibited. These products or substances must be collected in suitable containers, stored or recycled and however not abandoner in the environment. · Check that the power source is of the type required and that it is in excellent conditions of operation (cables section, pressure and piping, etc.). · During maintenance, operators should always wear either a n overall or any protection clothing. · If substances or materials dangerous to health are being processed or used, wear adequate clothes and protection, e.g. gloves, glasses, masks, caps, aprons, shoes. · When the machine is in operation make su re that no outsiders incautiously approach it or its controls. · Outsiders must not be allowed access to the work departments and especially near the operating machines (even when they are in a pause from work). · In case third parties are present (outsiders or colleagues) near the machines, the operator must see to their safety and warn them of the dangers. · Do not wear ample-sleeved clothes, neckties, scarves, rings, bracelets, and chains or similar clothes and objects that could get caught on moving parts and cause serious injuries. · After work or during pauses from work, do not leave the machine switched on (even if not operating) and unguarded. Non observance of this rule may cause serious accidents. · Before doing anything on the machine, make sure that the power sources are physically disconnected. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 4 · The machine cannot be used for working processes other than those provided for and for which it has been made. · Keep the work area and the surrounding area clean and in order; there should be no: grease, oil, water and things or materials that could in any way hamper or be dangerous. · For cleaning the work area do not use jets of compressed air; the work scraps could be dangerous and cause damage. · Do not approach moving parts while the machine is in operation. · Do not tamper with, or at any rate alter, the safety systems. · Do not carry out any modifications or tamper with the machine except for those operations allowed and provided for in the instruction manual. · Do not use machine parts separately from the rest of the machine or from the configuration foreseen by the manufacturer. · Never abandon the machine on. · It is a good rule to install a magneto thermal overload cut-out upstream from the electrical mains to safeguard the wires from short circuits or overloading. · Do not keep any inflammable material, like petrol, solvents, cylinders of gas, etc., near the machine. · Set up suitable fire-fighting equipment near the machine (fire-extinguisher loaded with C02); never use water to put out a fire. · Pay attention to the state of wear of the electrical cables; replace them if damaged; use cables of suitable cross-section and that always correspond to specifications. · The machine is equipped with all safety devices and control equipment, but the user must not think he is exempted from checking the correct operation of any device. 1.4 NOT PERMITTED USES, ANOMALOUS USES AND CONTRAINDICATIONS IN USE The manufacturing company declines all liability for damage to people or things deriving from the improper use of the machine. · The machine must be exclusively employed for such uses as specified in the project and in the relative supplying contract. The use of the unit with solvents other than those provided for is not advisable. For possible different uses please consult CLEAN.IT · It is forbidden to sprinkle, wash or in any way wet the machine with water jets. · Operators are forbidden to either get near the machine when it is working or to touch the product to control it. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 5 Any operation envisaging manual actions on the treated product has to be carried out only when the installation is stopped and the emergency stop pushbutton is on. · It is forbidden to climb on the machine. · It is prohibited to get inside the protected danger areas. · It is prohibited to enter the working areas, marked with yellow stripes, in which the machines composing the installation are set. · It is prohibited to tamper the security devices. · It is forbidden to use free flames. · It is forbidden to smoke near the machine. 1.5 INSTRUCTIONS CONCERNING THE MAINTENANCE AND REPAIR INTERVENTIONS ATTENTION! All operations of maintenance, repair and cleaning of the machine have to be carried out when the machine is stopped, the current disconnected and the emergency stop pushbutton on. AUTHORISED PERSONNEL List of the qualifications of the authorised personnel: Operator: he carries out the tasks needed for the operating of the installation: he operates the operation controls and other simple interventions linked to the ordinary production, daily cleaning and inspection. He only operates when protections are on. Mechanical maintenance man: he intervenes in all operating conditions and at all levels of protection. He can act with protections off because he has the means to set them off. He carries out all mechanical repairs/regulations, but does not operate on the electrical systems under voltage. Electrical maintenance man: he intervenes in all operating conditions and at all levels of protection. He carries out all electrical system repairs/regulations. The CLEAN.IT Customer assistance is at your disposal to organise further courses after the first starting of the installation. CLEAN.IT will not bear responsibility for the carrying out of modifications, variations and/or the installation of accessories not previously authorised. When substituting the components only use ORIGINAL SPARE PARTS. TECHNICAL ASSISTANCE CENTRE: O.M.P. s.r.l. Via LIVELLI 53 - 43010 - POLESINE PARMENSE (PR). - TEL. 0524-96105 - FAX 0524-96274 e-mail: clean.it@virgilio.it MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 6 1.6 REFERRING LABELS SYMBOLS AND ABBREVIATIONS USED IN THIS MANUAL - Italic print = Information for the operator - Normal print = Information for maintenance - POTENZIALE PERICOLO - POTENTIAL DANGER - DANGER POTENTIEL - POTENTIELLES GEFAHR - SUPERFICIE AD ALTA TEMPERATURA, VIETATO TOCCARE - HIGH TEMPERATURE SURFACE, DO NOT TOUCH - SURFACE CHAUDE - DEFENSE DE TOUCHER! - FLÄCHE MIT HOCHTEMPERATUR - BERÜHREN VERBOTEN - PERICOLI O INTERVENTI CHE POSSONO CAUSARE DANNI - HAZARD OR ACTION WHICH MAY CAUSE DAMAGE - DANGERS OU INTERVENTIONS QUI PEUVENT DETERMINER DES DOMMAGES - GEFAHRE ODER VORGÄNGEN, DIE SCHADEN VERURSACHEN KÖNNEN - VIETATO FUMARE NELLE VICINANZE DELLA - DO NOT SMOKE NEAR THE MACHINE - DEFENSE DE FUMER AUTOUR DE LA MACHINE - ES IST VERBOTEN, IN DER NÄHE DER MASCHINE ZU RAUCHEN - ATTACCO PER GANCIO SOLLEVAMENTO - JOINT FOR LIFTING HOOK - JONCTION POUR CROCHET LEVAGE - HÄNGER FÜR DEN HEBEHAKEN - VIETATO USARE FIAMME LIBERE NEL LOCALE DOVE E’ POSIZIONATA LA MACCHINA - DO NOT USE NAKED FLAMES IN THE ROOM WHERE THE MACHINE IS LOCATED - DEFENSE D’UTILISER FLAMMES LIVREES DANS LE LIEU OU’ LA MACHINE EST INSTALLEE - EST IST VERBOTEN, FREIE FLAMMEN ZU BENÜTZEN IN DEM SELBEN ZIMMER, WO DIE MASCHINE GESTELLT IST - USARE MASCHERA, GUANTI E OCCHIALI PER LE OPERAZIONI DI MANUTENZIONE A CONTATTO CON IL SOLVENTE - USE MASK, GLOVES AND GOGGLES FOR MAINTENANCE WORK INVOLVING CONTACT WITH SOLVENT - UTILISER LA MASQUE, LES LUNETTES ET LES GANTS POUR TOUTE OPERATION DE MANUTENTION AU CONTACT AVEC E PERC - VERWENDEN SIE SCHUTZMASKE, HANDSCHUE UND BRILLE BEIM HANDELN DES LÖSEMITTEL - LE OPERAZIONI DI MANUTENZIONE DEVONO ESSERE EFFETTUATE DA PERSONALE SPECIALIZZATO - MAINTENANCE OPERATIONS MUST BE PER FORMED BY TRAINED PERSONNEL - LES OPERATIONS DE MANUTENTION DOIVENT ETRE EFFECTUEES PAR PERSONNEL SPECIALISE - DIE WARTUNGSVORGÄNGE MÜSSEN IMMERBEI FACHPERSONAL DURCHGEFÜHRT WERDEN 1.7 PRELIMINARY NOTES MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 7 This manual refers to a drycleaning machine suitable for cleaning “textiles” in general. The machines uses the following solvent type: PERCLORETHEYLENE (CCL2=CCL2), no other types of solvent are allowed. The following indications are intended as a guide for avoiding any risks both in the running of the machine, or from the solvent itself, both towards the machine operator and the environment. Before connecting the machine to external supply sources, make sure that local and national laws regarding ENVIRONMENT PROTECTION, are being respected, especially concerning: - DISPOSAL OF STILL RESIDUES - DISPOSAL OF SEPARATOR WATER Make sure that the room can always be properly aerated , both in summer and winter, by means of a ventilator. Take into consideration the ventilator capacity (cubic metres/hour), which must be approximately 110% machine capacity in liters. See N.I.ISO 8232-1988 (F). E.g. following the formula, t = 1.1 * Cn (t=ventilator capacity in m³/h, Cn=machine capacity in liters), a 2 baskets machine must therefore have a ventilator power of t = 1.1 * 700 = 770 m³/h. This norm also dictates that the ventilator must be placed 0.5 Mt. from ground level, this will ensure an efficient removal of solvent fumes which, being heavier than air, are at ground level. Wherever the machine is being supplied with steam from a flame heated boiler, the boiler must be situated in a room which is adjacent to the room the machine is located in. The boiler room must preferably be aerated as if flames should come into contact with solvent fumes, the latter may decompose into toxic substances. NAKED FLAMES or stoves are strictly forbidden inside the room. BEFORE PERFORMING ANY CLEANING OR MAINTENANCE WORK ON THE MACHINE, ALWAYS PUT ON PROTECTIVE GLOVES AND FACE MASK. IF ANY SOLVENT SHOULD ACCIDENTALLY SPILL ONTO THE FLOOR, ACT IMMEDIATELY TO INCREASE ROOM AERATION AND IMMEDIATELY CLEAN UP THE SPILLAGE. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 8 2. UNIT DESCRIPTION 2.1 STRUCTURAL COMPOSITION (Fig. 1) On the rear of the machine we can find: 1) Warm solvent tank (3) 2) Destillator 1 3) Condenser 4) Destillator 2 5) Contact water separator and decanter 6) Base tanks (1 e 2) 7) Sludge pump 8) Drying chamber fan motor 9) Cooling system 10) Air filter 11) Main motor 12) 2nd chips keeper 13) Solvent pump 14) Spill tank (safety tank) EX) End cycle air exit EX FIG. 1 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 9 STRUCTURAL COMPOSITION (Fig. 2) On the front of the machine we can find: 15) Control panel 16) Loading unloading door 17) 1st chips keeper 18) Base tanks 1 and 2 19) Front panels 20) Electrical panel 21) Red alarm light 22) Yellow light 23) Good working green light FIG. 2 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 10 2.2 TECHNICAL FEATURES TANK CAPACITY DS 200 2 CESTI DS 750 3 CESTI DS 1500 8 CESTI TANK 1 LT 100 LT 230 LT 150 TANK 2 LT 100 LT 230 LT 250 WARM TANK LT 50 LT 65 LT 100 DESTILLER LT 110 N°2 X LT 180 N°2 X LT 180 MOTOR POWER MAIN MOTOR HP 0,16 HP 0,5 HP 1,5 SOLVENT PUMP HP 1,5 HP 1,5 HP 1,5 SLUDGE PUMP HP 0,75 HP 0,75 HP 0,75 FAN MOTOR HP 1 HP 2 HP 3 COOLING COMPRESSOR HP 3,5 HP 5 HP 5 ELECTRICAL AIR HEATER KW 5,85 / / ELECTRICAL DESTILLER KW 9 / / TANK HEATER KW 1,5 / / CONNECTIONS WATER 20°C - 10LT/MIN Æ 3/4” Æ 3/4” 20 Lt/min Æ 1” COMPRIMED AIR Æ 1/4” Æ 1/4” Æ 1/4” STEAM Æ 1/2” Æ 1/2” N°2 Æ 1/2” N°2 TERSION (400v/50Hz) 4 x 10 mm2 4 x 6 mm2 4 x 6 mm2 WORKING PRESSURES COMPRIMED AIR Bar 5 - 6 Bar 5 – 6 Bar 5 - 6 WATER Bar 2 - 6 Bar 2 – 6 Bar 2 - 6 STEAM Bar 4 Bar 4 Bar 4 USED POWER BOILER KW 18 / / MACHINE KW 4 KW 9 KW 9 CONSUMPTION FOR 4 CYCLES/HOUR ELECTRICAL KW h 3 KW h 4 KW h 4 WATER LT 160 LT 250 LT 250 STEAM KG/h 45 KG/h 55 KG/h 90 UNIT WEIGHT WITHOUT SOLVENT KG 1500 KG 2500 KG 2800 WITH SOLVENT KG 1850 KG 3340 KG 3600 RECUPER KG 300 KG 600 KG 400 DIMENSIONS WIDTH 1050 mm 2350 mm 3000 mm DEPTH 1900 mm 1800 mm 2130 mm HEIGHT 2100 mm 2600 mm 2600 mm MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 11 3. LAYOUT 3.1 MOVING AND TRANSPORTING PACKAGING The packaging of the machines is made b our industries according to the agreements signed each time with our customers or anyhow chosen according to the country of destination, or of the transportation mean used. Usually the car is covered with a transparent plastic sheet even in case of expedition in closed wood case. After installation, the packaging can be reused or disposed of according to the laws in force in the country of the customer. The weight of the packaging is indicated on the documents handed in to the forwarding agent and/or on the outside of the cases or crates. MOVING Machines must be transported complete with their packaging to the area in which they are to be installed. For lifting and movement the following should be used: · Means (bridge cranes, cranes, fork-lift trucks) with a minimum capacity exceeding the weight of the machine(s) (see identification plate). · Ropes, chains, eye-bolts, etc. suitable for the above load. All lifting and movement of machines or parts transported separately must be performed by trained personnel (slingers, fork-lift drivers, crane operators, etc.) and in the event that the overall dimensions of the load obstruct the operator’s vision, we recommend ground assistance by a person in charge of directing. 3.2 LOADING, UNLOADING AND TRANSPORT PRECAUTIONS TO BE TAKEN DURING TRANSPORT AND INSTALLATION Before being delivered to the shipping agent, the material is carefully checked. Upon receiving the machines check that they have not been damaged during transport or that the packaging has not been tampered with consequent removal of parts from inside. In the event of damage or missing parts, inform the carrier and manufacturer immediately, producing photographic proof. N.B. It is advisable to check that the supply corresponds to the order specifications. INSTRUCTIONS FOR TRANSPORT IMPORTANT! During transport, movement and positioning of the system there is: • Danger of tipping for components. • Danger of knocks and crushing for persons. Before the component of the system is lifted completely it is advisable to check that it is correctly balanced. Lifting operations must be performed smoothly (without jerking or jolting). Check that there are no persons in the danger zone. DURING LIFTING THE AREA SURROUNDING THE COMPONENT MUST BE CONSIDERED A DANGER ZONE. Components without packaging must be covered for transport. The manufacturer is not responsible for breakage during machine transport after delivery. All parts that could move during transport are firmly fixed, thus preventing them from moving dangerously or being accidentally dropped. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 12 ATTENTION! Do not allow the machine to swing when raised. Danger of crushing fore persons. Carefully lay the machine down on the floor in the exact place in which its installation is due. Be sure the floor is level and able to bear without collapsing the weight of the machine in working conditions. ATTENTION! During this stage pay attention not to crush people or things. 3.3 UNPACKING AND POSITIONING (LEVELLING) Should the machine be packaged, after placing it on the ground, remove the side walls and top of the box (or crate) and then the plastic covering in order to free the machine. The packaging material is reusable. IMPORTANT! In this phase take great care over fixing nails or protruding parts, as these can cause injury During moving and positioning, follow the instructions given in the paragraph on “MOVEMENT”. 3.4 PLACE OF USE OF THE MACHINE ALLOWED ENVIRONMENTAL CONDITIONS For a correct working, put the machine in an environment protected from atmospheric agents. It also needs to be dry and to have a concentration of dusty substances in the air within the limits envisaged by the laws in force in the E.C. HEIGHT Data concerning the installation performances are valid for installations in places whose height is lower than 1.0 m above sea level. Different situations need to be evaluated singularly in cooperation with the Technical Department of CLEAN.IT TEMPERATURE Working temperature has to be between 5° C and 35° C. HUMIDITY Degree of humidity had better not exceed 90%. LIGHTING The light system of the factory has to be considered important for the security of people and for the quality of work. The lighting of the work environment in which the installation is set has to be in conformity with the rules in force and with the community directives; room lighting is in any case responsibility of the customer. As for the intensity needed to operate safely on the installation, 200 lux need to be ensured. Maximum lighting: enough to avoid dazzlement of the operator. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 13 EXPLOSION AND/OR FIRE RISKY ATMOSPHERE In case of request for machines to be used in an explosion and/or fire risky atmosphere, the necessary procedures according to the rules in force on the matter (CEI 62.2, CEE n° 89-392 and following modifications) have to be agreed upon by the two parties in advance. N.B. the standard CLEAN.IT installation is not designed to work in explosion and/or fire risky atmosphere environments. ROOM NEEDED FOR OPERATING Mark the areas set for the operator by considering the need for operation, maintenance ad passing. The environmental and working conditions do not have to be of obstacle for the access to the installation controls, particularly to emergency stop. The operation of the installation has to be guaranteed, and the maintenance activity has to be taken into consideration. Pay special attention to the opening of the switchboards doors. The choice of the place or of the areas adequate for setting the installation is very important for the quality of work (maintenance, security, etc.) therefore this area has to be properly lighted and aired. It will also need to enable the passing of lift racks or of other means needed for maintenance. 3.5 INSTALLATION GUIDELINES The correct installation will allow the machine to work under optimum conditions. Please follow the following guidelines very carefully. 3.5.1 GENERAL INFORMATION 1) The machine must be firmly placed on a solid base using the appropriate fixing holes present on the base of the machine. 2) For best results, the water flow must not be lower than 10 lt./min with a minimum pressure of 2.5 bars. 3) The machine must be electrically earthed (grounded). 4) The water separator (A - Fig. 3) drainage valve must be connected to an appropriate container. 3.5.2 POSITIONING 1) We recommend you leave at least 30 cm free at each side of the machine and 1 metre behind in order to allow easy access for maintenance work and still cleaning. 2) Although the machine is stable, we recommend you level the machine and fit to the ground using appropriate fixing bolts. 3) Control that the ground be apt to bear the dynamic load as shown on the tables and on the declaration of conformity. 3.5.3 ELECTRICAL CONNECTIONS Before opening the electrical panel, rotate the general switch in the “0” position; then, connect the line to the R.S.T. clamps. Between the electrical connection and the unit, a three-pole magnetic -thermal switch must be installed, with a power suitable with the one indicated on the plate located behind the unit. The machine must be electrically grounded. 3.5.4 MOTOR ROTATION Check that the motors rotate correctly by switching on the pump for a short time. The pump must rotate clockwise; otherwise, reverse two threads of the R.S.T. and control again. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 14 3.5.5 STEAM SUPPLY (B - Fig. 4) Connect the machine to the steam supply using either iron or copper pipes. A cut-off tap must also be fitted between the steam line and the machine of 1/2”. We recommend to also fit a pressure adjuster in order to be able to adjust and stabilise the steam flow. For best working conditions, the steam pressure should be 4 bars. 3.5.6 COMPRESSED AIR The machine is fitted with its own pneumatic system. All cylinders are controlled by solenoid valves, the latter being supplied with compressed air either by an independent compressor or another source through the compressed air lubrication filter (C - Fig. 5) RANGE MIN. 5 bar - MAX 8 bar (controlled by handle B). If the unit is not equipped with autonomous compressor, connect the air inlet to the joint (A) with a Ø 6 tube. If the pressure is less than 5 bars, the machine stops showing alarm “MT16”. 3.5.7 WATER SUPPLY (A – Fig. 4A) Connect the water supply to the relative union using galvanised iron or copper pipes, placing a cut-off tap between the machine and the water supply. Then connect the water outlet (C) to the external drains. If the pressure is less than 2.5 bars, the machine stops showing alarm “MT16”. 3.5.8 OTHER CONNECTIONS (Fig. 6): rif. A = Sludge discharge rif. D = Service passing through rif. B = Solvent charge rif. E = Steam Outlet (condense) rif. C = Solvent discharge On DS 750 it is better to connect the exhaust air pipe (rif. EX FIG. 1) externally working area with a common rubber pipe or similar) FIG. 4 FIG. 4A FIG. 3 FIG. 5 FIG. 6 4. CONTROLS GUIDELINE MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 15 4.1 CONTROL PANEL (Fig. 7) A) Drying thermostat (working chamber outlet air) B) Drying thermostat (working chamber inlet air) C) Computer EL7 D) Loading unloading basket positioning buttons E) Main switch for unit turn on/off F) Emergency pushing button G) Pushing button to invert basket rotation in case of blocking H) Destillator 1 turning on/off switch I) Tank 3 solvent thermostat (warm tank) L) Destillator 1 thermostat M) Destillator 2 turning on/off switch N) Destillator 2 thermostat O) Carbon group selector P) Warm tank on/off switch Fig. 7 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 16 4.2 COMPUTER 4.2.1 COMPUTER DESCRIPTION (Fig. 8) The COMPUTER is controlled by a microprocessor and enables the operator to carry out up to 20 programs, each of which can be made up of from 1 to 45 steps. Each step takes from 1 to 255 seconds or from 1 to 255 minutes. The computer is divided into two parts: at the top the electronic programmer which automatically carries out various operations and controls; at the bottom the manual keyboard with 36 keys for manual operation. The computer is made to be fitted in front of the control panel and is provided with an LCD Display to indicate the various information during the different operative phases. It is complete with many options amongst which is the possibility of choosing the language preferred from a list of 5 languages being Italian, French, German, English and Spanish according to the country in which the machine is to be installed. It also offers the possibility of loading pre-defined programs via Memory Card avoiding considerable programming times. Technical features Relay contacts: 6A 250 Vac COS o 1 1A 220 Vac COS e 0.4 5A 24 Vdc resistite load Outputs: 48 relay outputs distributed as follow: 1 - 47 = Function relays 48 = Ringing relay Digital imputs: 39 digital inputs, 24 Vdc (supplied by EL7) distributed as follow 1 - 39 = managed at low level Programming: From the keyboard on board the machine Copy: Possibility of transferring data programs and messages on Memory Card Memory capacity: N° 20 programs on high level of 45 steps Temperature control: Possibility of setting and displaying 8 temperatures for each program Display: Back lit liquid display with 16 characters and 2 lines Manual pushing buttons: 36 buttons led equipped Fig. 8 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 17 4.2.2 FUNZIONE DEI TASTI Numbered keys 0 – 9 Numerical key that can be used for all functions Function keys 1 -36 Control several function of the machine both in manual or programming INC During the run it moves forward one step each time it is pressed. During programming it increments the number of the temperature regulation, the temperature value and the number of the step. DEC During programming it decrements the number of the temperature regulation, the temperature value and the number of the step. DEL During programming it removes the temperature regulations inserted. INS During programming it inserts the temperature regulations. ENTER For confirming any choice or setting both during programming and during the run. STEP During the run it allows the status of the temperature regulations to be seen. START Key with led. Starts up the run of the program selected. Allows a program to restart after a POWER FAILURE or after having made a STOP or a PAUSE. STOP Key with led. During the run it freezes the cycle time. Stops the Low Level Program (stop of the timers, outputs=0).. PAUSE Key with led. During the run it freezes the cycle time. RESET Ends programming and during the run, after pressing STOP or PAUSE, it aborts the program. Restart of the LowLevel Program after the Stop. MAN Let the switch between MANUAL to EDIT. NOTE: As regards the function of the keys during low level programming, consult LOW LEVEL PROGRAMMING. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 18 4.2.3 FUNCTION KEYS OPEN DOORS Unlok all doors and turn off alarms for loading, unloading and maintenance MAIN MOTOR Activate the main motor for basket rotation AIR INLET INTO DRUM During drying phase let the air across the working chamber FAN MOTOR Used for air circulation in drying and deodorization COOLING COMPRESSOR Used to cool down air in drying and deodorization HEATER Used to heat air for drying WORKING CHAMBER CLEANING At the end of washing phase, rinse the working chamber bottom WORKING CHAMBER INLET With the pump on let the solvent enter into drum WORKING CHAMBER OUTLET Let the solvent flow away from the drum through the chips keeper DRYING CONTROL Used during drying controls automatically this phase WORKING CHAMBER DECONTAMINATION With the recuper and at the end of the cycle, cleans the drum air SOLVENT FILLING Helps to fill or re-fill the machine with solvent PUMP MOTOR Turn on the solvent pump SOLVENT STEAM Let the unit clean with very hot solvent OUTLET TANK 1 Let the solvent flow from this tank to the pump OUTLET TANK 2 Let the solvent flow from this tank to the pump OPEN DOORS BASKET ROTATION DUMPER INLET DRYING FAN COOLING COMPRES HEATING CHAMBER CLEAN CHAMBER INLET CHAMBER OUTLET CHAMBER DRY CONTROL DECONT CHAMBER SOLVENT FILLING SOLVENT PUMP STEAM SOLVENT OUTLET TANK 1 OUTLET TANK 2 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 19 OUTLET TANK 3 Let the solvent flow from this tank to the pump OUTLET TANK 4 (optional) Let the solvent flow from this tank to the pump INLET TANK 1 Let the solvent flow through the pump to this tank INLET TANK 2 Let the solvent flow through the pump to this tank INLET TANK 3 Let the solvent flow through the pump to this tank INLET TANK 4 (optional) Let the solvent flow through the pump to this tank TOTAL DESTILLATION Turn off the minimum level of the still DESTILLATORE INLET Let the solvent flow through the pump to the still VACUUM PUMP (Optional) Let the machine to work under normal pressure SLUDGE PUMP Used to discharge the destillation Sludge SLUDGE OUTLET Let Sludge to flow from destillator to external barrel SLUDGE DRYING Let Sludge recirculation for total drying CARBON HEATING (Optional) Turn on carbon heating for recuper regeneration FILTER INLET (Optional) Let the solvent flow through an optional filter FILTER OUTLET (Optional) Used to discharge and clean an optional filter ULTRASONIC (Optional) Let the use of this system during cleaning phase SLUDGE EXIT FROM STILL 1 TO STILL 2 (only if 2 destillators are present) To guarantee better performance and keeps still 1 always clean All the above mentioned keys (except DOOR OPENING) may be used in every moment of the working program, during step programming or for a manual cycle. OUTLET TANK 3 OUTLET TANK 4 INLET TANK 1 INLET TANK 2 INLET TANK 3 INLET TANK 4 TOTAL DESTILL. INLET STILL VACUUM PUMP MUD PUMP OUTLET MUD DRYING MUD CARBON HEATING INLET FILTER OUTLET FILTER ULTRASONIC MUDS FROM STILL 1 TO 2 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 20 4.3 WORKING When the device is switched on after an autotest phase it will be automatically ready for manual operatios. 4.3.1 MANUAL WORKING: This is a run which allows the machine to be operated by direct use of the 36 function keys on the front panel. If more than one relay, 1 to 4, is actuated, all the output relays are automatically de-energised. This is because relays 1 to 4 may be used for piloting the motors, which must only be operated one at a time.. 4.3.2 AUTOMATIC WORKING: Allows one of the preset programs to be run (max. 20). After having supplied power to the equipment, key in START and then the number of the program to be run, step number, followed by ENTER. RESET to abort the operation. PROGRAM n. 3 STP. 1 Press START to continue with the program run or RESET to abort. If the number of the program chosen does not exist, the display will indicate for 1 second: Not Found then will return to await the choice of another program. During the program run it is possible to send the machine into two states: STOP - PAUSE. STOP By pressing STOP during the run of a program, the time is instantaneously frozen. Now press RESET to abort the program or START to proceed from the point of interruption. PAUSE By pressing PAUSE during the run of a program only the cycle time is frozen, but the display will show, in increment, the duration time of this state. Now press RESET to abort the program or START to proceed from the point of interruption. N.B. During PAUSE the outputs are not disabled. During the run of a program it is possible to display the regulations, i.e. see which have been set, their SET value and their present value. To do this press STEP to see which regulations have been enabled in that step. Then press a number equivalent to the regulation which is to be seen to display the relevant parameters. During the run it is not possible to change or enable or disable the regulation in the steps, nor their preset parameters. After having displayed the regulations, as described above, the display will return automatically after 3 seconds to showing the cycle parameters. During the run of a program, each time the INC key is pressed the current step ends and the next one is performed. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 21 4.4 SERVICE FUNCTIONS 4.4.1 USER SOFTWARE RELEASE NUMBER By the password 237 it is possible to give a release number to the high and low level program (0 - 250 range). (If you read 255: no version written). Pushing INS key It is possible to read the release during MANUAL or AUTOMATIC. 4.4.2 GENERAL TIMERS AUTOMATIC: pushing MAN key you can read the total lapsed time in AUTOMATIC. MANUAL: pushing PAUSE key you can make active a visible timer. Stop by RESET key. Random first minute start. 4.4.3 COPY FROM/TO MEMORY CARD All the programs stored in the memory (EEPROM) can be transferred from the device into an external memory, very similar to a credit card (MEMORY CARD) and vice versa. This allows an unlimited quantity of programs to be filed and subsequently reused.. A) To transfer the content of the memory onto the memory card, first of all switch off the equipment, insert the card correctly, then press MAN plus the appropriate password (see ACCESS PASSWORD page) followed by ENTER. The following message will be displayed: COPY ONTO MEMORY CARD ? (And pressing ENTER) ENTER COPY ONTO MEMORY CARD COPY ONTO MEMORY CARD COPY ONTO MEMORY CARD COPY FAILED COPY OK As indicated above, copying may take place regularly or may fail. In any case press ENTER to return to program no. N.B.: COPY FAILED may be due to a malfunctioning memory card, only inserted partially in the appropriate connector, inserted incorrectly, not inserted at all or to malfunctioning in the system hardware. B) In order to transfer the content of the memory card into the memory of the system, switch off the equipment, insert the card correctly, press MAN plus the number 230 followed by ENTER. The procedure is then the same as for "copy onto memory card", described previously. IMPORTANT: The memory card must only be inserted and removed when power is not supplied to the equipment. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 22 4.4.4 CHANGING THE LANGUAGE The equipment can display messages in 7 languages. A number is associated to each of them: 1 = ITALIAN 6 = planned 2 = ENGLISH 7 = planned 3 = FRENCH 4 = SPANISH 5 = GERMAN It is possibile to see wich 2 groups of user messages are memorized in EEPROM; from the display with the message MANUAL, press: MAN plus 201 followed by ENTER The following message could appear: L1 = 1 (ITALIAN) L2 = 3 (FRENCH) L1 is the language of GROUP 1 and L2 is the language of GROUP 2. Now press ENTER to choose the language. The following message will appear: 1=I 2=E 3=F 4=S 5=G 6= 7= Press a number from 1 to 7 to select the language and then ENTER. Or press any key to get out. Of corse, if a selected language, for example 5=G german, doesn’t have its user message in EEPROM, as in this example (Italian, French), only its system messages are visible. 4.5 PROGRAMMING – MODIFICATION There are two types of programming: HIGH LEVEL and LOW LEVEL HIGH LEVEL PROGRAMMING This consists in creating a sequence of timed steps each of which has a related configuration of function keys from 1 to 36. The function keys, as we will see later, are managed in turn by the low level program. From the manual condition of the machine, by pressing MAN the display await access password, displaying: MANUAL MAN ? 1 2 ENTER (Password) Edit prg. n. (Display) After having keyed in the number required (1 - 20) followed by ENTER, two possible situations are possible: MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 23 1) The chosen cycle is not in the memory and is therefore to be programmed 2) The chosen cycle already exists; in this case it is possible to see and, if necessary, change it. 4.5.1 NEW CYCLE 1) THE CHOSEN CYCLE DOES NOT EXIST: The programming phase is entered immediately after the display has shown for one second: Edit. Prg. n. 1 Not found! Followed by: Edit. Prg. n. 1 Reg. 1 0C Press ENTER to begin with programming Program n. 1 Store ? By pressing RESET programming is aborted, by pressing ENTER however the temperature regulations set will be stored and combined with PROGRAM 1 and the following message will appear on the display: PRG 1 STP 1 Function keys We are now at the first step, during the phase of programming the keys. Now press the keys from 1 to 36 to set the configuration of the keys relating to step 1. By pressing ENTER the configuration chosen will be called up and the display will show: PRG. 1 STP 1 Reg. 1 0C NO After having entered ENTER, display will show: PRG 1 STP 1 Time M Using the number keys we will now set the time in minutes (max. 200) of the duration of run of the step: PRG 1 STP 1 Time M200 Press ENTER and the display will indicate the seconds PRG 1 STP 1 Time S With the number keys we will now set the time in seconds (MAX 59) to be added to the minutes: PRG 1 STP 1 Time S 59 Press ENTER again and the whole value of the time in minutes and seconds will be displayed MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 24 PRG 1 STP 1 Time 200 M 59 S Press DEL to reset or ENTER to store: STP 1 Store ? Press ENTER again to confirm storage of step 1: PRG 1 STP 2 Function keys At this point the display will automatically show programming of step 2. Follow the same procedure for programming of step 1 if step 2 and subsequent steps are to be programmed; press RESET if other steps are not to be programmed. The system will automatically exit programming. 4.5.2 EXISTING CYCLE (MODIFY) 2 THE CHOSEN CYCLE ALREADY EXIST: The EDIT phase of the program will be entered and the display will show for 1 second: Edit. Prg. n. 1 Already exist ! Edit. Prg. n. 1 Reg 1 0C The parameters and the functions already set will then be displayed by means of the INC and DEC keys, with the possibility of deleting, entering or modifying as required, as for a non-existent program. On entering an existing cycle, 4 choices are possible: 1) Choose another cycle by pressing RESET 2) Modify the existing cycle both as regards the values of the regulations and their trigger step, change the configuration of the function keys and the time of the steps. 3) Enter one or more steps among the existing ones as follows: enter the steps of the program and, by means of the INC and DEC keys, scroll them forwards or backwards, then press INS to insert the new step. Example: if a step is to be inserted between step 3 and step 4 of a program, go to step 4 with the INC key and press the INS key; at this point step 4 will become step 5 and the new step 4 will be displayed, ready to be changed. The subsequent steps will automatically be incremented by one. 4) Delete one or more steps from the existing ones. As for inserting a step, position on the step to be deleted. PRG. 1 STP 3 Function keys DEL PRG. STP 3 Delete ? After having pressed DEL, the display will request confirmation of deletion of the step. At this point, by pressing RESET, we return to the step which was to be deleted; by pressing ENTER, the deletion is confirmed. Step 3, as in the example, will be deleted and the number of the subsequent steps will be decremented by one. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 25 4.6 VISUALIZATIONS 4.6.1 DISPLAY OF TOTAL WORKING The equipment counts a number known as "TOTAL WASHES", which is incremented at the end of the run of each program. It therefore indicates the total number of programs run. This number is only displayed and cannot therefore be zeroed alone: it is only zeroed by launching the EEPROM memory initialisation and deletion password. In order to display the total number of washes, proceed as follows: from the PROGRAM NO. message shown on the display, press MAN plus 215 followed by ENTER and the following will appear on the display: TOTAL WASHES 625 Press ENTER to exit It is possible a low level management (alarm, messages...). See low level manual. 4.6.2 HOURS OF WORKING DISPLAY There is a count of the washing time of the machine.. The hours of washing are the period in time in which the machine is running a program. Like total washes, the hours of washing can be zeroed by password. In order to display the number of washing hours, proceed as follows: from the message . MANUAL shown on the display, press MAN plus the number 218 followed by ENTER. The display will show: HOURS OF WASHING 122 Press ENTER to exit. It is possible a low level management (alarm, messages...). See low level manual. 4.7 ALARMS 4.7.1 ALARM CONTROLS Voltage blackout control: protected against line outages. In the event of cuts in the power supply, the current situation is stored in the memory. When power is restored, the display will indicate the number of the program which was being run and the number of the step reached plus the message POWER FAILURE. The operator can now decide whether to restart from the point of interruption by pressing START or abort the program by pressing RESET. Alarm control during an automatic cycle: While an automatic program is in execution, in case of alarm, the computer end all the functions. On the display will appear the code of the alarm, an acoustic signal will start as well as the red flashing light. To continue from this point, press the STOP button in order to turn off light and acoustic signal, correct the alarm cause and: 1. Press START – PAUSA - START to re-start from the reached point of the program or 2. Press RESET to re-start from the beginning. Alarm control during a manual function While a manual function is in execution, in case of alarm, the computer end all the functions. On the display will appear the code of the alarm, an acoustic signal will start as well as the red flashing light. To continue from this point, press the STOP button in order to turn off light and acoustic signal, correct the alarm cause, press MAN and then RESET. Now the unit is ready to work again. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 26 4.7.2 ALARM SPECIFICATIONS ALARM CODE CAUSE DESCRIPTION WHAT TO DO MT 1 Main motor stop Fix it into electrical panel MT 2 Cooling compressor stop Fix it into electrical panel MT 3 – 4 Fan motor stop Fix it into electrical panel MT 5 – 6 Pump stop (both solvent or Sludges) Fix it into electrical panel MT 8 Vacuum pump Stopp Fix it into electrical panel MT 9 Ultrasonic generator stop Fix it into electrical panel MT 13 Anti freeze thermostat steam coil See 6.8.1 pag. 39 MT 16 Air or water leaking See 3.5.6 e 3.5.7 pag. 14 NO H2O STILL Water separator alarm See 6.10.4 pag. 42 NO H2O FRIGO High pressare cooling system See 6.8.4 pag. 40 1° LEV SFTY STILL Max destillator level See 6.6.6 pag. 37 DOOR OPEN Front doors opened Check front doors WAIT DRY CTRL Drying pause - H2O ELETT STILL Max water level into separetor See 6.10.2 pag. 41 STILL SFTY VALVE Destillator safety valve See 6.6.6 pag. 37 TEST PPM Normal in case of ppm checker use - PINTRAP OPEN Back doors opened (except still) Check back doors STILL OPEN Destillator door opened See 6.6.6 pag. 37 2° LEV SFTY STILL Max level Sludge barrel See 6.7.3 pag. 38 4.8 FLASHING AND ACOUSTIC SIGNALS (Fig. 2) Above the command panel there are 3 flashing signals: First (21), flashing red, shows an alarm or something wrong on the unit. Second (22), yellow, shows the end of an automatic cycle and that the unit is in manual function. Third (23), green, shows that the unit is correctly in automatic cycle. Than there is an acoustic signals (siren); if the sound is alternate with the red flashing light the unit is in alarm condition while if the sound is continuous (20 seconds) the automatic cycle is ended. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 27 4.9 INVERTED ROTATION (G - Fig.7) This pushing button let the working basket turn in the opposite direction of regular rotation. It is very useful in case the working basket has been blocked by an external part of piece of this. In this case the working basket turn for a little while back to release the part involved. Is good to know that the main motor is equipped with a friction in order to stop the rotation before damaging components of the unit (Cap. 5.5). 4.10 EMERGENCY AND MAIN BUTTONS Main switch (E - Fig.7) let the operator to give or cut off tension at the whole unit. This is so used to turn on or turn off the whole installation. Emergency push button (F) once pushed, stops the unit in case of emergency and is positioned in a very easy and reachable position to be used at any time in any way. Once pushed it stays in that position and to be able to re start the unit is necessary to turn and extract the button itself. FOR BASKET POSITIONING, THERMOSTAT REGULATION AND DESTILLATOR CONTROLS SEE AHEAD ON CHAPTERS. 5.3, 5.4 e 6.8. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 28 5. PREPARING FOR USE 5.1 SOLVENT LOADING The machine number plate shows the amount of solvent necessary to fill the machine. To transfer the solvent from the solvent drum to the machine, proceed as follows: - Connect the solvent drum and the machine to valves (B - Fig. 8) using appropriate flexible tubes solvent resistant. - Open manual valve (X3). Doing this automatically the direct aspiration of the solvent pump starts (F). - Press on the computer board the function key: SOLVENT FILLING And the solvent will flow directly to tank 1; once full the tank 2 will be filled and at the end the operation will be automatically finished. Remind to close the manual valve (B) positioning the switch at the original position. CAUTION: THIS OPERATION MUST BE CARRIED OUT USING THE APPROPRIATE PROTECTION, SUCH AS GLOVES AND MASK, AS WELL AS ADEQUATE ROOM VENTILATION. Fig. 8 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 29 5.2 SOLVENT TRANFER (Fig. 9) For the different transferring possibilities take a look at the following schema following the arrows. I.e.: to transfer the solvent from tank 1 to tank n° 3 push buttons OUTLET TANK 1 – SOLVENT PUMP – INLET TANK 3. Fig. 9 5.3 TEMPERATURES SETTING AND CHECKING (Fig. 10) On the front panel there are 4 digital thermostats used to show and control temperatures of: A) Drying thermostat of the outlet air from the drum (pre-set at 65°C) B) Drying thermostat of the inlet air into the drum (pre-set at 75°C) I) Tank 3 solvent thermostat (hot solvent tank at 60° C)) L) Destillator 1 thermostat (135° C) M) Destillator 2 thermostat (135° C) To set the working temperature of the thermostats, press SET, then UP to increase or DWN to decrease the instrument temperature value. With models 4 buttons equipped, it is possible to exit from setting at any time pressing key FNC. Fig. 10 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 30 5.4 LOADING UNLOADING DOOR (A - Fig. 11) In the centre of the drum is the door, also called loading door. It is equipped with a safe and reliable locking system. The opening lever (B) is blocked by a pneumatic device (C) and its own micro switch (D) which prevents the machine from working if the door is not perfectly closed. To open the door, press the key OPEN DOOR Which unlock all the doors and turn on the flashing red light. Once the loading unloading door is opened, press at the same time buttons LOAD 1 and LOAD 2 in order to positioning perfectly the first loading baskets with door and loading cylinder. Once finished the unloading – loading of the first basket, repeat this operation to position the second basket. Correct position reached, baskets automatically stop also with the buttons pressed, to reach next position, release both buttons and press them again. NOTE: the door must be opened only when the machine is not running. IT IS FORBIDDEN TO CARRY OUT OPERATIONS WHICH MAY OPEN THE DOOR DURING WORKING CYCLE. IN CASE OF LACK OF AIR TO SAFETY SYSTEM, DO NOT TRY TO FORCE OPENING SINCE DOOR WILL BE LOCKED. CAUTION. DURING THE LOADING OF THE MACHINE, DO NOT EXCEED THE MAXIMUM LOAD LEVEL. OPEN ONLY WHEN THE MACHINE IS NOT WORKING. Fig. 11 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 31 5.5 MAIN MOTOR (Fig. 12) This is used to turn the working baskets into the drum to permit a good mechanical action of the solvent on the dirty parts as well as a correct exposition of the components at the drying air flow. Three are the main components: A) Electric motor B) Transmission reduction C) Positioning system and belts box This motor transmit the moving through the transmission reduction system directly to the working baskets into the drum. Using the regulation knob on the transmission it is possibile to increase or decrease the rotation speed of the working baskets simply rotating it clockwise or counter clockwise. THIS OPERATION HAS TO BE DONE WITH THE MOTOR IN RUNNING CONDITION – NEVER WITH THE MOTOR STOP The positioning system (proximity) check the baskets position and helps to load and unload the machine leaving baskets in the correct position of the loading door. N.B.: UNDER THE POSITIONING SYSTEM THERE IS AN ADJUSTABLE FRICTION FOR THE BASKET ROTATION. THIS MECHANICAL EQUIPMENT CONTROLS THE NECESSARY POWER AT WHICH THE BASKETS HAVE TO STOP IN CASE OF FAILURE DUE TO OBSTRUCTION OR CLOGGING. IT IS FORBIDDEN TO DO ANY ACTION ON THE MOTOR OR FRICTION WHILE THE MACHINE IS RUNNING (Except the speed regulation of the baskets rotation). Fig. 12 It is not necessary a specific maintenance to this equipment, once a while check the oil level through the little nut above the motor (D), and eventually fill with synthetic oil Shell Donax TA. MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 32 6. SPECIFIC COMPONENTS AND THEIR USE 6.1 BASE TANK (8 - Fig. 1 e 18 - Fig. 2) The base tank is used for containing the solvent necessary for dry cleaning, and is therefore controlled during operation in order to guarantee perfect sealing. It has been designed so as to self clean during the normal operating cycle, and is equipped with large sight windows which allow the level to be checked. It also features all the necessary connections for solvent valves, air outlets and the various accessories. THE BASE TANK IS FIXED TO A FLOOR TANK IN ORDER TO AVOID ANY SOLVENT LEAKS SPILLING OUT ONTO THE FLOOR. IT IS FORBIDDEN TO PERFORM ANY ACTION WHICH MAY COMPROMISE THE SEALING OF THE FOOR SPILL TANK. 6.2 HOT SOLVENT TANK (1 - Fig. 1) This component has the same characteristics of the tanks 1 and 2 with the possibility to be warmed. In this way, warming the solvent at the desired temperature (using thermostat on the control panel Cap. 5.3), it is possible increase the cleaning proprieties of the used solvent, improving the washing quality. 6.3 FIRST CHIPS KEEPER (B - Fig. 13) This has the function of preserving solvent piping from impurities which fall from pieces during the cleaning cycle. Its special construction permits the drying of these residues during the drying cycle, so that when carrying out the cleaning of the basket (see MAINTENANCE) the operator will not inhale any solvent gases. It is equipped with its own a pneumatic locking system (A) which prevents any accidental opening during the cycle and with a safety micro switch (C), which will not permit any machine operation if the cover is open. IT IS FORBIDDEN: TO PERFORM ANY OPERATIONS INVOLVING THE OPENING OF THE COVER DURING OPERATING CYCLE. IN CASE OF LACK OF AIR IN THE SAFETY SYSTEM, DO NOT ATTEMPT TO OPEN BY FORCE, AS THE COVER WILL BE LOCKED. Fig. 13 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 33 6.4 SECOND CHIPS KEEPER (A - Fig. 14) Has the same function of the first one (Cap. 6.3) and is mounted just after the first. It is equipped with a more precise filtration system in order to keep the most little impurities. During baskets cleaning (B) (see MAINTENANCE), the operator will not inhale any solvent gases because also this trap is equipped with a complete drying system of the contained residues. It is equipped with its own a pneumatic locking system (C) which prevents any accidental opening during the cycle and with a safety micro switch (D) which will not permit any machine operation if the cover is open. IT IS FORBIDDEN: TO PERFORM ANY OPERATIONS INVOLVING THE OPENING OF THE COVER DURING OPERATING CYCLE. IN CASE OF LACK OF AIR IN THE SAFETY SYSTEM, DO NOT ATTEMPT TO OPEN BY FORCE, AS THE COVER WILL BE LOCKED. MAINTENANCE WHEN THE UNIT NOT RUNNING At the end of each dry cleaning cycle open the cover by pressing push-button DOOR OPEN, take out the basket (B) and remove the residues, and keep them in an appropriate container. They must periodically be given to specialised disposal companies, these residues being classified as SPECIAL RESIDUES. Fig. 14 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 34 6.5 DRYING CHAMBER The DRYING CHAMBER (12 - Fig. 1) is made up of several components each having different functions, but with the aim of drying the parts which are in the basket. 6.5.1 FAN MOTOR The fan determines the air circulation inside the closed system. If your hear a whistling noise, introduce some drops of oil in the fan lubrication hole. 6.5.2 AIR HEATER This is necessary to heat the air in order to obtain solvent evaporation. For the following component of the drying chamber a special attention has to be kept: 6.5.3 DRYING AIR FILTER (Fig. 15) The drying chamber includes a air filter (A) which hold back lint that remains from the drying cycle. It is equipped with its own a pneumatic locking system (C) which prevents any accidental opening during the cycle and with a safety micro switch (D), which will not permit any machine operation if the cover is open. IT IS FORBIDDEN: TO PERFORM ANY OPERATIONS INVOLVING THE OPENING OF THE COVER DURING OPERATING CYCLE. IN CASE OF LACK OF AIR IN THE SAFETY SYSTEM, DO NOT ATTEMPT TO OPEN BY FORCE, AS THE COVER WILL BE LOCKED. Fig. 15 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 35 6.6 DESTILLATOR (Fig. 16) 6.6.1 GENERAL NOTICE The stills (A and A1) are used for regenerating solvent by freeing it of impurities which have melted into it during the various cleaning cycles. They basically consists of a parallelepiped shaped container with a double hollow space bottom forming the hot plate which creates solvent boiling. The still works on steam which is taken from an external boiler. The water consumption of the mini boiler is practically zero and only in the case of leakages will it be necessary to add water. The first still (A) works with the liquid that came directly from working chamber and regenerate the most of the received solvent. The second (A1) receive liquid from still 1 keeping it clean and always ready as well as destillating better the mud received and discharge them at the end. Main components: - High level control (D) - Low level control (B) - Security valve for the still chamber (E) (set at 0,5 bar) with its relative alarm thermostat (“STILL SFTY VALVE”) set at 90 °C. Fig. 16 MANUALE ISTRUZIONI INSTRUCTION MANUAL MANUEL INSTRUCTIONS HANDBUCH FÜR BEDIENUNG DS 750 36 6.6.2 SECURITY VALVE (E - Fig. 16) The still is equipped with a security valve regulated at 0,5 bar and guarantees that distillation takes place at a very low pressure. The valve is connected to the separator and on the connecting pipe there is a thermostat (regulated at 90° C) which stops the machine in case valve opens to show that the connecting piping between the still and the condenser are obstructed (alarm “STILL SFTY VALVE”). 6.6.3 FLOATING MICRO SWITCH MAX LEVEL (D - Fig.16) A floating micro switch allows to send to the still a solvent quantity equal to 3/4 of the total capacity. When it runs, an alarm come on “1° LEV SFTY STILL” and the unit stop working. It stays in this condition (except still heating) since the correct still level has been reached. 6.6.4 FLOATING MICRO SWITCH WORKING LEVEL (B - Fig.16) A floating micro switch controls that the solvent into the still during the distillation phase not goes under minimum level. If it happens the destillator heating will end. It is possible to distil all the solvent into the still (bypassing the low level) using key: TOTAL DESTILL 6.6.5 STILL WASHING DIFFUSER It diffuses the solvent of the walls of the still removing the dirt and accumulating it on the bottom. 6.6.6 FAILURE SIGNALS The still is connected to the COMPUTER and will be able to signal following failures (alarms): -“1° LEV SFTY STILL” STILL OVERFULL: the machine is blocked. The causes for this failure are: a) Still has not been turned on b) Too much solvent in the pre-washing c) Still is too dirty d) Wrong operations in manual operation e) Wrong operations in manual operation -“STILL OPEN”: the door of the still (C) is not perfectly closed. -“STILL SFTY VALVE”: SECURITY VALVE OPEN. if this alarm shows, it will be necessary first of all to disconnect the still, bring the running cycle to an end, turn off the machine and wait until it is cold; then disassemble the connecting piping to the condenser, clean them and re-assemble. 6.6.7 SLUDGE TRANSFERRING Moving sludge and mud from still 1 to still 2 is easily possible through the computer button: FROM STIL 1 TO 2 With this operation still 1 discharge everything is inside to still 2 for a better solvent regeneration and recovery, maintaining itself ready for next cleaning cycle or tank regeneration. 6.6.8 MAINTENANCE Every morning run the program to exhaust Sludge from the still (n. 20) and every week open the still door to clean its inside walls and bottom; to do this open the door (C) pressing key: OPEN DOOR Also this is equipped with its own a pneumatic locking system (F) which prevents any accidental opening during the cycle and with a safety micro switch (G), which will not permit any machine operation if the cover is open. Then there is a temperature control to avoid the door opening if the internal temperature exceed 40°C. MANUALE ISTRUZIONI INSTRUCTION M