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OMOGENEIZZATORE/POMPA AD ALTA PRESSIONE

HOMOGENIZER/HIGH PRESSURE PUMP

ISTRUZIONI DUSO E MANUTENZIONE

INSTRUCTIONS FOR USE AND MAINTENANCE

BETRIEBSANLEITUNG

INSTRUCTIONS DEMPLOI ET ENTRETIEN

INSTRUCCIONES PARA EL USO Y EL


MANTENIMIENTO

HANDLEIDING

Via M. da Erba Edoari, 29/A


43100 Parma, Italy
Tel: +39 0521/965411
Fax: +39 0521/242819
Internet: htttp://www.niro-soavi.it
E-mail: niro-soavi@niro-soavi.it
Niro Soavi S.p.A

FOREWORD

Dear Customer,

we wish to thank you for selecting our product and ensure you our best
assistance in order to enable you to make the most of your machine.

Also, we remind you that a good understanding of the contents of this manual -
through careful reading of all sections - is essential for the correct, safe use and
operation of the machine you have purchased.

No one should operate or perform maintenance on this machine without first


having read and understood the following Instructions for Use & Maintenance.

For any further support or information, you may contact us at the below listed
address.

Yours faithfully,

Niro Soavi S.p.A.


Via Mario da Erba Edoari 29/A - Parma, Italia
tel. +39 0521 965411
fax +39 0521 242819
e-mail: niro-soavi@niro-soavi.it
Internet: http://www.niro-soavi.it

0C00SE0C.DOC 0.0.1
Niro Soavi S.p.A

CONTENTS - SECTIONS

1. Technical Specifications
2. General Information
3. Machine Operation and Use
4. Maintenance
5. List of Spare Parts
6. Wiring Diagrams
7. Documentation about Suppliers and Components

HOW TO USE THE MANUAL

This manual is made of separate sections as indicated in the list of CONTENTS.


Each section is divided into chapters and paragraphs, and pages are numbered
separately in each section. A specific list of contents is given at the beginning of
each section.
The pictures and tables referred to in the text are numbered inside each section.

Before installing the machine you must be thoroughly familiar with the
information given in Section 2, Chapter 2.8 and, in particular, paragraph 2.8.5.

0C00SE0C.DOC 0.0.2
Niro Soavi S.p.A

SECTION 1
TECHNICAL SPECIFICATIONS
1.1. TECHNICAL DATA
1.2. FLOW-SHEET
1.3. FLOW-SHEET LEGEND (SPEC 102)
1.4. MACHINE INSTALLATION DRAWING
1.5. UTILITIES SPECIFICATIONS (SPEC 103)
1.6. RUNNING SEQUENCE (ONLY IF MACHINE IS SUPPLIED
WITHOUT ELECTRICAL POWER BOARD BY NIRO SOAVI)
1.7. ELECTRICAL SPECIFICATIONS
1.8. DECLARATION OF CONFORMITY CE

1c00se0c.doc 1.0.1
Niro Soavi S.p.A

1.1 TECHNICAL DATA SHEET

1 GENERAL
1.1 Serial Number 4537
1.2 Kind of Machine HOMOGENIZER
1.3 Model ARIETE
1.4 Type NS3006H
1.5 Execution Sanitary
1.6 Special Features 3A+ELECTROPOLISHED
1.7 MAX Operating Pressure 1000 bar
1.8 Flow Rate Type F
1.9 MIN Flow Rate / l/h @ / Hz
1.10 MAX Flow Rate 120 l/h @ / Hz
1.11 MIN Feed Pressure 5-6 bar
1.12 MAX Backpressure 10 bar

2 OPERATING CONDITIONS
2.1 Product CELL RUPTURE
2.2 MAX Viscosity <500 cP
2.3 MAX Relative Humidity 90 %
2.4 Ambient Temperature 40 C
2.5 MAX Altitude 1000 m
2.6 MAX operating temperature <90 C
2.7 MAX temperature CIP / SIP <140 C

3 TECHNICAL FEATURES
3.1 COMPRESSION BLOCK
3.1.1 Type MONOBLOCK VHP
3.1.2 Number of plungers 3
3.1.3 Material of plungers CERAMIC
3.1.4 Plunger diameter 12,7 mm
3.1.5 Stroke 40 mm
3.1.6 Pumping valve type PVB 1/2"
3.1.7 Overpressure valve SPRING LOADED setpoint 1100 bar
3.1.8 Connection, Inlet 3/4" TRICLAMP
3.1.9 Connection, Outlet 3/4" TRICLAMP

Scheda_c.doc 1.1.2
Niro Soavi S.p.A

3.2 HOMOGENIZING VALVE


3.2.1 Number of Stages 2
3.2.2 Type of actuator PNEUMATIC
3.2.3 Type of control PNEUMATICD.11,9-30
3.2.4 Homogenizing Valve Type D.11,9-30

3.3 DRIVE END


3.3.1 Main Motor (frame size; type) 132MB/6P AC
3.3.2 Main Motor Power 5,5 kW
3.3.3 RPM Crankshaft / MIN
3.3.4 RPM Crankshaft 171 MAX
3.3.5 Drive Type STD
3.3.6 Gearbox speed reduction ratio /

3.4 LUBRICATION
3.4.1 Type SPLASH
3.4.2 Lubricating system SPLASH SYSTEM
3.4.3 Oil Cooling system SPLASH SYSTEM

3.5 MAIN ELECTRICAL CIRCUIT


3.5.1 Number of phases 3
3.5.2 Voltage 460 V
3.5.3 Frequency 60 Hz

3.6 AUX ELECTRICAL CIRCUIT


3.6.1 Number of phases /
3.6.2 Voltage 24DC V
3.6.3 Frequency / Hz

4 OPTIONS
4.1 Suction side pulsation damper /
4.2 Delivery side pulsation damper /
4.3 Feeding pump /
4.4 Inlet pressure gauge /
4.5 Electric Power Board /
4.6 Overpressure Valve in Line / setpoint / Bar /

Scheda_c.doc 1.1.2
SPEC-E1C
Niro-Soavi S.p.A. ASYNCHRONOUS MOTORS
Specialty Products via M. da Erba Edoari, 29/A 26.02.02 0
Division 43100 PARMA (ITALY)

PHONE : +39.0521.965411 - FAX : +39.0521.242819


SPECIFICATION SHEET DATE REV.

1/220013 NS 3006H 4537 DD


NIRO SOAVI JOB MACHINE MODEL MACHINE SERIAL NO. SIG.

MAIN MANUFACTURER ABB PHASE NO. 3


MOTOR RATED OUTPUT 5,5 kW FRAME SIZE 132M
VOLTAGE 460 V MOUNTING DESIGN. N.F.
FREQUENCY 60 Hz THERMAL PROTECTION N.F.

EFFICENCY 86 % ROLLER BEARING NO

RATED CURRENT 11,9 A STANDARDS IEC-CENELEC


STARTING CURRENT 82,1 A
POLES 6
POWER FACTOR 0,78
CODE: CONNECTION STAR
MB6111Y2
CABINET RATED OUTPUT kW POLES
COOLING FAN VOLTAGE V PHASE NO.
MOTOR FREQUENCY Hz MOUNTING DESIGN.
RATED CURRENT A STANDARDS
CODE: CONNECTION

OIL PUMP RATED OUTPUT kW POLES


MOTOR VOLTAGE V PHASE NO.
FREQUENCY Hz MOUNTING DESIGN.
RATED CURRENT A STANDARDS
CODE: CONNECTION

FAN MOTOR RATED OUTPUT kW POLES


ON THE VOLTAGE V PHASE NO.
MAIN MOTOR FREQUENCY Hz MOUNTING DESIGN.
RATED CURRENT A STANDARDS
CODE: CONNECTION

RATED OUTPUT kW POLES


VOLTAGE V PHASE NO.
FREQUENCY Hz MOUNTING DESIGN.
RATED CURRENT A STANDARDS
CODE: CONNECTION

RATED OUTPUT kW POLES


VOLTAGE V PHASE NO.
FREQUENCY Hz MOUNTING DESIGN.
RATED CURRENT A STANDARDS
CODE: CONNECTION

RATED OUTPUT kW POLES


VOLTAGE V PHASE NO.
FREQUENCY Hz MOUNTING DESIGN.
RATED CURRENT A STANDARDS
CODE: CONNECTION
Niro-Soavi S.p.A.
SPEC-103C
Specialty Products via M. da Erba Edoari, 29/A UTILITY SPECIFICATION
Division 43100 PARMA (ITALY) 26.02.02 0
PHONE : +39.0521.965411 - FAX : +39.0521.242819 DATE REV.
1/220013 NS 3006H 4537 DD
JOB NIRO SOAVI MACHINE MODEL MACHINE SERIAL NO. SIG.

LUBRICATING & COOLING FLUID


Required Min Max
Pressure (Bar) 2 3
PISTONS WATER YES Temperature (C) 10 25
Consumption (l/h) 180
Pressure (Bar)
GEAR REDUCER NO Temperature (C)
Consumption (l/h)
Pressure (Bar)
OIL EXCHANGER NO Temperature (C)
Consumption (l/h)
Pressure (Bar)
STERILE CONDENSATE
NO Temperature (C)
EXCHANGER
Consumption (l/h)
Note : max. hardness < 15fH ; max. particle size = 60 microns .

COMPRESSED AIR
Required Min Max
Pressure (Bar) 7,5 10
COMPRESSED AIR YES 3
Consumption(Nm /h) 0
Pressure (Bar)
Temperature (C)
3
Consumption(Nm /h)

STEAM
Required Min Max
Pressure (Bar) (1)
STERILE CONDENSATE
NO Temperature (C)
PRODUCTION
Consumption (l/h)
(1) THE CLIENT MUST INSTALL A PRESSURE REDUCER AT THE STEAM INLET CONNECTION TO ADAPT THE PRESSURE TO THE MACHINE'S REQUIREMENTS

Pressure (Bar) (2)


PULSATION DUMPER NO Temperature (C)
Consumption (l/h)

ELECTRICITY
Electrical supply (V/Hz) V = 3x 460 Hz = 60
Power absorbed (kW) kW = 4,9
Current absorbed (A) A= 9,9
Note :
LEGEND SPEC - 102 C
Niro-Soavi S.p.A. TO CONCEPT FLOW SHEET
Specialty Products via M. da Erba Edoari, 29/A ____________________ REV.
Division 43100 PARMA (ITALY) DATE
PHONE : +39.0521.965411 - FAX : +39.0521.242819
Page 1 of 2 ____________________ 0
SIG.

1. INSTRUMENT SYMBOLS 5. MACHINERY AND EQUIPMENT

LOCAL AUTOMATIC ACTUATOR FOR REMOTE


CONTROL, GENERAL

IN MAIN PANEL
MANUAL ACTUATOR NOT FOR REMOTE
CONTROL

LIMIT VALUE H
H: HIGH OR OPEN AUTOMATIC ACTUATOR WITH INTEGRATED
MANUAL CONTROL FACILITY
L: LOW OR CLOSED

DIAPHRAGM ACTUATOR
POINT OF MEASUREMENT
T
WITHOUT INSTRUMENTATION
SOLENOID ACTUATOR

PISTON ACTUATOR

2. PROCESS LINES
ELECTRIC AC MOTOR
PRIMARY FLOW LINE, GENERAL
ADJUSTABLE SPEED CONTROL
SECONDARY FLOW LINE, GENERAL

COMPRESSOR OR VACUUM PUMP,


MECHANICAL CONNECTION
GENERAL

SUPPLY LIMIT MARKER


FAN

PUMP FOR LIQUIDS GENERAL


3. INSTRUMENT SIGNAL LINES
CENTRIFUGAL PUMP
GENERAL

HIGH PRESSURE PUMP


ELECTRICAL

PNEUMATIC 1-STEP HOMOGENIZER

HYDRAULIC
2-STEP HOMOGENIZER

CAPILLARY
FILTER, GENERAL

HEAT EXCHANGER WITHOUT CROSS


FLOW e.g. ELECTRIC HEATER
4. FLOW LINE ABBREVIATIONS
LIGHT SOURCE
AS AIR SUPPLY
CIP CLEANING IN PLACE
CS CONDENSATE SUPPLY VALVE CLOSES (FC)
CWS CHILLED WATER SUPPLY
ES ELECTRIC SUPPLY
VALVE OPENS (FO)
GS GAS SUPPLY
NS NITROGEN SUPPLY
OS OIL SUPPLY VALVE RETAINS POSITION
SS STEAM SUPPLY
WS WATER SUPPLY
FAIL-OPEN INDICATION FOR A 3-WAY VALVE
. R RETURN
LEGEND SPEC - 102 C
Niro-Soavi S.p.A. TO CONCEPT FLOW SHEETS
Specialty Products via M. da Erba Edoari, 29/A ____________________ REV.
Division 43100 PARMA (ITALY) DATE
PHONE : +39.0521.965411 - FAX : +39.0521.242819
Page 2 of 2 ____________________ 0
SIG.

6. LETTER CODE FOR IDENTIFICATION OF INSTRUMENT FUNCTIONS

FIRST LETTER SUCCEEDING LETTER (1)


MEASURED OR INITIATING VARIABLE MODIFIER DISPLAY OR OUTPUT FUNCTION

A ALARM
B DISPLAY OF STATE (2)
C CONTROLLING (4)
D DENSITY DIFFERENCE
E ALL ELECTRICAL VARIABLES (5) SENSING ELEMENT
F FLOW RATE RATIO
G GAUGING, POSITION OR LENGTH
H HAND (MANUALLY INITIATED) OPERATED
I INDICATING (3)
J SCAN
K TIME OR PROGRAMMED TIME
L LEVEL
M MOISTURE OR HUMIDITY
N USER'S CHOICE USER'S CHOICE
O USER'S CHOICE
P PRESSURE OR VACUUM TEST-POINT CONNECTION
Q QUALITY (5) INTEGRATE OR TOTALIZE INTEGRATING OR SUMMATING
R NUCLEAR RADIATION RECORDING
S SPEED OR FREQUENCY SWITCHING (2)
T TEMPERATURE TRANSMITTING
U MULTIVARIABLE MULTIFUNCTION UNIT
V VISCOSITY VALVE, DAMPER, ACTU, ELEMENT
W WEIGHT OR FORCE
X UNSPECIFIED (5) UNCLASSIFIED FUNCTIONS
Y VIBRATION COMPUTING RELAY, RELAY
Z EMERG. / SAFETY ACTING (2)

EXAMPLE : PDIRC DIFFERENTIAL PRESSURE INDICATION, RECORDING AND CONTROL


FIRST LETTER P, MODIFIER D, SUCCEEDING LETTERS I,R,C

1) NORMAL SEQUENCE OF SUCCEEDING LETTERS : B.I.R.C.T.Q.S.Z.A.


2) SIGNAL TYPE : ON/OFF
3) SIGNAL TYPE : CONTINUOUS
4) SIGNAL TYPE : NORMALLY CONTINUOUS. IF ON-OFF, S IS ADDED

5) A NOTE SPECIFIES THE MEASURED PROPERTY. E.g. FOR LETTER E, I, U, P OR F


Niro-Soavi S.p.A.
SPEC-E4C
Specialty Products via M. da Erba Edoari, 29/A RUNNING SEQUENCE
Division 43100 PARMA (ITALY) 26.02.02 0
PHONE : +39.0521.965411 - FAX : +39.0521.242819 DATE REV.

1/220013 NS 3006H 4537 DD


JOB NIRO SOAVI MACHINE MODEL SERIAL NO. SIG.

RUNNING SEQUENCE REGARDING THE SWITCHBOARD SUPPLIED BY THE CUSTOMER

ACTION RESULT
1 INSERT THE MAIN SWITCH

A SWITCHBOARD ENERGIZED

2 PUSH THE START BUTTON

A INSERT THE MAIN MOTOR


INSERT THE SOLENOID VALVE FOR WATER
B
SUPPLY
INSERT THE SOLENOID VALVE FOR AIR SUPPLY
C
AFTER 15 SECONDS
SETTING 420 mA SIGNAL OF MODULATING
2A
VALVE 1st STAGE

A HOMOGENIZERS WORKS ON PRESSURE

3 PUSH THE STOP BUTTON


DISCONNECT THE SOLENOID VALVE FOR AIR
A
SUPPLY
RESET 1st HOMO. STAGE MODULATING VALVE SETTING
B THE SIGNAL TO 4 mA

C DISCONNECT THE MAIN MOTOR


DISCONNECT THE SOLENOID VALVE FOR WATER
D
SUPPLY
INTERVENTION OF THE MAIN MOTOR
4
PROTECTION
REPEAT THE RESULT OF THE SEQUENCE
A
DESCRIBED AT POINT 3
INTERVENTION OF THE LUBRICATING OIL
5
PRESSURE SWITCH
REPEAT THE RESULT OF THE SEQUENCE DESCRIBED
A AT POINT 3, AFTER 15 SECONDS DELAY
INTERVENTION OF THE AIR INLET PRESSURE
6
SWITCH
LIGHTING OF THE LOW INLET AIR PRESSURE
A
WARNING LIGHT

7 INTERVENTION OF THE WATER FLOW SWITCH


REPEAT THE RESULT OF THE SEQUENCE DESCRIBED
A AT POINT 3, AFTER 15 SECONDS DELAY
INTERVENTION OF THE INLET PRESSURE
8
SWITCH
REPEAT THE RESULT OF THE SEQUENCE DESCRIBED
A AT POINT 3, AFTER 1 MINUTE DELAY
INTERVENTION ON THE EMERGENCY STOP
9
PUSHBUTTON
REPEAT THE RESULT OF THE SEQUENCE
A
DESCRIBED AT POINT 3

44__4537-E4C.xls
Niro Soavi S.p.A

NIRO SOAVI S.p.A.


Via Mario da Erba Edoari 29/A - 43100 PARMA - ITALY
Tel +39 0521 965411 - Fax +39 0521 242819

DECLARATION OF CONFORMITY

MACHINE: HOMOGENIZER ARIETE


Model: NS3006H
Serial number: 4537
Max Press. (MPa): 100
Rated Flow (dm3/h): 120
Year: 2002

The undersigned

DECLARES

under his own responsability that the above mentioned Machine, object of this
declaration,

IS IN CONFORMITY

with the precepts of the following EEC directives:


98/37/EEC
73/23/EEC and following updated 93/68 EWG
89/336/EEC

The above identified Machine has successfully passed all the trials and tests to
which it has been submitted.

PARMA 04/04/2002

D_ce_r1c.doc 0.0.1
Niro Soavi S.p.A

SECTION 2
GENERAL INFORMATION - INDEX
2.1. SAFETY
2.1.1 SAFETY INFORMATION
2.1.2 PERSONNEL SAFETY
2.1.3 USE OF THE MACHINE IN DANGEROUS ZONES
2.2. CE MARK AND ISO 9000 CERTIFICATION
2.3. IDENTIFICATION OF THE MACHINE
2.4. GUARANTEE
2.4.1 SCOPE OF THE GUARANTEE
2.4.2 DURATION OF THE GUARANTEE
2.4.3 APPLICATION OF THE GUARANTEE
2.4.4 EXCLUSIONS AND LIMITATIONS
2.4.5 HOW TO RETURN THE DEFECTIVE MATERIAL
2.5. HANDLING
2.6. RECEIVING AND CHECKING THE MACHINE
2.7. STORAGE
2.7.1 STORAGE BEFORE INSTALLATION
2.7.2 STORAGE FOR PERIODS LONGER THAN 3 MONTHS
2.8. INSTALLATION
2.8.1 POSITIONING
2.8.2 ACCESS TO THE INSIDE OF THE MACHINE
2.8.3 MACHINE LEVELING
2.8.4 CONNECTION TO UTILITIES AND PRODUCT LINE
2.8.5 INSTALLATION
2.8.6 POSITIONING THE ELECTRIC EQUIPMENT
2.8.7 ELECTRICAL CONNECTIONS
2.8.8 DIRECTION OF ROTATION OF ELECTRIC MOTORS
2.9. SPECIAL NOTES
2.9.1 CONTROL BOARD TO BE PROVIDED BY THE CUSTOMER
2.9.2 ELECTRIC MOTOR SUPPLIED BY THE CUSTOMER
2.10. NOTES ON MACHINE TEST
2.11. CLEANING THE MACHINE
2.12. DEMOLITION AND DISPOSAL
2.13. OPTIONS
2.13.1 SECOND STAGE HOMOGENIZING VALVE
2.13.2 ASEPTIC EXECUTION
2.13.2.1 STERILIZING THE MACHINE
2.13.2.2 REGULATING THE FLOW OF COOLING WATER
2.13.2.3 DESCALING AND WASHING
2.13.3 PARTIAL HOMOGENIZING SYSTEM
2.13.3.1 HOW THE BYPASS SYSTEM WORKS

2C001E0C.DOC 2.1.0
Niro Soavi S.p.A

2.1. SAFETY

These INSTRUCTIONS FOR USE & MAINTENANCE are part of the machine
and should accompany it throughout its service life until disposed of.
Before starting ANY operation, consult the relevant Section of these
INSTRUCTIONS.
Make sure that nobody has access to the machine before getting thoroughly
acquainted with these Instructions.

The only operations allowed are those described in these INSTRUCTIONS;


for any operation other than these, contact NIRO SOAVI Customer
Service.

CAUTION: Do not attempt tampering the calibration of any component or


part of the machine or to modify any parameter of programmable devices
unless expressly authorized in writing by NIRO-SOAVI.
Any calibration carried out by NIRO-SOAVI at the time of testing has the
purpose of ensuring the machines safety and troublefree operation: any
unauthorized modification will void the machines guarantee immediately.
Because the tampering of any safety device may undermine the safety of
the equipment, NIRO-SOAVI shall not be held liable for damages in case
of accidents resulting from such unauthorized modification.

Keep these INSTRUCTIONS FOR USE AND MAINTENANCE within the


operator's reach and make sure that their place of storage is suitable to
protect them from accidental damage.All operators must be thoroughly
familiar with the instructions given in this manual, comply with safety
regulations, use personal protection devices and avoid wearing clothes or
accessories which could get drawn into moving machine parts.
Operators must be familiar with the instructions given in this manual
before they can do any work on and with the machine.

WARNING: For safety during transport, the machine is supplied WITHOUT


LUBRICATION OIL. Before starting the machine fill with oil as described in
Section 4 -MAINTENANCE.

2C001E0C.DOC 2.1.1
Niro Soavi S.p.A

2.1.1 SAFETY INFORMATION


Although this machine has been designed to prevent all risks for operators the
possibility of risk for both personnel and materials or equipment is not excluded;
the general safety instructions and norms for operators and objects must be
observed scrupulously, taking every precaution to prevent accidents.
The machine must be used only if its state of preservation, operation and repair
is perfect and in compliance with what is required and specified in this manual.
Use of this machine is permitted only for the purposes for which it was
constructed and tested; use of the machine for purposes other that the ones
mentioned or beyond specified use limits shall relieve the manufacturer of all
responsibility in case of damage to persons or things and invalidate the
warranty.
Failure to service the machine according to the instructions provided in this
manual, or use of non-original spare parts, may lead to risks for the personnel
operating the machine.

2.1.2 PERSONNEL SAFETY


The machine must be used only by personnel members who are familiar with
the INSTRUCTIONS FOR USE AND MAINTENANCE and with the specific
technical information required to carry out their tasks, using suitable tools and
equipment; only authorized personnel are allowed to access, operate or service
the machine.
All members of personnel must wear clothes that are suitable to prevent
accidents due to clothing getting caught in moving machine parts or to contact
with sharp or pointed parts or with high temperatures.
Protection clothes, safety goggles and safety boots must be worn at all times.
We also recommend the use of personal protection devices to protect operators
from the noise that may be produced by the machine.
Operators must be familiar with the use of the equipment required to carry out
routine and extraordinary maintenance work.
In particular, these instructions must be read by all members of personnel who
may be operating or interacting with the machine, such as:
- Personnel in charge of transportation and handling the machine
- Personnel in charge of connecting the machine to supply mains
- The operator who is to use the machine
- Personnel in charge of servicing the machine
- Personnel who are to carry out machine tests and to check the
characteristics of the product treated.

2C001E0C.DOC 2.1.2
Niro Soavi S.p.A

2.1.3 USE OF THE MACHINE IN DANGEROUS ZONES


Use of the machine in dangerous zones is allowed only if the machine has been
designed specifically for use in such conditions using suitably certified
components.
Identification and classification of danger zones is the responsibility of the
customer who is required to specify them.
The factory electric system as well as ground and unipotential connections
must be designed so as to prevent any danger of explosion.
Where equipment for the detection of dangerous gas, liquids or vapors is used it
must installed by the user; the same applies to systems for ventilation and
exhaust of smoke and vapor from the danger zone.

All personnel must be aware of the potential hazards present in the danger
zone and connected with the use of dangerous products for the safety of
persons and of the environment.

Any tools and equipment used inside danger zones must be suitable for use in
these conditions; the user of the machine is responsible for selecting them and
making them available as well as for the way they are used.

It is extremely important to regularly check belt tension in order to prevent


dangerous overload or overheating as this could create a risk of fire or
explosion.

2C001E0C.DOC 2.1.3
Niro Soavi S.p.A

2.2. CE MARK AND ISO 9000 CERTIFICATION

The machine has been designed and built in accordance with EEC standards
on the safety of equipment (CEE/98/37).
NIRO-SOAVI guarantees that this machine complies with the above-mentioned
standard by marking the front of the machine with "CE" as shown in figure 2.2.1
here below, on the front part of the machine.
In Section 1 TECHNICAL SPECIFICATIONS we have attached the
Declaration of Conformity CE of the machine.

Niro Soavi S.p.A.


via M. da Erba Edoari, 29/A 43100 PARMA (ITALY)

YEAR

MAX PRESS.

3
RATED FLOW (dm /h)

TYPE S.N.

FIGURE 2.2.1

In addition to this, NIRO SOAVI is certified according to UNI EN ISO 9001 for
design, manufacturing and servicing of homogenisers and high pressure
pumps, therefore your machine has been enginnereed and produced according
to approved quality procedures.
See figure 2.2.2 for the UNI EN ISO 9001 Quality System Certificate.

2C001E0C.DOC 2.2.1
Niro Soavi S.p.A

FIGURE 2.2.2

2C001E0C.DOC 2.2.2
Niro Soavi S.p.A

2.3. IDENTIFICATION OF THE MACHINE

The machine is identified by the name plate (fig.2.2.1) located on the front panel
(or on the pulley protection panel, for the Hercules versions without casing),
which includes
- the manufacturer's name
- model and type
- serial number.
The serial number is also punched on the compression head.
This number should always be quoted in any correspondence addressed to
NIRO-SOAVI's Customer Service in order to identify the machine properly.

2C001E0C.DOC 2.3.1
Niro Soavi S.p.A

2.4. GUARANTEE

If not specified otherwise in the order confirmation, the terms and conditions of
guarantee are as follows:

2.4.1 SCOPE OF THE GUARANTEE


NIRO-SOAVI guarantees the good quality and workmanship of its products and
shall - during the specified guarantee period - repair or replace free of charge
any part whose failure or premature wear and tear are the result of poor quality
of materials, defective workmanship or assembling.
The guarantee shall not apply to those parts whose failure or wear and tear are
due to:
- operator's negligence in checking the levels of the fluids, cleaning the filters,
providing the correct utility lines or improper feeding;
- insufficient infeed pressure in the machine;
- use of the machine with operating values exceeding the ones specified in
the contract, especially with respect to maximum pressure, flow, product
treated, operating and washing temperatures, feed pressure, specifications
of required utilities.
- use of inappropriate tools for the ordinary or extraordinary maintenance;
- failure to perform or incorrect maintenance;
- alterations or modifications carried out - whether directly or indirectly -
without the specific authorization in writing by NIRO-SOAVI;
- failure to comply with the INSTRUCTIONS FOR USE & MAINTENANCE.
- incorrect machine use, incorrect operating procedures and conditions
- incorrect machine installation or incorrect layout of feed line
- use of unsuitable components upstream or downstream the machine, and in
particular use of inadequate feed pump.

For this reason, we strongly recommend that the instructions contained in this
Manual are understood and followed, as a pre-condition for the correct and safe
use of the machine.

Using the machine and reading the INSTRUCTIONS FOR USE AND
MAINTENANCE imply integral acceptance of Warranty conditions.

For further information about application of the Warranty, see General Terms of
Sale.

2C001E0C.DOC 2.4.1
Niro Soavi S.p.A

2.4.2 DURATION OF THE GUARANTEE


The guarantee shall last for 12 MONTHS from the date of delivery of the
machine, unless otherwise specified in the Order Confirmation.
Such period shall remain unchanged even in the event that spare parts
replacements or repairs are carried out during the 12-month period.

2.4.3 APPLICATION OF THE GUARANTEE


As a condition of the applied warranty, any parts claimed to be defective by the
customer shall be provided to NIRO SOAVI to establish the cause.
The cost of shipping of materials shall always be charged to the customer.
Any work required for replacement/repair under guarantee shall be executed -
at NIRO-SOAVI's option, on the manufacturer's premises, on thirds' party or
directly on the spot.
The cost of shipping materials to the customers presmises shall always be
charged to the customer, especially in the case of urgent and specials
shipments of material or spare parts.
For any work carried out locally, the customer shall provide and pay for the
necessary utilities, extraordinary equipment, auxiliary personnel that may be
required and the costs of travel, board and accomodation of NIRO-SOAVI's
technicians.

2.4.4 EXCLUSIONS AND LIMITATIONS


The guarantee shall not cover the materials and parts subject to normal wear
and tear such as, but not limited to, all the gaskets used in the machine, V-belts,
plunger seals and relevant packing and support washers, safety valve seat,
filters, etc., as well as those parts whose life can not be estimated beforehand -
such as lamps, fuses, plungers - together with any coating, delivery valve and
their seats, homogenizing valve, pressure gauges.
For the components and accessories bought from independent Vendors, the
guarantee shall be the one granted to NIRO-SOAVI by such Vendors.

2.4.5 HOW TO RETURN THE DEFECTIVE MATERIAL


Before returning to NIRO-SOAVI any part for which a replacement/repair under
guarantee is claimed, the necessary approval shall be ontained from NIRO-
SOAVI's Customer Service.
All parts shall be properly packed to avoid any damage in transit, and
accompanied by:
- reference to the purchase order number;
- machine serial number;
- code number of the part;
- accurate description of the defect and the circumstances which caused it.
All parts approved to be under guarantee are delivered ex works; replaced parts
are the property of NIRO-SOAVI and shall be returned ex works.

2C001E0C.DOC 2.4.2
Niro Soavi S.p.A

2.5. HANDLING

CAUTION: These instructions shall be made available to the


personnel involved in the handling and installation of the machine.

The machine is sent to the Customer usually packed in a properly sized wooden
crate and wrapped in plastic film for additional protection, unless otherwise
specified in the Order Confirmation.
The wooden crate allows the machine to be handled with a fork lift or crane, and
appropriate marks are provided on the crate at the points for running steel
cables or belts for lifting (figure 2.5.1).

FIGURE 2.5.1

2C001E0C.DOC 2.5.1
Niro Soavi S.p.A

Concerning the dimensions and weight of the machine, see the Installation
Drawing shown in Section 1 TECHNICAL SPECIFICATIONS, in order to use
the proper lifting equipment.
The weight given is merely indicative and should be used only to select the
correct handling and transport means.
Please note that the center of gravity of the machine lies towards the
compression head (front part).

When handling unpacked machines use fork lifts (unless otherwise specified in
the handling instructions) and make sure that the compression head lies on the
operator's side. Forks should be adequately spaced and sized so as to
accomodate the entire base of the frame (figure 2.5.2) to prevent damage to the
machine frame or panels.

Side panels can be removed during transport to prevent damage; the front part
of the bodywork, under the compression head, has not been constructed to
support the weight of the machine. Do not use this part as a lifting point as this
could result in damage.

G G

FIGURE 2.5.2

CAUTION: In order to ensure a balanced handling of the machine and


avoid damage to the machine itself or hazards for the personnel, all
movements should be carried out VERY SLOWLY by authorized
operators, who must wear suitable protection devices and comply with
safety regulations.

2C001E0C.DOC 2.5.2
Niro Soavi S.p.A

WARNING: Before handling the machine, make sure that the route to be
followed and the intended place of installation are clear of any obstacle.

WARNING: Operators are required to read these instructions before


handling the machine; all personnel involved in handling of the machine
must be acquainted with transport and handling regulations, as well as
with regular safety standards.

WARNING: Use only tested hoisting devices approved to support the


machines weight, as indicated in the dimension drawing in Section 1
TECHNICAL SPECIFICATIONS.
Do not under any circumstances leave suspended loads and never stand
below suspended loads.

WARNING: The floor on which the machine is to be placed must withstand


to at least 150% of the machines weight indicated in the Installation
Drawing in Section 1 TECHNICAL SPECIFICATIONS.

2C001E0C.DOC 2.5.3
Niro Soavi S.p.A

2.6. RECEIVING AND CHECKING THE MACHINE

Unless specified otherwise in the Order Confirmation, once the machine has left
the Manufacturer's premises, any damage shall be under the responsibility of
the carrier - whether an independent one or a Customer's employee.
Therefore, when receiving the machine, the following should be checked:
- contents of the packing against the Packing List;
- integrity of the packing, so that any evident damage can be immediately
reported to the carrier;
- any damage suffered by the machine as a result of improper transport by the
carrier.
In order to minimize the amount of inconvenience for the Customer, NIRO-
SOAVI Shipping Department is always available to assist with clarifications,
evaluation of any damages, and any other action required to restore the
machine to its proper and safe conditions.

2C001E0C.DOC 2.6.1
Niro Soavi S.p.A

2.7. STORAGE

2.7.1 STORAGE BEFORE INSTALLATION


During the time preceding installation, the machine and its apparatus should be
conveniently stored in closed, clean premises to avoid deterioration and
preserve its efficiency.
If no storage place can be provided other than outdoor, a waterproof cover
should be provided to prevent contact with dust, humidity, rain, etc.
Special attention should be given to electric control boards and electronic
equipment, which are easily affected by humidity and low temperature.
If separate from the machine, they should be stored indoors and provided with
special humidity absorbers.

WARNING: Storage temperature should not be less than -5C and more
than +55C; humidity should be less than 95%, with no-condensate.
Vibrations should be avoided as much as possible.

2.7.2 STORAGE FOR PERIODS LONGER THAN 3 MONTHS

If the machine is expected to remain stored for over three months before
installation, provide a closed storage place protected from bad weather, dust or
corrosive releases, as described before. Observe the above precautions for
electric components.
In addition YOU MUST:
- loosen the tension of V-Belts using the appropriate tighteners (sees Section 3
- MAINTENANCE);
- disassemble the plungers and seal packings (see Section 3 -
MAINTENANCE)

WARNING: Pistons and seal packings should be reassembled, and belts


tensioned at the time of machine installation.

WARNING: In case the machine plungers are chrome coated, or are using
a tungsten carbide detonated coating (see Section 1 TECHNICAL
SPECIFICATIONS), they must be disassembled together with the packings
if the machine is in storage more than ONE month.

2C001E0C.DOC 2.7.1
Niro Soavi S.p.A

2.8. INSTALLATION

2.8.1 POSITIONING
The correct positioning of the machine within the production line is a pre-
condition for ideal performance and easy access for ordinary maintenance.
For this reason, according to the machine dimensions (see Section 1
TECHNICAL SPECIFICATIONS), allow enough space around the machine for
the service personnel to carry out the necessary maintenance.
Specifically, allow clearance for the eventual replacement of the main motor
using suitable lifting gear (crane or fork lift).
The front part and head require routine servicing; allow sufficient space to
permit complete removal of the head if required.
In addition, make sure the machine is not placed near sources of heat which
may undermine the necessary cooling, or near obstacles which may obstruct a
free air flow.
Plan suitable drainage points to be available in the area where the machine is
installed, in order to avoid its flooding, and avoid water hosing of the machine
through ventilation openings.

CAUTION: the floor on which the machine stands must have a bearing
capacity of at least 150% of the machine's weight indicated in the
Installation Drawing in Section 1 TECHNICAL SPECIFICATIONS.

2C001E0C.DOC 2.8.1
Niro Soavi S.p.A

2.8.2 ACCESS TO THE INSIDE OF THE MACHINE


The machine is provided with a satin-finish stainless steel fairing for:

- protection of the internal components from dirt, water or fouling with product;
- easy cleaning of the external parts;
- operator's protection from moving, under voltage or hot parts which may be
hazardous for the personnel, in compliance with EC standards and CE mark
requirements, and safety regulations in force in the country where the
machine is installed.

CAUTION: to avoid any danger of injuries to the operators, the machine


should be operated ONLY with the panneling in place or protections
completely closed.

Panels may be removed to allow maintenance and/or installation work to be


carried out.
Side panels are fitted with handles and special key locks to access the inside of
the machine.

WARNING: To prevent accidents, ensure that ALL retainers are


tightened?? before starting the machine; to remove or replace panels
always use the handles provided. Depending on the size of the panels,
two persons might be needed to remove or instal the panels.

CAUTION: Before removing the protection panels, the installation/


maintenance personnel should cut off the power input to the machine by
locking the appropriate power switch with a padlock.

2C001E0C.DOC 2.8.2
Niro Soavi S.p.A

2.8.3 MACHINE LEVELING


To ensure a smooth, vibration free operation, the machine should be properly
leveled and its legs should rest evenly on the floor.
To this effect, the machine is supplied with adjustable legs and rubber pad
(figure 2.8.1, item 1); in some cases, with fixed legs which do not require to be
adjusted or with pivoting wheels which have to be locked before operating the
machine.
For the leveling, proceed as follows:
- lift the machine and place the pads under the legs;
- lower the machine until the legs sit firmly on the blocks;
- adjust height from floor by tightening or loosening the adjustable legs, then
check the levelling with respect to the machined surface of the head;
- make sure that the machine's weight is divided among all legs;
- lock the legs using the appropriate lock ring (figure 2.8.1, item 2).
In some cases, due to vibrations, the machine may move and consequently
cause stress to the piping; if you wish to avoid this, the leg pads can be secured
by steel rings fixed to the floor.

FIGURE 2.8.1

2C001E0C.DOC 2.8.3
Niro Soavi S.p.A

2.8.4 CONNECTION TO UTILITIES AND PRODUCT LINE


The type, dimension and position of the connectors normally used to connect
the machine to the production line are specified in the dimension drawing in
Section 1 TECHNICAL SPECIFICATIONS.
The machine also includes (section 1 TECHNICAL SPECIFICATIONS):
- water connection for lubrication of packs and cooling (max. hardness 8 dH /
15 fH; recommended chloride value < 25 mg/liter, max 200 mg/liter
- water drain pipe;
- (possible) connection for compressed air (for homogenizers provided with air-
operated control system);
- (possible) connection for steam (for aseptic versions)
- condensate drain from lubrication system;
- discharge grid for cooling air.

For the specific requirements of each machine, type of connections and fluid
specifications, please refer to Section 1 TECHNICAL SPECIFICATIONS.
As far as the utility connections, we recommend providing on/off solenoid valves
designed to open at the machine start (if not already included in the machine) to
be placed at the machines utilities inlet ports.
In particular, the manual valves of the lubrication water circuit should remain
always open, in a position which allows controlling an adequate flow of water for
lubrication or production of enough condensate (for the aseptic version).
Keep in mind that excessive lubrication water can lead to flooding of the sump
where water is collected, with the risk of water going into the drive section and
polluting the lubrication oil; for this reason it is important to regularly drain any
condensate or water that may be found in the lubrication circuit, as described in
Section 4 - MAINTENANCE.

WARNING: For the machines provided with aseptic system, the Customer
shall be responsible to install a steam pressure reducer to protect the
aseptic system and ensure operators safety. Fluid specifications are
shown in Section 1 TECHNICAL SPECIFICATIONS.

In case a pipe is used for the water drainage, when calculating the required
diameter and slopes, remember that water is discharged by gravity and not by
pressure. Provide an adequate degree of slope in the system to avoid water to
accumulate in the sump.

WARNING: For the disposal of waste water or cooling water, refer to the
specific regulations in force locally. No traces of lubrication oil or product
residues are allowed in the effluents disposed.

2C001E0C.DOC 2.8.4
Niro Soavi S.p.A

Cooling air is discharged through grids, situated on the top of the machine,
controlled by a fan of suitable size for free discharge (not for all models).
In case the discharged air needs to be conveyed via ducts, please contact
NIRO-SOAVI's Technical Office for details.

WARNING: No device designed to throttle, whether totally or in part, the


delivery pipe, is allowed to be installed downstream the machine, as this
may cause risk of excessive pressure in the pipes and compression head.
In fact, the machine has been designed to withstand output
counterpressures not bigger than those indicated in the Technical
Specifications, Section 10 but, as this is a positive-displacement pump it
can create dangerous overpressure which can burst the pipes
downstream the machine when the outlet is closed for the liquid flow.

WARNING: For safety reasons we recommend you ALWAYS install a


safety valve downstream the machine to protect the line and users. You
should also ensure that all the valves used downstream the machine are
NORMALLY OPEN valves, so that they will not close in case of accidental
stops or emergency power down, or power failures. The machine has
been designed to have a certain level of inertia, so it will go on pumping
even after the main motor has been disconnected..

FIGURE 2.8.2

2C001E0C.DOC 2.8.5
Niro Soavi S.p.A

2.8.5 INSTALLATION
These guidelines are provided to ensure correct machine installation and
operation and guarantee long life to the machine and its components while
preventing situations of danger for operators.

For high-pressure positive displacement pumps and homogenizers, infeed


pressure must ALWAYS be kept over a minimum level for correct operation
without cavitation conditions which could damage the machine. The minimum
values indicated in Section 1 TECHNICAL SPECIFICATIONS must be
observed strictly; in any case, depending on the process temperature and
viscosity characteristics, it is necessary to ensure that infeed pressure is
constant and sufficient to prevent cavitation and underfeeding of the
machine.
For further information or special requirements ALWAYS contact NIRO
SOAVI

to feed the machine use an infeed pump with delivery 1.2 times greater than
the rated flow in case of machines with 3 or more pistons, and 1.5 times in
case of machines with 1 or 2 pistons. Pump delivery must be calculated at
least over the minimum pressure required for feeding.

If a positive displacement pump (lobe, single screw, etc.) or diaphragm pump


is used , a suitable by-pass pipe regulated by a modulating valve on the
infeed pump, and/or an adequate speed regulating system for the infeed
pump, to ensure correct machine feeding

if the products treated vary greatly in terms of viscosity, or if a positive-


displacement pump must be used for viscous products and washing water,
you must use a pump speed adjustment system regulated by infeed pressure
to ensure that machine feeding is correct under all conditions, including
during transitory production stages.

installation of the two homogenizers or piston pumps in series can only be


carried out provided a few changes are made, such as providing speed
variation of both machines controlled by an an infeed pressure adjustment
loop and installation of a by-pass system; for information in this respect
please contact NIRO SOAVI

it is necessary to use a feeding pump for each single machine; do not install
two or more machines in parallel with one single feeding pump to prevent
dangerour pulsation interferences

the feeding line between the feed pump and the homogenizer or piston pump
must be direct, possibly without bends, and with a size equal to or greater
than the size of the homogenizer/piston pump, without section variations, to

2C001E0C.DOC 2.8.6
Niro Soavi S.p.A

prevent loss of load; the radius of curves must be as large as possible to


prevent loss of load especially in the infeed stage and to avoid noise
problems at delivery.

we recommend you install a pressure gauge near the area where product is
fed into the homogenizer / piston pump in order to check infeed pressure; this
pressure gauge can be supplied as an optional by NIRO SOAVI and can be
standard, with minimum contact or with continuous analog signal for remote
control.

if filters need to be installed on the feeding line, you must allow a clear area
at least 3 times the size of the pipe used; you also need to install a pressure
gauge downstream the filter to check actual infeed pressure and prevent filter
clogging and danger of cavitation of the machine. For cleaning purposes we
recommend installing parallel filters to be used alternatingly.

every homogenizer or piston pump is characterized by pulsating operation:


for this reason, depending on the kind of system and machine flow, we
recommend you install a pulsation damper both for suction and delivery
(providing up to 20 bar maximum counterpressure on the line)

the pulsation damper is always recommended for flow rates exceeding


50006000 l/h; on the suction end, it must be installed as close as possible to
the machine inlet, while on the delivery end it must be installed on a
horizontal pipe at a distance of minimum 1 meter from adjacent bends. For
technical details about size and installation please contact NIRO SOAVI

the pulsation damper must be installed in a vertical position; do not install the
damper so that the flow enters the damper directly, otherwise the damper will
fill up too quickly and become less effective as no air will be left at the top

if the feed pump is connected to a tank, ensure that no air is sucked in by the
suction inlet through the creation of vortices by fitting suitable internal barriers
to divert the flow; the suction inlet must be sotto battente? at all times

we recommend you install a suitable safety valve downstream the


homogenizer or piston pump in order to protect the system from possible
overpressure caused by inexperience or incorrect operation procedures
downstream the machine; the safety valve fitted in the machine, even where
a piston pump is used, will protect the machine, but not the system to which it
is connected, in case of dangerous overpressure.

2C001E0C.DOC 2.8.7
Niro Soavi S.p.A

Never use the machine to fully drain the feeding tank, to avoid product
suddenly running out during operation under pressure, but provide at least
one level sensor to remove pressure (in the case of a homogenizer) and
stop the machine before the product being fed runs out

the product treated must contain no air or gas, to prevent cavitation problems
in the machine. If the product contains air because it is very viscous or due to
previous processing phases, you need to remove the air using appropriate
deaeration equipment

if processing temperature exceeds 90 C, it is absolutely necessary to


increase feeding pressure due to increased steam pressure which can lead
to cavitation.
Feeding pressure should therefore be increased by 1 bar for each 5 C of
temperature increase above 90 C added to the minimum feeding pressure
specified in Section 1 - TECHNICAL SPECIFICATIONS.
This value must be doubled in case of products with a viscosity value greater
than 500 cP.
For special products and special process temperatures contact NIRO SOAVI

the machine is fitted with automatic pumping spring valves; the load is
defined according to the type of valve and the characteristics of the product.
This means that if the machine has been stopped or is inactive, and the
feeding line is open and under pressure, you are able to check the flow of
product through the machine. To make sure there is no product flowing
through the machine when the machine is inactive, the user must provide a
cutoff valve for the feeding line upstream the machine.

2C001E0C.DOC 2.8.8
Niro Soavi S.p.A

2.8.6 POSITIONING THE ELECTRIC EQUIPMENT


Our machines are supplied in the standard version without electric power board;
this will be designed and constructed according to the specifications of the
machine as an optional; in any case the machine is fitted with a terminal box
which houses all the connections of the electric devices installed in the
machine, excluding the motors.

Where the electric board is supplied, and as a general recommendation, the


cabinet containing the electric control and power equipment - if not built in the
machine - should be placed as far as possible in clean, dry, ventilated premises
which should be free from vapour, suspended dust or corrosive release. Before
ordering the machine, the Customer should make sure that the intended place
of installation is suitable to protect the equipment from any aggression.
Besides, it should be ascertained that no heat sources are present in the vicinity
to avoid local overheating and ensure that all electric equipment can be cooled
down efficiently.
When forced ventilation is provided, any air vent should remain unobstructed. If
it has been established that the ambient air is not suitable for proper ventilation,
an air duct should be provided, in addition to selecting a control board suitable
for the particular operating conditions existing locally.
For the type, overall size, weight and installation requirements of the control
board, see Section 1 TECHNICAL SPECIFICATIONS (if the board has been
supplied by NIRO-SOAVI).

2C001E0C.DOC 2.8.9
Niro Soavi S.p.A

2.8.7 ELECTRICAL CONNECTIONS


The power line to the control board should be of appropriate type according to
the length, type of routing, ambient temperature, nature of the load, and always
in accordance with the provisions of the local regulations on this matter.
If no specific agreements have been made in writing with NIRO-SOAVI, the
user shall be responsible for establishing the features of the power line and
earthing conductor up to the terminal board of the machine, as well as selecting
appropriate protection devices against short-circuits and contact voltage.
Where the electric board is supplied by NIRO SOAVI we will provide a list of
cables with size calculated assuming a length of 50 meters, closed conduit with
three-pole cables and 40 C ambient temperature.
As far as the power details of the machine and wiring diagrams, reference
should be made to the electric specifications and diagrams shown in Section 1 -
TECHNICAL SPECIFICATIONS and in Section 6 WIRING DIAGRAM.

CAUTION: The indications given concerning the wiring refer to standard


laying and environmental conditions; the values shown are purely
indicative, therefore they should ALWAYS be cross-checked by the user
depending on the actual operating conditions.

The electric connections between machine and electric power board and
between electric power board and power mains must be made by the Customer
who is also responsible for checking that they have been properly executed and
that they comply with the wiring diagram, before the machine is started up.
NIRO SOAVI shall not be liable for injury to people or damage to objects
caused by incorrect connection of electric equipment; all electric connection
must be checked by authorized personnel.
If in doubt please contact NIRO SOAVI.

2C001E0C.DOC 2.8.10
Niro Soavi S.p.A

2.8.8 DIRECTION OF ROTATION OF ELECTRIC MOTORS


At the time of wiring, make sure that all motors rotate in the correct direction:

CAUTION: To check the direction of rotation, the motors should be


operated ONLY by impulses.
When performing these operations, follow strictly the safety rules and
stay away from any moving part inside the machine.
Remove only the panels on the LEFT HAND SIDE of the machine.
Before starting the machine, make sure that the protection panels on the
RIGHT HAND SIDE (drive) of the machine are in place.

main motor: the correct direction of rotation is shown by the arrow on the
flywheel; it is COUNTERCLOCKWISE for machines with FORCED
LUBRICATION and gear reducer); COUNTERCLOCKWISE for machines
with splash lubrication (see Section 1 - TECHNICAL SPECIFICATIONS),
unless otherwise specified by the direction of the arrows on the machine
(flywheel and/or motor)
oil pump motor (only for machines with motor-driven lubrication pump): follow
the direction of the arrow printed on the pump body. In case of mistake, the
low pressure in the circuit triggers the pressure switch, which prevents the
machine operation;
electric fan of main motor (only for machines designed for variable speed):
follow the direction indicated by the arrow;
electric fan of machine body: follow the direction indicated by the arrow;

Auxiliary motors may be installed depending on the type of machine: verify the
actual installation with reference to the technical sheet and the wiring diagrams,
Section 1 -TECHNICAL SPECIFICATIONS.
If the direction of rotation is not correct, reverse any of the two phases of the
supply cord.

CAUTION: Before starting the motors ensure that ONLY installation


personnel are present in the vicinity, and that NOBODY is in contact with
the machine.

2C001E0C.DOC 2.8.11
Niro Soavi S.p.A

2.9. SPECIAL NOTES

2.9.1 CONTROL BOARD TO BE PROVIDED BY THE CUSTOMER


If the electric power and control board (optional) is not supplied with the
machine, NIRO-SOAVI will include a Technical Sheet (Section 1 - TECHNICAL
SPECIFICATIONS) showing the electrical requirements of the machine,
together with an operation sequence to enable the Customer to establish the
elements of the control board and the operating features of the required
protection devices for a correct execution and the selection of appropriate
control and protection devices.

CAUTION: NIRO-SOAVI shall not be held liable for damages caused to


either persons or the machine due to mistakes made in the design and/or
execution of the control board.

CAUTION: The control board should be built in accordance with the local
operational and safety regulations in force.

2.9.2 ELECTRIC MOTOR SUPPLIED BY THE CUSTOMER

The electric motor shall be made in accordance with the general specifications
laid down by NIRO-SOAVI as to POWER, NUMBER OF POLES, SIZE,
SERVICE (Section 1 - TECHNICAL SPECIFICATIONS).

The motor shall be placed either on the supporting plate and secured by bolts in
the holes provided (or made at the time of installation) taking care that the
motive pulley is in line with the flywheel.

For information on installation and tensioning of V-belts see Section 3 -


MAINTENANCE.

2C001E0C.DOC 2.9.1
Niro Soavi S.p.A

2.10. NOTES ON MACHINE TEST

Before shipment all of our machines are accurately tested by qualified


personnel through operational tests which simulate the normal working
conditions.
Through the operational tests - run with cold water - it is possible to verify the
actual performance of the machine against the design data, the calibration of
safety, control and check devices, the conditions of any seals, as well as the
noise and vibration-free operation of the machine and the parameters
introduced in any programmable instruments or equipment that might be used.
To test the conditions of operation of the machine (flow rate with the maximum
operating pressure allowed, noise level, electric absorption) the machine is run
with water at a temperature of approximately 20 C, so it is possible to verify the
deviation of the machines actual flow rate compared to the rated value 5%
with product.
However, at the time of start-up, after the machine has been installed in the
production line, a final test of the conditions of operation is required.
Upon request of the Customer, NIRO SOAVI can dispatch an engineer for the
first machine start-up in order to check that the wiring has been executed
correctly and that the machine has been properly installed, besides providing
any additional information or instruction to the operators and service personnel
with reference to this Manual.

CAUTION: Should the Customer decide not to ask for the attendance of
our engineer at the time of the start-up, NIRO-SOAVI shall not be liable for
damages to persons or property caused by failure to observe the
instructions provided in this Manual (INSTRUCTIONS FOR USE AND
MAINTENANCE).

2C001E0C.DOC 2.10.1
Niro Soavi S.p.A

2.11. CLEANING THE MACHINE

The machine is supplied with external paneling in glazed stainless steel plate
(ARIETE version) which is easy to clean with water.
Washing prevents the deposit of product residuals on the machine: wash the
bodywork with running water from time to time, paying particular attention to the
compression head and the sump.
If required you may use a cloth and any standard mild detergent.
To prevent water from entering the machine, place a suitable covering over the
ventilation hole; do not wet the electric panel or the control panel.
The HERCULES industrial version is supplied without external paneling, but
only with protection panels to cover moving parts: in this case make sure you do
not wet unnecessarily the electrical components of the machine.

WARNING: Before washing with running water, make sure that power has
been cut off by means of the sectioning switch of the supply line that
should be locked with appropriate padlock.

2C001E0C.DOC 2.11.1
Niro Soavi S.p.A

2.12. DEMOLITION AND DISPOSAL

The demolition and disposal of the machine must be carried out in compliance
with various procedures according to the type of material to be disposed of.
First of all, it is necessary to:
- discharge lubricating and hydraulic oils for separate disposal;
- disassemble the electric system (components, cables and protection
sheaths) and all the plastic parts for separate disposal.
The machine is manufactured with the following materials, in various quantities:
- stainless steel;
- steel alloys and steel for construction purposes;
- cast iron.
The following are also present in very limited amounts:
- aluminium;
- copper;
- bronze;
- ceramic;
- PTFE;
- nitrile;
- viton;
- PVC.
- PEEK
- Elastomers and plastic materials.

All these materials must be disposed of in compliance with the regulations


currently in force in the country at the time of disposal.

2C001E0C.DOC 2.12.1
Niro Soavi S.p.A

2.13. OPTIONS

2.13.1 SECOND STAGE HOMOGENIZING VALVE


As an option, a second homogenizing stage can be installed on NIRO-SOAVI
Homogenizers in series with the first stage valve.
In this way it is possible to reduce the increase of viscosity produced by the
treatment of the product, in case it contains colloidal or thickening substances.
Although the micronization effects obtained with the 1 stage are unaffected, the
2nd homogenizing stage reduces the product viscosity and allows the
distributing of the pressure drop.
Moreover, it is possible to avoid the clustering of micronized particles, due to
the homogenizing effect.
The application of the 2nd stage should be decided on the basis of specific
considerations concerning the type of product.
As a general rule, the second stage pressure is usually applied as 1/10 to 1/5 of
the maximum homogenizing pressure, according to the processed product
requirements.

The formula which relates the homogenizing pressures in a two stage system
(see figure 2.13.1) is the following:

Ptot = P1 = P2 + dP

where:
Ptot = P1 is the total pressure measured on the compression head,
equivalent to the 1st stage pressure

P2 is the pressure applied to the 2nd stage

dP = P1 - P2 is the pressure difference between the 1st and the 2nd stage,
applied in the passage through the 1st stage valve.

Do not hesitate to contact NIRO-SOAVI for advice and clarifications.

2C001E0C.DOC 2.13.1
Niro Soavi S.p.A

P2

dP

Ptot = P1

FIGURE 2.13.1

2.13.2 ASEPTIC EXECUTION


Whenever a sterile plant and product needs to be ensured, an aseptic version
of the NIRO-SOAVI machine is available.
This can be achieved by running sterile condensate through the plungers in the
seal section and through the seal of the homogenizing valve shaft using
appropriate sterile chambers to avoid contamination from outside sources.
Condensate is produced by steam condensation at a temperature of
approximately 140 to 150C through water run in a heat exchanger.
The cooling water should be clean and preferably softened to avoid scaling
deposits in the exchanger.
Water hardness must be under 8 dH / 15 fH, with recommended chloride
value < 25 mg/liter and in no case greater than 200 mg/liter.
The required flow rate and water temperature values are indicated in the
consumption tables, Section 1 TECHNICAL SPECIFICATIONS.

2C001E0C.DOC 2.13.2
Niro Soavi S.p.A

2.13.2.1 STERILIZING THE MACHINE

Before starting up the machine following an extended period of standstill - or at


first start-up - we recommend sterilizing the areas to be maintained aseptic with
live steam (max temperature 150 C at 3.8 bar) and with the machine stopped:
to do so, open the steam on/off tap without sending any water to the exchanger.
After sterilizing cool down the system by flowing the sterile condensate obtained
from steam condensation through the aseptic circuit.
This operation should be performed with the machine stopped to avoid
damaging irreparably the seal packings of the plungers.
The machines product circuit can be sterilized using live steam or pressurized
water, with a maximum temperature of 150 C and for maximum 30 minutes. To
avoid damaging the seal packings of the plungers and thus reduce their life, we
recommend that you stop the machine before sterilizing it or that you alternate 1
minute operation phases with 10 minute stops (in case of fixed flow rate/speed
machines), or with the lowest speed possible in case of operation with
frequency converter.
During the sterilizing phase the alarm for " HIGH CONDENSATE
TEMPERATURE" may go on: you may either exclude it or just switch it off.

2.13.2.2 REGULATING THE FLOW OF COOLING WATER

During operation, the cooling water on/off valve (whether manual or solenoid)
should remain open.
An additional manual valve on the outlet of the exchanger has been provided to
control the water flow and obtain sterile condensate at a temperature of 40 to
50C. This has the extra advantage of helping reduce any waste of softened
water.

2.13.2.3 DESCALING AND WASHING

The use of water even when softened - for steam condensation inevitably
produces some deposits of lime in the exchanger.
Whenever a reduced exchange power is noticed - evidenced by an insufficiently
cooled condensation - a descaling of the aseptic system is required.
It is impossible to predict the frequency of this operation, since the formation of
lime deposits depends largely on the hardness of the water available.
For more details on maintenance operations, see Section 4 - MAINTENANCE.

2C001E0C.DOC 2.13.3
Niro Soavi S.p.A

2.13.3 PARTIAL HOMOGENIZING SYSTEM


NIRO SOAVI homogenizers can have installed, as an option, a partial
homogenizing system, to homogenize only a part of the total flow which is then
mixed with the remaining non homogenized part in a special mixing chamber
(see figure 2.13.2).
The homogenized part is normally around 30% of the total capacity of the
system.
A typical application is the homogenization of fresh milk where only the fat part
(milk cream) coming directly from the centrifuge is homogenized then mixed
downstream of the homogenizing valve to get fresh milk with standardized fat
content.
The system includes, in addition to the homogenizing valve, a special mixing
chamber featuring the recombination of the two portions using the high speed
turbulence of the flow, plus a by-pass system with pneumatic valve and check
valve (see figure 2.13.3) to feed the machine properly during the centrifuge
desludging phase and avoid underfeeding at the homogenizer inlet.
A typical scheme of partial homogenizing system is shown in figure 2.13.4.

FIGURE 2.13.2

2C001E0C.DOC 2.13.4
Niro Soavi S.p.A

2.13.3.1 HOW THE BYPASS SYSTEM WORKS

To make the by-pass circuit work properly, it is necessary to open and close the
pneumatic butterfly valve (position A, figure 2.13.3) with a signal coming from
the centrifuge.
This valve must be closed during normal operation, opened during desludging
phase and cleaning of the equipment.

FIGURE 2.13.3

Follow the instructions below for the correct operation of the system:
Open the pneumatic butterfly valve few seconds before the desludging phase
of the centrifuge; the single-acting check valve installed prevents the product
to be homogenized from flowing through the by-pass even when the butterfly
valve is open

2C001E0C.DOC 2.13.5
Niro Soavi S.p.A

Close the pneumatic butterfly valve few seconds after the desludging phase
of the centrifuge has been completed;

Keep downstream the homogenizer a minimum backpressure of 12 bar, to


allow the backflow of the homogenized product into the suction manifold
through the by-pass, when opened. Thus it is necessary to avoid a free
discharge into an open vessel or tank without pressure; if the backpressure
generated by the downstream plant is not enough to make the system work
properly, it will be necessary to install a suitable adjustable backpressure
valve.

WARNING: To ensure the complete and proper cleaning of the by-pass


circuit, it is necessary to keep the pneumatic butterfly valve (pos. A, figure
2.13.3) during the cleaning phase. Moreover, the backpressure
downstream the homogenizer must always be higher than the suction
side pressure.

SKIMMED 70%

515% 100%

CREAM 1525%

FIGURE 2.13.4

2C001E0C.DOC 2.13.6
Niro Soavi S.p.A

SECTION 3
OPERATION & USE OF THE MACHINE -
INDEX
3.1. GENERALS
3.2. CHECKS BEFORE START-UP
3.3. START-UP PROCEDURE
3.3.1 OPERATORS POSITION
3.3.2 CONTROL PANEL
3.3.3 START-UP
3.4. OPERATION AND ADJUSTMENT
3.4.1 HOMOGENIZING PRESSURE ADJUSTMENT 1 STAGE
3.4.2 HOMOGENIZING PRESSURE ADJUSTMENT - 2 STAGES
3.4.3 REMOTE PNEUMATIC CONTROL (OPTIONAL)
3.5. MACHINE STOP
3.5.1 EMERGENCY STOP
3.6. CLEANING
3.7. SAFETY DEVICES
3.7.1 OVERPRESSURE VALVE
3.7.1.1 OPERATION
3.7.1.2 CLEANING
3.7.2 PROTECTIONS ON MAIN MOTOR
3.7.3 EMERGENCY PUSH-BUTTON
3.7.4 COMPRESSION HEAD GUARD
3.8. TROUBLESHOOTING
3.9. SPECIAL FEATURES OF NON STANDARD MACHINES

3C001E0C.DOC 3.1.0
Niro Soavi S.p.A

3.1. GENERALS

The NIRO-SOAVI Homogenizer consists of a positive-displacement piston pump


provided with automatic valves with suction and delivery spring , connected to a
homogenizing section where the product undergoes the process of high-pressure
micronization to reduce the size of the solid particles suspended in the fluids and
achieve homogenous dimensional distribution.
This process can be applied to a wide range of products with variable viscosity,
and it allows to obtain more stable suspensions through micronization and
dissipation of solid particles, depending on the level of pressure applied.

To find out about the specific configuretion of the machine, model, technical data,
accessories and optionals, see Section 1 - TECHNICAL SPECIFICATIONS.

WARNING: For safety during transport, the machine is supplied


WITHOUT LUBRICATION OIL inside the drive section.
Before carrying out any operation fill with oil as described in Section 4
MAINTENANCE, paragraph 4.9 LUBRICATION.

3C001E0C.DOC 3.1.1
Niro Soavi S.p.A

3.2. CHECKS BEFORE START-UP

WARNING: The operating temperature of the machine must be between


+5C and +40C; maximum humidity 90%; maximume altitude 1000 m.
For operating conditions outside these value limits a special version must
be used.

WARNING: Any operation involving the removal of the machine panelling


should be performed with the MACHINE STOPPED AND ISOLATED from
the power line by locking the isolator switch with a padlock, so that
nobody can accidentally give power to the machine.

Since the NIRO-SOAVI homogenizer has been designed to reach high


pressures, good practice is to take certain precautions to avoid injuries/damage
to persons, the plant or the machine itself.
These instructions refer to the first startup or after period during which the
machine is not in constant use.
For correct and safe use of the machine we recommend that you carry out the
periodical check required depending on the type of machine use, to ensure the
machine is in perfect condition and prevent possible problems, if any; it is also a
good practice to check from time to time that the machine is being operated in
accordance with the prescription of the manual.
Specific indications concerning normal start are given in chapter 3.3.
Check the connections with utilities and product line. Refer to Section 1
TECHNICAL SPECIFICATIONS for their specifications and location.
Check that the pipes upstream and downstream the machine are clean and
free from scaling or welding residues which may damage the machine
seriously.

CAUTION: Do not use the machine to dispose of any impurities found in


the piping up- and downstream the machine

Check the V-belt drive assembly. For the correct tensioning and alignment of
belts refer to Section 4 - MAINTENANCE.

3C001E0C.DOC 3.2.1
Niro Soavi S.p.A

Verify the level of lubrication oil through the sightglass: this should be
covered with oil by 3/4 or reach the level shown on the special visual
indicator. When checking the oil level, the machine should be stopped,
because normally the start-up causes the level to lower as it fills the circuits.
If topping-up is needed, use only the oil types indicated in Section 4 -
MAINTENANCE.
For machines equipped with gear reducer, check the level of lubrication oil
through the inspection hole provided on the reducer. If topping-up is needed,
use only the oil type indicated in Section 4 -- MAINTENANCE.
Make sure that the high pressure flanges, unions and nuts in the
compression head are properly tightened to the values shown in the
"Tightening torque" table, Section 4 - MAINTENANCE, .
Verify that plungers are tight and that seal packings are in place, if they have
been removed during storage or after standstill of over 3 months.
Check the direction of rotation of motors as described in Section 2 -
GENERALS, chapter 2.8.7.
Make sure that all protection panels are in place and securely fixed.

CAUTION: Failure to observe the last recommendation here above may -


in case of machine starting - result in a severe risk of injury for anyone
standing near moving parts.

Make sure that the homogenizing pressure controls (figure 3.2.1) (air-
operated switch A and reducer B) are either completely loosened or on the
OFF position, and that any manual controls are fully loosened (fig.3.2.2)
Verify that all safety and protection devices are in perfect operating condition.
Make sure that any valves and parts of the system downstream the
homogenizer are open to prevent overpressure in pipes when the
homogenizer is started.

3C001E0C.DOC 3.2.2
Niro Soavi S.p.A

2
C

1
A

FIGURE 3.2.1

FIGURE 3.2.2

3C001E0C.DOC 3.2.3
Niro Soavi S.p.A

3.3. START-UP PROCEDURE

3.3.1 OPERATORS POSITION


To ensure the safe use of the machine during start-up and adjustment
operations, we recommend that the operator should stand as indicated in figure
3.3.1.
The control panel - configurated according to the Customer's requirements - is
on the left hand side of the machine front; an EMERGENCY STOP PUSH-
BUTTON is always fitted on each machine.

ATTENTION: Adequate free space must be provided in front of the


machine under any circumstances in order to allow immediate access to
the emergency push-button and any start/stop or setting devices.

FIGURE 3.3.1

3C001E0C.DOC 3.3.1
Niro Soavi S.p.A

3.3.2 CONTROL PANEL


The control panel is located on the front left side of the machine (in the Ariete
version with paneling).
There is a single panel for all the different languages which shows the symbols
and instruments used to control the machine (see fig. 3.3.2):
Emergency Stop push-button to halt the machine instantly in case of
emergency
On/Off push-button (indicated by the symbols I/O); general alarm light (with !
symbol). These controls are available only if the electric board has been
supplied by NIRO SOAVI
Pneumatic controls for adjustment of the homogenizing pressure (1st and 2nd
stage) consisting in an air-operated control to switch pressure ON and OFF
and a pneumatic regulator to increase or reduce pressure (shown on a
measuring scale)
Pressure gauges for controlling pressure of air sent to the pneumatic head
in order to reach homogenizing pressure.
Pressure gauge for controlling pressure of drive lubrication oil, identified by a
relevant symbol

NIRO SOAVI

FIGURE 3.3.2

3C001E0C.DOC 3.3.2
Niro Soavi S.p.A

3.3.3 START-UP
WARNING: The lubrication oil indicated in the specifications is suitable
for operating temperatures between +5C ed i +40C: DO NOT START the
machine if ambient temperature is lower than +5C to avoid damage to the
lubrication system.
Check with NIRO-SOAVI Customer Service for the type of lubricant
suitable for the specific local conditions.

ATTENTION: If ambient temperature is lower than +5C, do not start the


machine before checking the conditions of the plunger water lubrication
system and any water heat exchanger.

Once all preliminary checks have been completed, the machine can be started
following the procedure below.
Open all on/off valves on utility lines (water, air, steam) and regulate the flow
rates if necessary.

ATTENTION: The machine must NEVER be started without water for


plunger lubrication, otherwise serious damage could be caused to the
seal packings and plungers; with ceramic plungers, this incorrect
procedure may cause plungers failure because of thermal shock. For
further details on thermal shock problems with ceramic plungers see
Section 4 - MAINTENANCE.

WARNING: An excess of cooling water can lead to flooding of the sump or


excessive water splashing on guiding pistons, with the risk of water going
into the drive section. It is therefore important to check the water flow and
adjust it to approximately 60100 l/h per piston. The lubrication circuit
should be regularly drained to drain out any water that might have gone
inside the oil.

Feed the machine with product at the required flow rate and pressures as
indicated in Section 1 TECHNICAL SPECIFICATIONS.

WARNING: Feeding pressures lower than the limits given will cause
CAVITATION in the machine, recognized by the typical noise produced by
the head, which will seriously damage the whole machine. NIRO SOAVI
shall not be libale for breakages, malfunctions or damage to the machine
caused by CAVITATION even if this occurs during the 12 month guarantee
period.

3C001E0C.DOC 3.3.3
Niro Soavi S.p.A

Give power using the main switch on the electric power board
Press the start push-button. In case the control board has been supplied by
NIRO-SOAVI, this operation allows to start the machine according to the
correct sequence, depending on the type of machine and optionals provided:
- opening of any utility solenoid valve (optional)
- start of the oil motor-driven pump (if this type has been provided)
- start of electric fans (if provided)
- start of main motor.
In case the control board is supplied by the Customer, the correct operating
sequence is provided (see Section 1 TECHNICAL SPECIFICATIONS), and
should be observed strictly.
To identify the machine configuration refer to Section 1 TECHNICAL
SPECIFICATIONS.

3C001E0C.DOC 3.3.4
Niro Soavi S.p.A

3.4. OPERATION AND ADJUSTMENT

Once the machine has been started, before increasing the homogenizing
pressure, check that the machine itself is operating normally, with a particular
attention paid to the feed pressure, establishing it is stable and within limits as
prescribed in Section 1 TECHNICAL SPECIFICATIONS.
Then it is possible to operate the control devices in order to increase the
homogenizing pressure up to the desired process value.
If your machine is equipped with a second stage homogenizing valve, refer to
paragraph 3.4.2.

3.4.1 HOMOGENIZING PRESSURE ADJUSTMENT 1 STAGE


This type of adjustment, through an air-operated cylinder, controls the position
of the homogenizing valve to establish the homogenizing pressure.
On the machine front panel (see figure 3.4.1) it is located a pneumatic switch
(A) and a pressure regulator (B).
Adjustment operations consist of:
make sure that pressure reducer (B) is fully backed off, counterclockwise
set the pneumatic switch to ON position;
rotate the reducer knob clockwise until the desired homogenizing pressure is
obtained, by reading the reached value on the pressure gauge.

CAUTION: To allow a slow, gradual pressure increase, the pneumatic


adjustment system has been designed to ensure a certain inertia.
Operate the pressure regulator slowly while checking the actual
homogenizing pressure increase until the operating value has been
reached.

WARNING: check the increase of air pressure on the pneumatic head


using the pressure gauge installed on the panel control; this makes it
possible to have a slow increase of homogenizing pressure. It is also
possible to use the air pressure gauge to refer to if the head pressure
gauge is not working correctly.

Once the homogenizing pressure has been set to the desired value, lock the
reducer knob (B) by pressing it.

If the set pressure is the one used normally during production, the
homogenizing pressure can be applied or released by operating ONLY the
pneumatic selector (A), with the reducer left on the adjustment position.

3C001E0C.DOC 3.4.1
Niro Soavi S.p.A

CAUTION: this procedure is allowed ONLY for machines with operating


pressure up to 250 bar, to prevent overstressing the machine and avoid
too rapid an increase of pressure as this could cause the safety valve to
open.

2
C

1
A

FIGURE 3.4.1

3C001E0C.DOC 3.4.2
Niro Soavi S.p.A

3.4.2 HOMOGENIZING PRESSURE ADJUSTMENT - 2 STAGES


To adjust the pressure, follow the same steps as for the single-stage machine.
In order to adjust the pressure, please read carefully what is written in
paragraph 3.4.1, and in specific all warnings.
The pressure to be applied by the second stage varies from about 1/10 to 1/5 of
the maximum homogenizing pressure, according to the product handled.

WARNING: The intended homogenizing pressure value must be set FIRST


on the second stage, THEN on the first stage to reach the total desired
pressure.
A different operating sequence may result in SERIOUS RISK because the
machine may inadvertently and suddenly reach higher pressure values
than those for which the machine is designed..

Adjustment operations consist of (see figure 3.4.1):


make sure the pneumatic regulator is completely backed off counterclockwise
set the 2nd stage pneumatic switch (A) to ON position;
rotate the 2nd stage reducer knob (B) until the desired homogenizing
pressure is obtained, by reading the reached value on the pressure gauge.
set the 1st stage pneumatic switch (C) to ON position;
rotate the 1st stage reducer knob (D) until the desired homogenizing
pressure is obtained, by reading the reached value on the pressure gauge.

WARNING: To allow a slow, gradual pressure increase, the pneumatic


adjustment system has been designed to ensure a certain inertia.
Operate the pressure regulator slowly while checking the actual
homogenizing pressure increase until the operating value has been
reached.

ATTENTION: check the air pressure increase on the pneumatic adjuster


using the air pressure gauge located on the control panel; this allows a
slow rise of the pressure. It is also possible to use this air gauge as a
reference for the homogenizing pressure in case the main gauge on the
compression block is not working properly as a temporary solution to be
able to work with the machine.

Once the homogenizing pressure has been set to the desired value, block the
reducer knob (B and D) by pressing it.
If the set pressure is the one used normally during production, the
homogenizing pressure can be applied or released by operating ONLY the
pneumatic selector (A and C), with the reducer left on the adjustment position.

3C001E0C.DOC 3.4.3
Niro Soavi S.p.A

CAUTION: this procedure is allowed ONLY for machines with operating


pressure up to 250 bar, to prevent overstressing the machine and avoid
too rapid an increase of pressure.

CAUTION: To release homogenizing pressure in a two-stage system you


need to reverse the procedure used to give pressure.
Therefore first release pressure from the 1st stage and then from the 2nd
stage.

3C001E0C.DOC 3.4.4
Niro Soavi S.p.A

3.4.3 REMOTE PNEUMATIC CONTROL (OPTIONAL)


The pneumatic control for adjustment of homogenizing pressure can be
designed as a remote system using a proportional solenoid valve (requiring
minimum 7.5 bar air pressure supply) actuated by a 420 mA signal; the type
of system used depends on the configuration selected by the Customer.
The method for adjusting homogenizing pressure is the same as the one
described for standard pneumatic systems in paragraphs 3.4.1 and 3.4.2.
The supervision and control system (installed by the Customer) must send an
electric regulation signal to the proportional valves, with suitable ramp time and
graduality.

CAUTION: Even with remote control, if the system has two stage the
intended pressure value should be set FIRST on the second stage, THEN
on the first stage to reach the total desired pressure.
A different operative sequence may result in SERIOUS RISK because the
machine may inadvertently reach higher pressure values than those
designed for the machine.

It is important to send the signal gradually over approximately 30 seconds/1


minute to avoid a sudden increase of homogenizing pressure which could cause
the overpressure valve located on the compression head to open.
The remote control system via proportional solenoid valve uses also an
ON/OFF solenoid valve for switching pressure on and off; this can be installed
as an optional even with the manual control system instead of the pneumatic
switch (see paragraphs 3.4.1 e 3.4.2).

Another optional available is the automatic pressure control system, actuated by


a regulation loop which can also mount, as an optional, a pressure gauge with
420 mA analog outpu. Using this system it is possible to set an operating
pressure value which will be kept constant even if the operating conditions of
the machine or of the product change (e.g. variations in flow rate.
Fpr further information about operating and control features please contact
NIRO SOAVI.
Machines fitted with remote system for control of the homogenizing pressure
can also be equipped, upon request by the Customer, with local repetition of
remote controls for operation during servicing.
The use of the local system is described in paragraphs 3.4.1 and 3.4.2.

3C001E0C.DOC 3.4.5
Niro Soavi S.p.A

3.5. MACHINE STOP

To stop the machine, follow these steps:


release the homogenizing pressure by operating either the pneumatic switch
to the OFF position, or the remote control electric valve (or proportional
valve) via an appropriate electric signal
press the stop push-button (if available on the machines control panel) or
give a stop signal via the control system. For machines with electric board
supplied by NIRO-SOAVI this operation makes it possible to stop any
auxiliary electric motors and the main motor by following the correct
sequence given in Section 1 - TECHNICAL SPECIFICATIONS for Customers
who wish to make their own board if it has not been supplied by NIRO
SOAVI;
cut off power using the main switch.

3.5.1 EMERGENCY STOP


In case of dangerous situations or serious machine failure, the operation can be
immediately halted by pressing the emergency push-button located on the front
panel (figure 3.5.1)
After you have done that, release pressure following the procedure described
before.

WARNING: Before resuming the machine operation, elimitate the


condition which led to the emergency stop.

WARNING: By resetting the emergency push-button to its normal status,


the machine is not started automatically, but it is enabled to start
operating through the normal startup procedure.

S RGE
E N
M C
E Y

S T OP
FIGURE 3.5.1

3C001E0C.DOC 3.5.1
Niro Soavi S.p.A

3.6. CLEANING

A thouroug of the machine will maintain the sanitary or aseptic conditions as


necessary to avoid harmful deterioration or contamination of the product
handled.
When designing the machine, special care has been given to the parts in
contact with the product to make them easily cleanable (C.I.P.) and to avoid
recesses where the product may stagnate.
However, the following recommendations should be followed to ensure hygiene:
to avoid the formation of a product film on the inner surfaces and product
deposit, the machine should be cleaned IMMEDIATELY after production. Do
not allow the product to rest inside the machine, and do not let the empty
machine stand still without rinsing it;
make sure that any residue of chemical solution used for cleaning is
completely removed by rinsing the machine thoroughly;
if the cleaning solutions involve the use of concentrated products or powders,
first prepare the solutions separately in order to avoid any undissolved clods
or solid particles.

Cleaning should be performed in a closed cycle (C.I.P.) while the machine is


running at homogenizing pressure equal to zero (for homogenizers).
This allows avoiding energy waste and damage to the homogenizing valve.

WARNING: For the machines with variable or double capacity, the


cleaning should be performed at the maximum speed admitted, however
not exceeding the maximum operating capacity by more than 20% (see
Section 1 TECHNICAL SPECIFICATIONS).

WARNING: The products used for cleaning and rinsing of the equipment
should contain only the substances specified in Table 3.6.A.
The presence of CHLORINE and IODINE ions - including simple traces - is
very harmful to the materials used in the construction of the machine, as
it may lead to stress corrosion phenomena which may cause the
compression block failure in a short time and unpredictably.

3C001E0C.DOC 3.6.1
Niro Soavi S.p.A

TABLE 3.6.A

P R O D UCT max concentr. max temp. (C)


(%)

Caustic Soda (NaOH) 3 90


Nitric Acid (HNO3) 1 70
Phosphoric Acid (H3PO4) 3 85
Hot Water - 95
Hot Pressurized Water / Steam - 130

CAUTION: Dispose of the cleaning solution and washing fluids as


prescribed by the laws in force locally.

3C001E0C.DOC 3.6.2
Niro Soavi S.p.A

3.7. SAFETY DEVICES

NIRO-SOAVI machines are provided with safety devices to prevent reaching


critical conditions which may cause sudden breakage of the machine and
hazards for the personnel.
In addition the machines are designed with ample safety margins, in
consideration of high pressures which may be reached as a result of improper
operations by the user or failures of the line in which the machine has been
included.
The following safety devices have been incorporated: overpressure valve on the
compression head, electric protections on the main motor (if the machine
includes a control board), an emergency push-button and a guard to protect the
head, as described here below.

3.7.1 OVERPRESSURE VALVE


The pressure relief valve has been designed by NIRO-SOAVI to protect the
machine from the possibility of overpressure which might be producted inside
the compression head as a consequence of the pumping action of the machine.

CAUTION: The safety valve is used to protect the machine; piping


downstream the machine can be protected only if a valve is fitted on the
line.

ATTENTION: the valve protects only the pressurized chamber on which it


is installed.

It features the following advantages:


reduced maintenance
designed to "3-A" Standards, suitable for C.I.P.
it closes automatically in case the overpressure is released to allow the
immediate resuming of production
accurate calibration and repeatable actuation.

3C001E0C.DOC 3.7.1
Niro Soavi S.p.A

3.7.1.1 OPERATION

The valve consists of a ball maintained in place in its seat by a spring, which
allows it to open when the calibration set point is exceeded.
The spring loading should not be changed as this would modify the valve
opening value and cause the immediate forfeiture of the safety conditions
established by NIRO-SOAVI and the guarantee. Therefore a seal has been
applied to the spring load adjustment nut.
In the event the calibration setting is exceeded, the valve opens automatically
and lets the product flow out of the discharge pipe; it closes again when
pressure reduces below the opening value. This can be achieved by adjusting
the pressure regulating device until the valve is closing, or reducing the pump
speed in case of high pressure pumps.

Once the valve has closed again, normal operating pressure can be re-
established, provided the machine has not been damaged and the cause of
overpressure has been addressed.

ATTENTION: The discharge pipe must ALWAYS be directed downwards to


avoid harming the operator; the Customer shall be responsible to install a
funnel to collect the outcoming product and carry it to the drainage
system

ATTENTION: Dispose of any waste fluids as prescribed by the laws in


force locally.

ATTENTION: the valve seat of the overpressure relief valve is damaged to


some extent each time the valve blows. This will lower the pressure
setpoint of the safety valve. Therefore it is necessary to replace seat and
ball to recover the original setpoint conditions.

3C001E0C.DOC 3.7.2
Niro Soavi S.p.A

3.7.1.2 CLEANING

The part in contact with the product is normally cleaned during the machine
washing (C.I.P.).

CAUTION: it is ALWAYS necessary to disassemble the valve from the


compression head and clean it manually, especially the valve seat and the
discharge pipe, after any overpressure relief valve discharge.

For disassembling and maintenance, please refer to Section 4 -


MAINTENANCE.

CAUTION: Do not disassemble the valve body and do not remove the
plastic cap. Changes to the safety valve setting are not allowed and shall
invalidate the guarantee and affect protection of the machine, of its
components and of the operators, unless a written authorization has been
obtained from Niro Soavi.

3.7.2 PROTECTIONS ON MAIN MOTOR


If the machine is supplied by NIRO-SOAVI complete with electric power board,
this includes the electric protections suitable for the main motor power and
amps, type of starting device and conditions of operation. These protections
consist of magnetic and thermal cutout switches, quick fuses or automatic
switches for short-circuits, automatic switches or the frequency converter itself
for protection against overheating.
For the specific case see Section 1 TECHNICAL SPECIFICATIONS.

3.7.3 EMERGENCY PUSH-BUTTON


On the front panel of the machine there is installed an emergency stop push-
button (figure 3.5.1) of the colour prescribed by the safety standards in force.
This device allows the operator to stop the machine immediately in case of
hazardous situations for the personnel or the machine itself (abnormal
operation, unusual noise, risk of failures).
For the stop procedure and relevant notes see paragraph 3.5.
In the event that the machine is supplied complete with the electric power
board, the main switch can be used for emergency stops as well.

WARNING: When positioning the machine and making the connections


with the production line, allow enough space to reach the emergency stop
push-button of the machine quickly and without obstacles.

3C001E0C.DOC 3.7.3
Niro Soavi S.p.A

3.7.4 COMPRESSION HEAD GUARD


The compression head is provided with an additional guard to protect the
operator from any projection of machine parts, from high temperatures possibly
reached by the head and from any injury caused by protruding, sharp parts.

WARNING: The machine should not be used if the guard is not correctly
secured in place.

3C001E0C.DOC 3.7.4
Niro Soavi S.p.A

3.8. TROUBLESHOOTING

This chapter lists the most frequent problems which are likely to be encountered
during the machine operation, their possible causes and remedies in order to
restore normal working conditions.
If the failure persists, or does not appear among those listed below, our Service
Department will be pleased to give you the advice and means required to
achieve the best possible results.

TROUBLE POSSIBLE CAUSE REMEDY

1. The machine does main motor does not check the electrical
not run start wiring, fuses, automatic
switches

the drive belts are replace or tighten the


broken or loose belts
2. There is no product no feed flow or feed properly the
flow pressure to the machine machine (see Section 1
inlet TECHNICAL
SPECIFICATIONS)
feeding piping clean properly the
clogged or closed pipeline and filters
bypass valve (if any) close the bypass
opened valve
3. Reduced flow rate not enough feeding feed properly the
machine
not correct operation clean or remove
(wear) of suction / particles between valve
delivery valves and seat (see Section
4 - MAINTENANCE)
verify the wear
conditions of the seating
surface of the valves
and if needed replace

3C001E0C.DOC 3.8.1
Niro Soavi S.p.A

TROUBLE POSSIBLE CAUSE REMEDY

3. Reduced flow rate slipping belts


provide correct belts
tension (Section 4 -
MAINTENANCE)
low main motor speed verify the correct
motor speed (Section 1
TECHNICAL
SPECIFICATIONS)

leakage on plunger replace (Section 4 -


packings MAINTENANCE)
air into the product eliminate air
broken valve springs replace (Section 4 -
MAINTENANCE)
4. Noisy compression broken springs replace (Section 4 -
head MAINTENANCE)
not enough or too feed properly the
high feeding pressure machine
worn out pumping replace (Section 4 -
valves MAINTENANCE)
pumping valves not verify the valve
working properly cleaning and wear
air into the product eliminate air
5. Noisy drive end wear of bearings check,
lubricate/grease and
eventually replace the
bearings
loose plungers tighten (Section 4 -
MAINTENANCE)
not enough feeding feed properly the
pressure machine
6. Noisy belt drive slipping belts provide correct belts
tension (Section 4 -
MAINTENANCE)

3C001E0C.DOC 3.8.2
Niro Soavi S.p.A

TROUBLE POSSIBLE CAUSE REMEDY

7.Vibrations of the the machine is not check the machine


machine properly supported by level adjusting the feet
all feet height
not enough feeding feed properly the
pressure machine (see Section 1
TECHNICAL
SPECIFICATIONS)
pulsations at suction install suitable
and / or delivery pulsation damper
(contact Niro Soavi)
8.No cooling water on valve on water plant open
plungers closed
water filter clogged disassemble and
clean
no pressure in the check the required
water circuit water supply conditions
at Section 1
TECHNICAL
SPECIFICATIONS
9. Pulsating delivery not enough feeding feed properly the
pressure pressure machine
damaged or worn out replace (Section 4 -
pumping valves MAINTENANCE)
pump valves not Contact NIRO SOAVI
suitable for the product
valves springs not Contact NIRO SOAVI
suitable for the product
Unsteady Adjust the
backpressure backpressure

3C001E0C.DOC 3.8.3
Niro Soavi S.p.A

TROUBLE POSSIBLE CAUSE REMEDY

10.Total lack of Not enough flow See trouble point 3


homogenizing pressure
Damaged Check, clean or
homogenizing valve replace (Section 4 -
MAINTENANCE)
No air pressure in Check the pneumatic
pneumatic circuit circuit and the air supply
(Section 4 -
MAINTENANCE)
Defective pneumatic Replace
actuator
11.Homogenizing Not enough feeding Feed properly the
pressure not reached pressure machine
Blocked Disassemble and
homogenizing valve clean (Section 4
MAINTENANCE)
Worn out Replace (Section 4
homogenizing valve MAINTENANCE)
Faulty pressure gauge Replace (Section 4
MAINTENANCE)
Damaged Replace (Section 4
homogenizing valve MAINTENANCE)
shaft

3C001E0C.DOC 3.8.4
Niro Soavi S.p.A

TROUBLE POSSIBLE CAUSE REMEDY

12.Fluctuating Air or bubbles in the Remove air or


homogenizing pressure product bubbles

Air into the Release pressure,


compression head then apply pressure
again
Not enough or Feed properly the
unsteady feeding machine
pressure
Not correct operation
Check, clean or
of the pumping valves replace (Section 4
MAINTENANCE)
Not correct operation Check the pneumatic
of the homogenizing plant and dampening
valve dampening device device (Section 4
MAINTENANCE)
Pumping valves not Contact NIRO SOAVI
suitable for the product
Unsteady Adjust the
backpressure backpressure

13.Noisy homogenizing Worn out Replace (Section 4 -


valve homogenizing valve MAINTENANCE)

No oil or air pressure Check and restore


into the dampening correct operating
device conditions (Section 4
MAINTENANCE)

Resonance in the Modify the


plant backpressure; install
pulsation damper
dowstream; move away
the existing damper;
contact NIRO-SOAVI

3C001E0C.DOC 3.8.5
Niro Soavi S.p.A

TROUBLE POSSIBLE CAUSE REMEDY

14.Oil level drops Leakage in the Check the plant and


quickly lubricating circuit look for leakage,
replace gaskets, tighten
joints, replace the oil
cooler

15.White foam in the Water into the oil Stop the machine for
lubricating oil at least 1 hour and drain
water from lowest point
(Section 4
MAINTENANCE)

Water in the oil Pressure check the oil


because of broken oil cooler and replace
cooler
Excess of water on Adjust the water flow
the plungers to reduce splashing and
sump flooding
16. Oil overheats and Machine overload Eliminate overload
darkens
Faulty oil cooler or Check the oil cooler
lack of cooling water and the water flow
Worn out bearings Contact NIRO SOAVI
17.No oil flow and Wrong oil pump Change the direction
pressure rotation of rotation of the oil
pump (Section 2
GENARAL
INFORMATION)
Failure of the oil pump Contact NIRO SOAVI

3C001E0C.DOC 3.8.6
Niro Soavi S.p.A

TROUBLE POSSIBLE CAUSE REMEDY

18.Not enough oil Leakage on the Check the oil circuit,


pressure and lubricating circuit replace gaskets and
intervention of pressure tighten joints
switch
Low oil level Restore correct oil
level
Worn out sliding Contact NIRO SOAVI
bearings or crankshaft
Faulty pressure switch Check the pressure
switch and in case
replace; contact NIRO
SOAVI
Leaking oil cooler Check and replace;
contact NIRO SOAVI
19. Main motor Too high Reduce to nominal
overload homogenizing pressure value
Wear on drive end Check wear and
contact NIRO SOAVI
Too high belts tension Check belts tension
Faulty main motor Check main motor; in
case replace
20.Oil leakage in the Leakage from Replace gaskets
water sump crossheads seals (Section 4
MAINTENANCE)
Scratched crosshead Replace (contact
extensions NIRO SOAVI)

3C001E0C.DOC 3.8.7
Niro Soavi S.p.A

3.9. SPECIAL FEATURES OF NON STANDARD MACHINES

BLANK PAGE

Ricerca Guasti - 21.2


Niro Soavi S.p.A

SECTION 4
MAINTENANCE - INDEX
4.1. GENERAL INFORMATION
4.2. ORDINARY MAINTENANCE
4.3. TIGHENING BOLTS AND STUDS
4.4. COMPRESSION HEAD
4.5. HOMOGENIZING GROUP
4.6. OVERPRESSURE VALVE AND PRESSURE GAUGE
4.7. TRANSMISSION
4.8. POWER END - CRANKCASE
4.9. LUBRICATION
4.10. PNEUMATIC PLANT
4.11. ASEPTIC PLANT

4c00se0c.doc 4.0.1
Niro Soavi S.p.A

4.1. GENERALS

This Section contains the necessary information to maintain your machine in


perfect operating conditions.
The steps described are easy to follow and normally do not require the back-up
of a qualified technician.
However, NIRO-SOAVI Customer Service will be glad to provide the necessary
supplements of information and means to reach the target quickly and effectively
and to dispatch its technicians for on-the-spot assistance or as part of a Planned
Maintenance Service; please contact us for further information.
A careful reading and consulting of the Sections of this Manual are essential to
execute a correct maintenance and ensure a good, lasting performance of the
machine as well as compliance with safety regulations currently in force.

CAUTION: For the personnel safety, any check and maintenance operation
should be carried out with the MACHINE STOPPED and with the isolator
switch LOCKED (with the appropriate padlock) in the OPEN POSITION.

CAUTION: The use, access to internal parts and maintenance of the


machine should not be allowed to any personnel not acquainted with the
indications of this Manual, which should be made available to as many
operators as possible.

CAUTION: The only operations allowed are the ones described in this
INSTRUCTION MANUAL; for extraordinary work on the machine please
contact our Service Department.

4c010e0c.doc 4.1.1
Niro Soavi S.p.A

4.2. ORDINARY MAINTENANCE OPERATIONS

Here below are the tables showing the periodical maintenance required by the
machine to operate efficiently and safely.
Values shown refer to a normal use of the machine; heavy-duty conditions or
particularly abrasive/aggressive products may reduce sensibly the life of some
parts, which should therefore be checked more frequently.

In case of machine malfunction or abnormal noise, we suggest you try to


identify the components which seem to produce the noise and check whether
they have been correctly assembled and tightened or whether they might be
worn and in need of replacement.

In particular, machines operatine on very high pressure (over 600 bar)


require frequent servicing to replace gaskets, plunger seals, delivery
valves, valve seats and springs, homogenizing valves, depending on the
type of product used see the Table of Periodical Maintenance for high
pressure machines in addition to regular checks.

All the operations listed here below are described with detailed procedures in
the following paragraphs.

Execute carefully all the checks prescribed in these tables and note
scrupulously the DATE, MACHINE HOURS, OPERATOR in the Tables for the
checks to be performed every 1500 HOURS - 6 MONTHS and every 3000
HOURS - 12 NONTHS. In this way the machine will be maintained in the best
conditions of running and safety, and a track will be kept of the maintenance
operations actually completed.

CAUTION: The Periodical Maintenance tables shown below refer to normal


operating conditions and in any case provide merely an indication as to
the average life of a component and not a guarantee of minimum
component life.
Special conditions such as high operating pressure, high temperature,
steam sterilization and frequent washing, incorrect operating procedures,
can substantially affect the life of the machine and of its components and
therefore the intervals suggested for maintenance of compression head
components may vary significantly.

As additional tool for ordinary maintenance of the machine, please refer to the
form CHECKLIST FOR MACHINE INSPECTION at Section 5 SPARE
PARTS LIST.

4c010e0c.doc 4.2.1
Niro Soavi S.p.A

PERIODICAL MAINTENANCE TABLE GENERIC FOR ALL MACHINES

When Action required Machine hrs


After first start- Check belt tensioning 200
up replace lubrication oil 500
replace lubrication filter 500
Every day check oil level and top up and if needed
visual check for leaks in seals and gaskets
Once a week - visual check of plunger gaskets
40 hrs drain condensate from lubrication system
check tightening of nuts and plungers
check drive
check belt tensioning
check tightening of drive elements and
reducer support

When Action required Mach. Operator Date


(hrs) hrs
1500 and change lubrication oil
every clean/replace filters (lubrication
1500 hrs system, pneumatic system, water
system)
check drive belt wear, tensioning
and if required replace
check wear of plungers and if
required replace
check pressurization of pneumatic
system and oil level
check oil level in gear reducer
3000 and check / replace springs and
every pumping valves
3000 hrs check / replace homogenizing
valve
every replace lubrication oil in gear
5000 hrs reducer (mineral oil)

4c010e0c.doc 4.2.2
Niro Soavi S.p.A

When Action required Mach. Operator Date


(hrs) hrs
4500 change lubrication oil
clean/replace filters (lubrication
system, pneumatic system, water
system)
check drive belt wear, tensioning
and if required replace
check wear of plungers and if
required replace
check pressurization of pneumatic
system and oil level
6000 check / replace springs and
pumping valves
check / replace homogenizing
valve
7500 change lubrication oil
clean/replace filters (lubrication
system, pneumatic system, water
system)
check drive belt wear, tensioning
and if required replace
check wear of plungers and if
required replace
check pressurization of pneumatic
system and oil level
9000 check / replace springs and
pumping valves
check / replace homogenizing
valve
10500 change lubrication oil
clean/replace filters (lubrication
system, pneumatic system, water
system)
check drive belt wear, tensioning
and if required replace
check wear of plungers and if
required replace
check pressurization of pneumatic
system and oil level
12000 check / replace springs and
pumping valves
check / replace homogenizing
valve

4c010e0c.doc 4.2.3
Niro Soavi S.p.A

When Action required Mach. Operator Date


(hrs) hrs
13500 change lubrication oil
clean/replace filters (lubrication
system, pneumatic system, water
system)
check drive belt wear, tensioning
and if required replace
check wear of plungers and if
required replace
check pressurization of pneumatic
system and oil level
15000 check / replace springs and
pumping valves
check / replace homogenizing
valve

PERIODICAL MAINTENANCE TABLE FOR HIGH-PRESSURE MACHINES


(OVER 600 bar)

When Action required Machine hrs


Every 50 hrs visual check for leaks in packings and
head gaskets
check tightening of nuts in all high-
pressure head elements
Every 100 hrs check packings and head gaskets and if
required replace
check pumping valve seats and if required
replace
check ball valves and if required replace
check springs and if required replace
check homogenizing and if required
replace
Every 200 hrs check oil-air operated system for vibration
damping in homogenizing valve
check cooling water piping, check water
flow
tighten nuts in high-pressure head using
dynamometric wrench

4c010e0c.doc 4.2.4
Niro Soavi S.p.A

ORDINARY MAINTENANCE LOG

When Action required Mach. Operator Date


(hrs) hrs

4c010e0c.doc 4.2.5
Niro Soavi S.p.A

4.3. TIGHTENING NUTS AND STUDS

All the studs used in the compression head are subject to vibrating stress so, in
addition to being made of special, highly resistant material with an accurate
processing cycle, they require specific tightening in accordance with the values
shown in Table 4.3.1.
It is also necessary to frequently check screwn and nuts to make sure that they
do not become loose.
NIRO SOAVI supplies a Maintenance box with the wrenches needed for the
nuts fitted on their machines; we suggest you use a dynamometric wrench (not
included) to check tightening torques as specified in the table below.

STUD SIZE TIGHTENING TORQUE TIGHTENING TORQUE


(N*m) (lb.*ft.)

M8 8 10 6 8

M 10 15 20 11 15
M 12 25 30 19 22
M 16 60 70 44 52
M 20 120 140 89 104
M 24 210 230 155 170
M24x2 235 260 174 192
M 27 310 340 229 251
M27x2 350 390 258 288
M 30 410 450 304 332
M 33 560 600 413 445
M33x2 635 680 469 502
M39 880 960 650 709

TABLE 4.3.1

4c010e0c.doc 4.3.1
Niro Soavi S.p.A

ATTENTION: The head maintenance operations require disassembling the


parts which are secured by studs and nuts.
When tightening them, refer to the torque values shown in Table 4.3.1 to
avoid imposing abnormal stress and undermining their strentgh.

CAUTION: For safety reasons it is strictly forbidden to replace studs in the


high-pressure head with non-original spare parts, which might not be able
to stand the stress applied resulting in severe risk of injury!

4c010e0c.doc 4.3.2
Niro Soavi S.p.A

4.4. COMPRESSION HEAD (MULTI-BLOCK VHP)

ATTENTION: The compression head maintenance operations require to


remove the head guard, unscrewing the side screws.
The machine should not be used if the guard is not correctly secured in
place.

ATTENTION: The head maintenance operations require disassembling the


parts which are secured by stud bolts and nuts.
When tightening them, refer to the torque values shown in Table 4.3.1 to
avoid imposing abnormal or excessive stress and undermining their
strentgh.

Before giving a description of maintenance operations, it is important to


remember that couplings in high pressure seal areas are made with O-rings,
made of plastic or elastomers, sometimes fitted with anti-extrusion rings, made
with materials suitable for contact with the products handled and capable to
withstand the temperatures reached by the machine.
It is good practice to replace the gaskets not only when clearly leaking or when
damaged, but also every time you are reassembling parts which are in contact
with the gaskets.
Gaskets should be greased with a food-grade lubricant and assembled with
non-sharp tools which might damage them; in any case keep in mind that forced
or incorrect assembling can affect the life and seal of gaskets.
To identify and position gaskets correctly, refer to the drawings provided herein
for the disassembling of compression head and its components and to the
general drawings in Section 5 SPARE PART CATALOGUE.

These maintenance instructions refer in particular to very high pressure heads


Multi-Block VHP, especially designed and constructed with highly resistant
materials for safe and reliable performance under high-pressure operating
conditions..

ATTENTION: the compression head type Multi-Block VHP is built using


several parts connected together by studs and nuts. It is extremely
important to follow the correct assembling procedure to avoid possibile
misalignment of the parts with consequent not correct tightening of all the
gaskets. During assembly proceed carefully with progressive tightening
of ALL the nuts of the head one after the other and in cross, till the final
tightening with torque wrench (not supplied).

4C042E0C.DOC 4.4.1
Niro Soavi S.p.A

4.4.1 PUMPING PLUNGERS


The plungers normally supplied for very high pressure heads (VHP) are made of
solid ceramic.
This gives them high surface hardness and excellent resistance to wear, for
longer life of plunger gaskets.
The ceramic material used is compatible with most of the washing methods
normally used; if in doubt about the use of washing products contact Niro Soavi
for information and suggestions.

Ceramic plungers are sensitive to sudden temperature changes (thermal shock)


which can result in breakage.
You should therefore avoid sudden temperature changes above 70 C, and
check that lubrication water is always present to avoid local overheating of
plungers which can both damage gaskets and break plungers.
For this reason machines fitted with ceramic plungers are equipped with flow
switch which triggers an alarm to halt the machine.

CAUTION: if the machine is fitted with ceramic plungers, specific


instructions must be followed to prevent breakage of the plungers due to
thermal shock. More specifically you should bear in mind the following
information:
Thermal shock is due to rapid temperature change in the fluid which is
in contact with the plunger, exceeding approximately 70 C
Make absolutely sure that the plungers are not operated without liquid
even for a short period of time; the temperature generated on the
surface of the plunger due to friction can result in the plunger breaking
once the cooling water is opened
Avoid changing quickly from a hot liquid to a cold liquid even inside
the compression head, where the plunger moves alternatingly.
The temperature of water must remain within the specified range
(10+25 C or +40+60 C for aseptic machines). See Section 1 -
TECHNICAL SPECIFICATIONS
Temperature variation over time must be 70 C in 15 minutes (about 5
C per minute).

CAUTION: avoid to by-pass the alarm and machine stop if there is no


water for plunger lubrication. If the electric board is not supplied by Niro
Soavi, follow the steps given in the instructions to make the electric board
with the required protection devices.
The flow switch does not exclude the possibility of plungers breaking.

It is also absolutely necessary to assemble the plungers precisely as specified


to avoid misalignment problems with consequent breakage of the plunger.

4C042E0C.DOC 4.4.2
Niro Soavi S.p.A

CAUTION: it is important to periodically and regularly check tightness of


both plunger and plunger extension, whether with threaded connector or
clamp, to make sure that they will not loosen or disconnect during
machine operation, with consequent breakage of the plungers or of other
machine parts.

4.4.1.1 DISASSEMBLING

ATTENTION: Removing the plungers can result in damage to the gaskets


(packings) : check their condition and if necessary replace them before
assembling back the plungers and head (see paragraph 4.4.2). Before you
begin with disassembly make sure all the necessary spare parts are
available.

Ceramic pistons (figure 4.4.1) are fixed by a clamp (B): to remove them first
unscrew the clamps retaining screws (A) and move the plunger away from the
extension (C). To open the clamp it may help to insert one of the screws in the
middle bore of the clamp to expand it.

To pull the plunger away from the extension of the guide plunger you need to
rotate the crankshaft; to do this open the right side panel and rotate the
flywheel: follow the instructions and safety rules described in chapter 4.1 and
4.7.

FIGURE 4.4.1

4C042E0C.DOC 4.4.3
Niro Soavi S.p.A

In the VHP high-pressure head the plunger gaskets are housed inside
removable flanges which can be accessed from the read of the head, inside the
water sump.
For complete disassembly instructions see paragraph 4.4.2.

4.4.1.2 ASSEMBLING

CAUTION: The ceramic plungers fixed by clamps do not have a specific


direction for assembly, and can be mounted from either end.

To assemble the plungers refer also to the specific instructions given in


paragraph 4.4.2 describing packing assembly.
Below we describe the procedure for fixing the plungers which complements the
operations described above.

Once the flange which contains the packing and the plunger has been fixed on
the studs and on the special centering dowels, it is possible to fix each plunger
to its guide plunger, using a clamp (item. B, figure 4.4.1) and correctly tightening
the retaining screws. (tightening torque 78 N*m).

Take care not to bend the ceramic plungers as you risk breaking them.

CAUTION: We recommend you move the plungers to the outer dead


center (completely forward) by rotating the flywheel, while the guide
plungers must be taken back to the inner dead center (completely back),
in order to have more space for tightening the packing flanges.

CAUTION: Plungers must be mounted one by one, starting with the outer
and leaving the middle one(s) last for easier access.

Once all the nuts of the packing flanges have been tightened (see details in
paragraph 4.4.2) proceed as follows (figure 4.4.1):

Insert the clamp (B) onto the end of the guide plunge extension (C) or on the
part of the plunger which protrudes from the packing flange
Move the guide plunger extension completely forward, by rotating the
flywheel manually, until the plunger is right against the extension (C)
Move the clamp into position, against the diameter enlargement of the
extension, then tighten the clamp with the screws (A), by applying a 78 N*m
tightening torque.
Repeat this procedure for every plunger, starting with the outer ones.

4C042E0C.DOC 4.4.4
Niro Soavi S.p.A

CAUTION: During assembly make sure that the plunger and clamp are
fixed in the correct position, and that the various clamps do not interfere
with one another during alternating plunger movements. We therefore
suggest that you rotate the drive pulley by hand to verify that plunger
movement is correct.

CAUTION: tighten the nuts DIAGONALLY, as shown in figure 4.4.2; apply


the torque values given in table 4.3.1.

FIGURE 4.4.2

4C042E0C.DOC 4.4.5
Niro Soavi S.p.A

4.4.2 PLUNGER SEALS


The lifetime of these parts is dependent on the following factors:
- Working pressure
- conditions of plungers surface;
- process temperature;
- type of product;
- machine underfeeding (not enough feeding pressure, see Section 1
TECHNICAL SPECIFICATIONS for reference);
- worn out parts (washers, spacers) in contact with the seals.

The life of gaskets, and in particular of plunger packings, is not covered by


guarantee and cannot be estimated beforehand; we therefore suggest you
calculate the average life of the packings in order to schedule preventive
maintenance.
To avoid situations where production has to be stopped due to missing plunger
gaskets, we suggest you schedule preventive replacement on the basis of their
expected mean life.

In high-pressure machines, check and preventive replacement of packings


should be carried out every 100200 hours.
Replacement is necessary when you notice leaks from the sump; the production
cycle can be allowed to go on if the leak is not too big.

Plunger gaskets in high-pressure machines must be considered as one single


seal system, in which all the components contribute to the life and efficiency of
the gasket; we therefore recommend that you replace all the support and anti-
extrusion rings during maintenance work, in order to increase the life of the
sealing system.

For the maintenace procedure and seals replacement it is necessari to


disassemble the pumping plungers, therfore follow the specific directions of
paragraph 4.4.1.

CAUTION: Before you begin with maintenance and gasket replacement


make sure all the necessary spare parts and tools are available.

4C042E0C.DOC 4.4.6
Niro Soavi S.p.A

4.4.2.1 DISASSEMBLING

Plunger gaskets are housed inside the flanges located in the rear part of the
head, so disassembly must be carried out through the part of the sump behind
the head.

CAUTION: To carry out maintenance FIRST remove the packing of the


middle plunger (for machines with 3 plungers; of the central plungers for
machines with more than 3 plungers), THEN of the side plungers.

With reference to figure 4.4.3:


move the plunger all the way forward (outer dead center);
remove the plunger clamp (figure 4.4.1 item B) by loosening the screws
(figure 4.4.1 item A); if necessary insert one of the two screws in the middle
bore of the clamp to loosen it;
move the guide plunger all the way back (inner dead center);
disconnect water or sterile condensate pipe;
loosen the retaining nuts (N) of the packing flange (E) and remove it;
pull out the packing flange (F) together with the plunger, if necessary use a
lever on the flange (F);
remove the packing (H + R + M + L) and piston (G) from the flange (F).

4C042E0C.DOC 4.4.7
Niro Soavi S.p.A

FIGURE 4.4.3

FIGURE 4.4.3

4C042E0C.DOC 4.4.8
Niro Soavi S.p.A

4.4.2.2 ASSEMBLING

For assembly refer to figure 4.4.4, which shows how to assemble the elements
which make up the plunger packing:
prepare the rings (H) which are supplied ready cut and preformed
insert the rings in the flange which contains the packing (F) as specified
below
insert the plastic ring (R) to the bottom of the flange
insert, one at a time, the rings (H) which make up the seal packing, taking
care to stagger the joints regularly (for exambple by 120). If the packing is a
standard type with multiple V rings or a single plastic piece, insert it all in one
go.
Insert the plunger to give the rings the required shape
Insert the double conic washer (M) as shown in the picture, making sure that
the direction of assembly is the one shown in the cross section
Insert the packing washer (L); in some cases this washer can be made up
by two separate washers (L1, L2) made with both plastic and metal material.
Lay the retaining flange (E) against the rear part of the flange which contains
the packing (F)

FIGURE 4.4.4

4C042E0C.DOC 4.4.9
Niro Soavi S.p.A

Install the o-ring (P figure 4.4.3) or, where used, the antiextrusion (R) ring
on the front of the flange (F)
Insert the pre-assembled packing on the studs, check position against
centering dowels
Tightent the nuts diagonally (N)
Mount the plunger as described in paragraph 4.4.1

4.4.3 SUCTION AND DELIVERY VALVES


The good conditions of suction and delivery valves are essential for a trouble-
free operation of the machine; an impaired seal of the valves would cause
leakage and product backflow, resulting in pressure and flow instability.
The valve assembly (figure 4.4.5) consists in a ball, a seat, a spring, a guide for
the spring which acts as stop for the balls and a ball guiding element. In some
versions the valve seat and guiding element can be made into a single element
(figure 4.4.6).
Seat and ball are made of special hard alloys, very resistant to wear; these
however need to be replaced if they show signs of wear on the surface or if
pressure becomes unstable or the machines flow is reduced.
The spring tends to lose gradually the original elasticity and, for this reason, it
should be replaced approximately every 1000 hours of operation, unless broken
earlier generally because of the machine is not fed correctly.

For the replacement procedure of the valve assembly see here below; follow the
specific assembly drawings in Section 5 SPARE PARTS CATALOGUE.

4.4.3.1 DISASSEMBLING

To remove the valve assemblies requires:


On suction: disconnection and disassembly of suction manifold, disassembly
of retaining flanges of valve assembly (if separate from manifold, item U on
figure 4.4.3)
On delivery: disassembly of delivery manifold (A, figure 4.4.3). Before you
proceed with disassembly the homogenizing assembly must be removed
together with any other head accessories (pressure gauge, safety valve)

4C042E0C.DOC 4.4.10
Niro Soavi S.p.A

CAUTION: The components to be removed (suction manifold, flanges,


delivery manifold) are heavy. You need to wear personal protection
devices such as safety boots and gloves, and use suitable lifting gears.
The weight of the components can be calculated by assuming a specific
weight of approximately 8 kg/dm3. These operations require 2 people.

FIGURE 4.4.5

Once the manifolds have been removed, the valve assemblies for suction and
delivery are the same, with the configuration shown in figure 4.4.5 or 4.4.6.
Bear in mind that the seat (E) made of special wear-resistant material is forced
into the seat housing (A) so in case of replacement it must be removed with the
help of a press.

4C042E0C.DOC 4.4.11
Niro Soavi S.p.A

P
N

H
L

FIGURE 4.4.6

4.4.3.2 ASSEMBLING

To mount the valve assemblies refer to figures 4.4.5 and 4.4.6 (as an
alternative).
Carefully place the o-rings (H + N + F) and the relative anti-extrusion rings (L
+ P + G) in the slots provided, if necessary use food-grade vaseline to hold
them in position
For delivery valve assemblies, position the seat housing (A), and the guide
(M) where present, using the existing studs as guides
For suction valve assemblies, the seat housing (A), and the guide (M) where
present, must be placed on the bottom support flanges or on the suction
manifold itself, if made as one single element (depending on machine model)
Insert the inner components: ball (D), spring (C) and valve cap (B), making
sure that the position of the spring is correct
If necessary check that the ball (D) can be lifted, by pushing it from
underneath

4C042E0C.DOC 4.4.12
Niro Soavi S.p.A

Position the delivery manifold, and tighten the nuts using the torque values
specified in table 4.3.1. When tightening proceed gradually through ALL the
nuts and tighten them in circle with all the other parts of the head in place.
Position the retaining flanges of the suction valve assemblies, or the
complete suction manifold if made as one single elements (depending on
machine model), and tighten all the nuts using the torque values specified in
table 4.3.1
Mount the suction manifold

WARNING: when tightening the head nuts observe the tightening torques
shown in chapter 4.3, Table 4.3.1; use a torque wrench (not provided).

4.4.4 VALVE SEATS


Valve seats (figure 4.4.5 e 4.4.6, item E) are of removable type; they are made
from a particularly hard material to ensure wear resistance and longer lifetime.
Possible light marking by pricks on seat surface does not affect the valve
sealing and functionality.
The lifetime of the seats is normally longer than the one of the valves, and
depends on the characteristics of the product and on the working conditions of
the machine.
In case of particularly abrasive products, seats can be refurbished or replaced
when necessary.
To do this you need to remove the seats from their housing (figure 4.4.5 e 4.4.6,
item A); a press may be needed both for disassembly and then for re-assembly.
Once the seats have been installed, the operating pressure of the machine will
block them into position, so it is important to increase pressure very gradually
when the machine is first started-up after replacements.
To aseemble and disassemble the valve groups follow the directions at
paragraph 4.4.3.

CAUTION: The tools used for removing the valve seats are NOT included
in the maintenance box. Tightening of the head nuts must be made using
the torque values indicated in chapter 4.3, Table 4.3.1.; use a torque
wrench (not supplied).

4C042E0C.DOC 4.4.13
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4.5. HOMOGENIZING GROUP

4.5.1 HOMOGENIZING VALVE

The homogenizing valve consists of 3 parts (figure 4.5.1):


- lower head or passage head (A)
- impact head (B)
- impact ring (C).
The homogenizing effect occurs - at very high speed - during the passage
between the exposed surfaces of the two heads, and is completed by the
impact with the external ring.
The high pressure fluid dynamic effects which take place inside the
homogenizing valve are extremely complex; generally speaking it is possible to
describe the micronization of the particles dispersed in the liquid phase as a
resulting of combined turbulence, shear, local cavitation and high speed impact
effects.
These three parts, manufactured from very hard material, are normally subject
to more or less wear, depending on the type of product handled; therefore,
various effects resulting from wear or damage can be noticed on their surface:
- radial grooves developing from the internal diameter (fig. 22.14-S1);
- small craters next to the external diameter (fig. 22.14-S2);
- large craters and wear next to the internal diameter (fig. 22.15-S3).

B S1 S2

A
C

B
C

S3 S4

FIGURE 4.5.1

4c053e0c.doc 4.5.1
Niro Soavi S.p.A

When the grooves reach the external diameter, the homogenizing efficiency
collapses, therefore the component should be replaced either when the grooves
cover nearly 3/4 of the useful surface or whenever a reduced homogenizing
efficiency is noticed.
In some cases, because of extreme wear of the parts, the homogenizing
pressure cannot be achieved anymore, therefore the complete homogenizing
valve must be replaced.
Some local cavitation effects may sometimes create some craters or strong
wear path on the valve surface, therefore it is necessary to proceed with
replacement of the parts.
As far as the impact ring (figure 4.5.1 pos. C), it has the dual function of
completing the homogeneization by impact and protecting the body of the
homogenizing assembly from erosion.
Due to wear, a groove (S4) is produced on its internal surface, and good
performance is undermined.
We recommend replacing the ring when the groove is approximately 1 mm
deep.

CAUTION: the impact head and the passage head are manufactured from
a material whose hardness is suitable to withstand the abrasive action of
the product handled for a long time.
Whenever wear signs appear that may jeopardize the homogenizing
efficiency, working surfaces can be rectified to remove max 1 mm of
material: this can be done either at NIRO-SOAVI or at properly equipped
workshops.

ATTENTION: The above mentioned indications are related to normal


conditions and are general guidelines for ordinary and preventive
maintenance.
It in necessari to mention that the wear of the components of the
homogenizing valve is something absolutely NORMAL, and depends on
the various phenomenons which take place inside the homogenizing
valve. In case the wear of the valve is considered too fast, please contact
NIRO SOAVI for advice and possible alternative solutions.

4c053e0c.doc 4.5.2
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4.5.2 HOMOGENIZING GROUP

Follow the below listed instructions for the ordinary maintenance of the
pneumatic actuated homogenizing group.

DISASSEMBLING

Taking figure 4.5.2 as reference:


disconnect the line of the pneumatic-hydraulic control of the piston on the
front panel of the machine

CAUTION: oil dripping may occur when disconnecting the pipes of the
pneumatic-hydraulic system: provide a container to collect such oil and
dispose as prescribed by the local regulations.

CAUTION: the homogenizing assembly block is quite heavy! For all


handling operations use both hands to avoid any accident to the
personnel, and use suitable personal safety protections.

Loose the nuts (M) of the studs of the homogenizing group


Remove the pneumatic actuator group (L) and the supporting flange (N)
which are coupled through the screws (K)
pull out the guide (H) together with the shaft (S) on the impact head (G); if
needed you can lever on the slot provided
in case of excessive vibrations or noise produced by the valve, you need to
check the surface of the impact head shaft (S) and, if required, replace the
guide bushings (J) made of self-lubricating plastic material
Remove the homogenizing valve block (B) and put it on a suitable workbench

4c053e0c.doc 4.5.3
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FIGURA 4.5.2

Disassemble from the bottom the valve group parts (see details in picture
4.5.3): passage head spacer (Y), passage head (V) and impact ring (U)
The above mentioned items are assembled into an housing (D)
Remove also all the Oring gaskets (Z, W, E, F) and the antiextrusion rings
(A, C) if installed
Remove the guide (T) of the impact head (G) and check its inner surface; if
wear marks are present or there is excessive play between the guide (T) and
the impact head (G) it is necessary to replace it

4c053e0c.doc 4.5.4
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ASSEMBLING

CAUTION: the homogenizing assembly is normally subject to high


pressure and temperature conditions which impose a considerable stress
on the seal gaskets.
To ensure a correct operation and avoid product leakage or product
contamination, it is recommended to replace all gaskets every time that
the homogenizing group is disassembled.

CAUTION: to facilitate the gasket assembling, grease them with food-


grade Vaseline or similar.

FIGURA 4.5.3

Put the homogenizing valve chamber (B) on its side and insert the impact
head guide (T)
Put inside the impact head (G) and make sure this is not coming out of its
guide (T)
Assemble the impact ring (U)
Put the homogenizing valve chamber on the studs and push it towards the
compression head
Assemble the impact ring (U) and the passage head (V) inside the housing
(D), including the Orings (E, F), then put all the parts inside the valve
chamber (B)

4c053e0c.doc 4.5.5
Niro Soavi S.p.A

Insert the spacer (Y) complete with Oring gaskets (Z, W) and antiextrusion
rings (C, A), if present
Slide the homogenizing chamber on the studs towards the compression
head, taking care of the Oring (Z) and of the antiextrusion ring (A) to avoid
they can come out of position

Prepare for assembling the impact head shaft (S) and its guide (H) (figure
4.5.2):
Insert from the top the plastic bushings (J) inside the guide (H); this is usually
not required if the bushings are not removed from their location or are not
damaged
Place the gaskets (P) and (R) into their grooves
Put from the top the impact head shaft (S) into the guide (H) being careful not
to damage the gasket (P)
Check the smooth sliding of the impact head shaft (S) into the guide (H)

Proceed with assembling of the homogenizing group:


Insert the assembly guide and impact head into the homogenizing chamber
(B), from the top
Assemble the flange (N) together with the pneumatic actuator (L) on the
homogenizing chamber (B)
Tighten completely the nuts (M) in cross
Connect the piping of the pneumatic control system

The above indications are valid for both homogenizing valves, on machines
supplied with second stage homogenizing valve (available as option).

4c053e0c.doc 4.5.6
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4.5.3 POSSIBLE CONFIGURATIONS FOR THE HOMOGENIZING VALVE

A characteristic of the homogenizing assembly is that homogenizing valves of


different sizes can be installed in the same valve housing. In particular, with
reference to figure 4.5.4, the impact head (G) is made as one single element
with relative shaft.
In this case the spacer (T) is no longer used as guide for the impact head.
Maintenance procedures for disassembly and assembly of parts are the same:
the only difference is that the impact head is mounted together with the guide
(H) by inserting the shaft (G) from the bottom.
It is important to always refer to the specific detail drawings in Section 5
SPARE PARTS CATALOGUE.

FIGURE 4.5.4

4.5.4 PNEUMATIC ACTUATOR

The pneumatic control assembly - comprising a pneumatic actuator (L) - does


not require any particular maintenance (fig. 4.5.2).
In case of oil leak or difficulty to keep the homogenizing pressure not related to
any other cause (see Section 3 Chapter 3.8) it is possible to replace the
gaskets of the pneumatic actuator.
In order to replace the gaskets, it is necessary to ask for the necessary spare
set to the Niro Soavi Spare Parts Dept.
To remove the pneumatic actuator (L) it is necessary to remove the four screws
used to fix the actuator itself on its supporting flange.

4c053e0c.doc 4.5.7
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The pneumatic actuator cylinder, used to close the homogenizing valve and
achieve homogenizing pressure, is connected in the bottom part to an
hydraulic/pneumatic system for dampening pulsations.
The presence of air in the bottom part of the pneumatic cylinder may cause
incorrect operation of the dampening system resulting in abnormal noise level
and vibrations of the homogenizing valve, particularly if the machine operates
with two homogenizing stages.
In this case you need to eliminate the air by pressing the pneumatic switch 3 or
4 times to apply and release pressure.

Please follow the specific instructions listed at SECTION 4 Charter 4.10


Pneumatic Plant.

4.5.5 ASEPTIC VERSION

The homogenizing assembly used in the aseptic version is the same as the one
used in the sanitary version in terms of functional features; the only difference is
that the impact head shaft is flushed with sterile condensate used as barrier
fluid.
The homogenizing chamber body has all the connections with the system for
distributing sterile condensate, and the guide of the impact head shaft has
outlets for the condensate with relative gaskets, as shown in figure 4.5.7.

It is important to always refer to the specific detail drawings in SECTION 5


Spare Parts Catalogue.

FIGURE 4.5.7

4c053e0c.doc 4.5.8
Niro Soavi S.p.A

4.6. OVERPRESSURE VALVE AND PRESSURE GAUGE

4.6.1 OVERPRESSURE VALVE


The pressure relief valve (see SECTION 3 - Paragraph 3.7.1) is usually
installed on the compression head or on the high-pressure delivery line to
protect the machine and operators from accidental overpressure which can
create risk of danger.

Maintenance (figure 4.6.1) requires only checking and, if necessari, replacing


the sealing gaskets (B) between head and seat (D) of the valve, of the anti-
extrusion rings (A, C), of the ball (N) and of the valve seat (D).
To disassemble the valve from its operating position slowly loosen the nuts (G)
and pull out the complete valve (J) and the flange (F).
Loosening of the nuts (G) involves gradually releasing the spring load until the
ball pressing shaft reaches the elastic ring stop (L).
Once the whole valve body has been removed, you can remove the ball (N) and
then the seat (D); if necessary use an extractor for the extraction slot provided
in the seat (D).
After that remove the O-ring (B) and the anti-extrusion rings (A)and (C).

Make sure you do not lose the ball (E), as the valve cannot work without it; we
recommend you always keep a spare seat and ball in case you need to replace
them.
Valve maintenance does NOT require replacing the spring; to avoid sudden
release of the springs preloading DO NOT remove the elastic ring (L)..
Carefully clean the seat (B) from any product residues but take care not to
damage the sealing area.
If the sealing area between the seat (B) and the ball (N) is damaged or worn
out, there can be product leaks and the valve can be triggered at a pressure
value lower than the valve setting; we therefore recommend you replace the
seat and, if required, the ball.

Steps to be followed for disassembly:


- Insert anti-extrusion ring (A), gasket (B) and anti-extrusion ring (C) in
their housing in the head; food-grade Vaseline or other suitable
lubricants should be used for easier assembly
- Insert the seat (D) inside the housing in the head, complete with O-ring
gasket (E)
- place the ball (N) in position making sure it will not fall down, and fit the
complete valve body (J) with its flange (F) so that the middle shaft rests
on the ball (N)

4c063e0c.doc 4.6.1
Niro Soavi S.p.A

- the flange (F) will normally be separate from the beat due to the spring
preloading; to disassemble it you need to gradually loosen the nuts (G)
on the studs (H) until the valve is fully locked

For futher information on operation of the overpressure valve see paragraph


3.7.1.

WARNING: it is absolutely FORBIDDEN to modify the overpressure valve


setpoint and break the seal, unless with written authorization by NIRO
SOAVI.
In case of modification of the valve setpoint without authorization, the
warranty on the machine is immediately void, and moreover this may
cause ranger for the safety of the personnel using the machine, as the
overpressure relief valve is a fundamental safety device for the machine
accordino to the CE safety regulations.

CAUTION: It is absolutely FORBIDDEN to close the discharge pipe of the


overpressure valve with a valve. The valve discharge must always be
unobstructed and turned downwards.

4c063e0c.doc 4.6.2
Niro Soavi S.p.A

FIGURE 4.6.1

4c063e0c.doc 4.6.3
Niro Soavi S.p.A

4.6.2 PRESSURE GAUGE


The pressure gauge installed on the machine is a component of fundamental
importance as it makes it possible to measure the machines operating pressure
and thus keep its operation under control.
With a faulty pressure gauge the required working pressure cannot be
maintained, so we recommend you keep a spare pressure gauge in stock in
case a replacement is needed.
The type of pressure gauge installed can vary depending on the machine model
or if optional configuretions are used.
The standard pressure gauge is analog with Bourdon spring and sanitary baffle
separator especially designed by NIRO SOAVI; it is also equipped with a
separator used to filter the normal pulsations of the plunger machine to allow
steady readings of operating pressure.
Never separate the pressure gauge from its separator.
Other versions of pressure gauges or pressure measuring devices are available
as alternatives:
analog pressure gauge with signal transmitter: with 420 mA output for
remote transmission of pressure signal
pressure transducer: this is a sensor which gives an electric signal to be
amplified in order to obtain a 420 mA output of the pressure signal
digital pressure gauge with built-in display: this transducer has a display to
directly indicate the pressure value measured. Powered by internal battery.

The pressure gauge normally requires no maintenance, however we


recommend a periodical check to:
verify the condition of the diaphragm which comes into contact with the
product; if it is punctured or damaged the pressure gauge must be replaced
for analog pressure gauges, check the level of glicerine inside the dial; if
necessary fill the dial up to with 99.5% pure glicerine
replace the gasket between the pressure gauge and the head

For instruments provided with electric equipment refer to the wiring diagram,
which also indicates the setting range of the instrument.

4c063e0c.doc 4.6.4
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Refer to figure 4.6.2: to disassemble the pressure gauge (or pressure gauge
with transmitter, or pressure transducer) you need to loosen the nuts (G) and
pull out the pressure gauge complete with flange (F).
The pressure gauge (A) and flange (F) can be separated once the semi-rings
(D) have been removed.
Figure 4.6.3 shows the analog configuretion for disassembling the pressure
transducer.

FIGURE 4.6.2

Steps to be followed for assembly (figure 4.6.2 or 4.6.3):


- insert the gasket (E) on the pressure gauge rod (used only to protect from dirt)
-insert the gasket (G) inside its housing in the flange or head; food-grade
Vaseline or other suitable lubricants should be used for easier assembly

4c063e0c.doc 4.6.5
Niro Soavi S.p.A

- insert the anti-extrusion ring (C), if used, on the manometer; this ring is
used in high-pressure versions from 600 bar upwards
- insert the flange (F) on the pressare gauge body (A) and fit the two semi-
rings (D) to hold the flange in position
- insert the pressure gauge prepared in this way into its housing, and place
the flange (F) on the studs (H)
- screw the nuts on (G) by hand before tightening them fully.

FIGURE 4.6.3

4c063e0c.doc 4.6.6
Niro Soavi S.p.A

In high-pressure versions, equipped with transducer (T) or digital pressure


gauge (M) (see figure 4.6.4), a threaded locking ring (D) is used.

FIGURE 4.6.4
For disassembly, unscrew the ring (D) and pull the instrument out; remove also
the gasket (B) and anti-extrusion rings (A, C) from their housing.

For assembly follow these steps (figure 4.6.4):


- fit anti-extrusion ring (C), gasket (B) and anti-extrusion ring (A) onto the
end of the pressure gauge (M) or transducer (T); food-grade Vaseline or
other suitable lubricants should be used for easier assembly
- fit the pressure gauge (M) or transducer (T) into its housing; with digital
pressure gauges make sure you do not force the element using the
head of the instrument to prevent breakages
- tighten the locking ring (D) fully

4c063e0c.doc 4.6.7
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The digital pressure gauge (M) will switch off automatically after a few
minutes if no pressure is measured, to preserve the internal battery.

To start the pressure gauge simply press the front ZERO/ON push-button;
keep this button pressed for a few seconds to reset the instrument to ZERO
if the reading given is NEGATIVE.

If the display reads BATT it means that the battery is down and needs to
be replaced.
Disassemble the pressure gauge and, on a dry surface, remove the rear
screws to lift off the cover on the battery housing. The battery used is a long
life 9V lithium battery, size PP3; in special circumstances a standard 9V
alkaline battery may be used.

4c063e0c.doc 4.6.8
Niro Soavi S.p.A

4.7. TRANSMISSION

The machine is equipped with a direct trapezoidal belt drive system which uses
pulleys on the motor shaft and crankshaft.

CAUTION: All inspection and maintenance operations must be carried out


with the MACHINE NOT IN OPERATION; the power mains switch must be
LOCKED IN THE ON POSITION (with a padlock) for the safety of personnel.

The elements of the drive system usually require only a visual inspection, carried
out with the machine not in operation, to check for possibile lubrication oil leaks
and, more importantly, for loosening of nuts, bolts, belt tensioning components
and reduction gear support parts.
Excessive movement of drive components, due to loosening of locking elements
caused by vibrations, can result in slack couplings and consequent breakage of
elements during machine operation.

CAUTION: It is important to regularly check tightening of nuts and bolts in


the belt tensioning system and reduction gear support system. Abnormal
vibrations due to incorrect machine operation or cavitation conditions can
cause these components to loosen and damage the drive system.

Instructions for maintenance of drive components are given below.

4c072e0c.doc 4.7.1
Niro Soavi S.p.A

4.7.1 INSTALLING THE BELTS

CAUTION: All inspection and maintenance operations must be carried out


with the MACHINE NOT IN OPERATION; the power mains switch must be
LOCKED IN THE ON POSITION (with a padlock) for the safety of personnel.

INSPECTION OF THE PULLEYS

Worn pulleys significantly reduce the life of belts, which can touch the bottom of
the groove causing slipping which provokes wear and superficial burning.
If the sides of the groove are hollow, the contact between the sides of the belt
and the pulley is not uniform, and the lower part of the pulley causes wear of the
lower edge of the belt, causing it to break prematurely.
Thus, it is necessary to check the state of wear of the pulleys and remove any
rust, grease or oil that may be present.

ALIGNMENT CHECK

Correct alignment is essential to ensure long-life of the drive belts.


This operation must be carried out during assembly by skilled personnel: it is
important to check alignment by placing a metal ruler on the 2 pulleys (fig.4.7.2).

FIGURE 4.7.2

If necessary alignment can be corrected by loosening the retaining bolts of the


conic bush and slightly move the driven pulley (by a few mm.) to reach optimal
position then lock the bushing.

4c072e0c.doc 4.7.2
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SELECTION OF BELTS

Use at the same time belts of the same make, of the same type and of the same
lot, since there may be differences both in size and in performance.
Moreover, it is essential not to use new belts with others that have already been
used, because of a different extension, adjustment to the grooves of the pulleys,
and differences in performance, which would considerably affect the duration of
the drive train.
In order to ensure correct operation and avoid premature breaking, the belts must
be stored without any noticeable bends and must not be exposed to
temperatures that are too high or too low, or to a high degree of humidity.

ASSEMBLY OF THE BELTS

On NIRO SOAVI machines equipped with direct V-belt drive the motor unit which
carries the driving pulley is mounted on a mobile support.

An adjustable tie rod makes it possible to change the distance between the
driving pulley and the driven one to allow installation and tensioning of the driving
belts.

To ad just the position of the motor support plate, it is necessary to tighten or


loose the tensioner with appropriate lever.

For correct belts tensioning refer to paragraph 4.7.3.

During installation belts must never be forced with a tool into the pulleys grooves
to avoid the risk of damaging both thus reducing the life of the drive.
To make this operation easier simply reduce the distance between the pulleys.
Fit the belts into the grooves and rotate the pulley to facilitate insertion and
prevent damage.

4c072e0c.doc 4.7.3
Niro Soavi S.p.A

FIGURE 4.7.3

4c072e0c.doc 4.7.4
Niro Soavi S.p.A

4.7.2 STRETCHING THE BELTS

WARNING: Control and servicing operations must be carried out WITH THE
MACHINE NOT IN OPERATION and with the sectioning switch of the imput
line LOCKED (by means of a lock) IN OPEN POSITION for the safety of the
personnel.

WARNING: The V-belt transmission may create danger of crushing or


entrapment. Use always the necessary fixed protections and in case
remove them only after having checked the machine to be completely
stopped in any moving part.

The ideal stretch is the lowest at which the belts do not slip under maximum load.
During the first 24-48 hours of running-in, check the stretch frequently; remember
that excessive stretch reduces the life of the belts and of the bearings that
support the drive.
Arrange for the stretch to be tightened as soon as any slipping occurs.

Belt slipping can cause overheating and create hazard particularly if the machine
is designed for operation in danger zones (explosion-proof version).

The following are two methods to identify the correct degree of stretching of the
belts; the first, which is easier, can be used when a new train of belts is installed,
or after loosening them completely; the second allows stretch to be checked even
during normal operations of servicing and control. The procedures of the
operations are described in paragraph 4.7.1.

4c072e0c.doc 4.7.5
Niro Soavi S.p.A

BELTS TENSIONING FIRST METHOD

Before stretching the belts assembled on the pulleys, trace two fine marks across
the back of one belt and measure the distance between them; they should be as
far from each other as possible but must remain on the straight-line of the belt.
Stretch the belts gradually after having them rotate for approx. 1 minute in
successive stages; at each stage, tighten the belts so that the distance between
the two marks has a percentage increase as shown in table 4.7.4, considering
the case of medium diameter pulleys.

Type of transmission Not constant Torque


- one small size pulley
0,8%
- short shaft center distance
- medium or big size pulleys
1%
- medium or big shaft center distance

TABLE 4.7.4

BELTS TENSIONING SECOND METHOD

Measure the length of the free section "t" (figure 4.7.5) and apply to its half-point
a force P perpendicular to the belt, that causes a deformation of 1.6 mm every
100 mm. of free length:

F=1,6 x T/100 (mm)

The intensity of the force, in Newton, should be in the interval of values shown in
table 4.7.6; it is measured by means of a special dynamometer which is not
supplied.
In order to calculate the peripheral speed value it is sufficient to use the formula:

V = 0.052 X n X d (m/s)

where n is the number of revolutions per minute of the crankshaft, as indicated in


SECTION 1 TECHNICAL SPECIFICATIONS, and d is the diameter of the
flywheel indicated in metres.
It is important to remember that at the first stretching, the correct value is 1.3
times the maximum value shown in table 4.7.6, so as to compensate the natural
extension and initial settling of the belts.

4c072e0c.doc 4.7.6
Niro Soavi S.p.A

FIGURE 4.7.5

Forza / Force P (Newton)


Tipo / Type D (mm)
V = 010 m/s V = 1020 m/s V = 2030 m/s
6795 12 18 10 16 8 - 14
SPZ
> 95 19 26 17 24 15 22
100140 22 32 18 26 15 22
SPA
> 141 33 48 27 40 23 34
160265 38 56 32 50 28 42
SPB
> 266 57 72 51 64 43 58
224355 72 102 60 90 50 80
SPC
> 356 103 132 91 120 81 - 110

TABLE 4.7.6

4c072e0c.doc 4.7.7
Niro Soavi S.p.A

4.7.3 MAINTENANCE OF BELTS

The belt drive is an efficient, reliable means for power transmission.


The following are some simple instructions to ensure reliability and long life of the
system.

LOOK AND LISTEN


This allows you to easily identify the defects to be corrected:
- Visual check if any oil or grease is present on the belts, since this may cause
premature deterioration; excess oil on the supports and bearings may cause the
belts to be dirtied, while a lack may cause increased friction and subsequent
burning of the belts due to overload.
- Listening to the noise during transmission.
If there is any screeching when the motor accelerates or during operation at full
load, this means that there is insufficent stretch of the belts.
Once the correct stretch has been restored, if the noise persists try to identify any
overload in transmission (due to wear, seizure, insufficient lubrication...).
The presence of a regular squeaking, similar to that of a bearing that is
insufficiently lubricated, does not cause any damage to the transmission and may
be caused by the presence of dirt.
Do not try to eliminate this noise by oiling the belts.

DIRT AND FOREIGN MATERIALS


Dirt and dust may accelerate wear of the belts and pulleys and obstruct a good
traction.
It is necessary to regularly clean the drive system and prevent any foreign
material from being trapped between the belts and pulleys.

OVERLOADS
Any overload shortens the life of the belts.
Check that operation is taking place under the initial project conditions, and that
no overloads occur due to wear or slipping and superficial burning.

PROTECTIONS
The drive should always be protected by a suitable guard, which not only protects
the operators but also protects the parts from dust or dirt and contact with foreign
objects which may cause serious damage to the system.

BREAKING AND CRACKS


Check the condition of the belts, and see if there are any cuts or cracks, that are
a sign of excessive wear and the need to replace the part.

4c072e0c.doc 4.7.8
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TENSIONING
Check and maintain the correct stretch of the belts, to prevent irregular
vibrations.

EXPOSURE TO HEAT
Check that the belts are not exposed to sources of heat; an exposure to
temperatures greater than 60C will shorten their life.

WEAR
Check the condition of the sides of the belt: an anomalous wear may cause
slipping or excessive wear of the grooves of the pulleys.

4c072e0c.doc 4.7.9
Niro Soavi S.p.A

4.7.4 ASSEMBLING AND DISASSEMBLING PULLEYS

Drive pulleys are usually mounted both on the crankshaft drive end and on the
motor shaft using a Taper-Lock conical bushings.
With reference to figure 4.7.6, the procedure for disassembly is the following:

FIGURE 4.7.6

- loosen retaining screws A


- use one of the screws in bore B to force the bush open
- extract the bush and pulley from the shaft.

Assembly procedure:
- clean bush and shaft thoroughly
- insert Taper-Lock bush into pulley
- partially insert threaded screws into bores (A)
- mount the pulley on the shaft
- align the pulleys
- tighten screws A fully

If the motor pulley is not fitted with a Taper-Lock bushing, to install or remove
the pulley use a suitable pulley extractor and threaded rod for mounting the shaft,
using the threaded bore on the end of it.

4c072e0c.doc 4.7.10
Niro Soavi S.p.A

4.8. POWER END - CRANKCASE

The reciprocating linear motion of the plungers is created by an oversized and


sturdy crank mechanism (crankshaft, connecting rod, crosshead).
The system is illustrated in the general exploded view (figure 4.8.1) below.

FIGURE 4.8.1

The type of construction, the high-quality materials used and the careful
assembly by highly-qualified personnel are a guarantee of excellent reliability and
durability.

Correct lubrication is fundamental for the life of the drive body and of its
components, so it is absolutely necessary to comply with the instructions given in
terms of recommended change frequency (Chapter 4.2), filter cleaning, level and
type of lubricant used (Chpater 4.9).

Under normal conditions the power end does not require servicing. Should you
notice abnormal noise levels, irregular machine operation or low pressure of
lubrication oil triggering the pressare switch, contact NIRO SOAVIs Customer
Service to request technical service.

4c081e0c.doc 4.8.1
Niro Soavi S.p.A

Under normal working conditions and without specific faults, it is recommended


to check the sleeve bearings (W) and crank pin bearings (S), the wrist pin (O)
and its bearing on the conrod (R) at least every approx 10.000 hours of
operation, and to check the roller bearings (B) of the crankshaft at least every
20.000 hours of operation.
Such kind of maintenance requires skilled personnel, therefore it is
recommended to contact NIRO SOAVI Customer Service for advice and support.

The only ordinary maintenance operation required is replacement of guide


plunger gaskets, in case of lubrication oil leaks inside the sump.
If the surface of the crosshead extension is badly scratched, it is necessary to
replace the complet guide pistons.
Such kind of maintenance requires skilled personnel, therefore it is
recommended to contact NIRO SOAVI Customer Service for advice and support.

CAUTION: All inspection and maintenance operations must be carried out


with the MACHINE NOT IN OPERATION; the power mains switch must be
LOCKED IN THE ON POSITION (with a padlock) for the safety of personnel.

WARNING: Lubricating oils are extremely harmful to environment and


should be disposed of correctly in suitable disposable, in accordance with
the local regulations, to avoid environment and water pollution.

4c081e0c.doc 4.8.2
Niro Soavi S.p.A

4.8.1 REPLACING GUIDE PLUNGER GASKETS

Before removing the flanges you need to drain out, at least partially, the oil
inside the body to prevent accidental spillage.
Refer to figure 4.8.2 for the assembly and disassembly procedures described
below.

FIGURA 4.8.2

DISASSEMBLY
remove the plunger following the procedure described in Charter 4.4
loosen the screws (K) and extract the flange (M) from the guide plunger (Q)
remove the scraping ring (L) and the seal gasket (J)

ASSEMBLY
fit the scraping ring (L) and gasket (J) inside the flange (M), in the seat.
check and clean the plunger stem, if the surface is badly scored or the chrome
plate damages the whole plunger must be replaced. The guide plunger stem
cannot be supplied separately as spare part
insert the complete O-Ring flange (H) onto the guide plunger (Q) as far as the
edge. During assembly take care not to damage the sealing lip of the gaskets;
use lubrication grease for easier assembly
- tighten the screws (K).

4c081e0c.doc 4.8.3
Niro Soavi S.p.A

In some models a rubber bellows is installed to protect the guide plunger stem. In
this case the bellows must be removed to replace the gaskets, and then inserted
onto the guide plunger stem (Q) and snapped on locked against the flange (M) in
the seat provided.

4c081e0c.doc 4.8.4
Niro Soavi S.p.A

4.9. LUBRICATION

Proper machine lubrication is required to guarantee its correct operation.


For this reason it is absolutely necessari to follow directions for oil change
intervals (see Charter 4.2), the cleaning or replacement of filters, check of oil
level and use of specified lubricating oil.

The lubrication system can be either FORCED or SPLASH, depending on the


machine model; see Section 1 TECHNICAL SPECIFICATIONS to find out
type of lubrication used.

For topping-up and replacement use ONLY the oils shown in Table 4.9.1; table
4.9.2 indicates the capacity of the lubrication system for the various models.

CAUTION: The lubrication oil is suitable for operating temperatures


ranging from 5C and +40C: please contanct NIRO-SOAVI Customer
Service to obtain the type of lubricant suitable for any specific conditions
found locally.

CAUTION: Used oils are extremely harmful to environment and should be


disposed of correctly, in accordance with the local regulations.

CAUTION: All inspection and maintenance operations must be carried out


with the MACHINE NOT IN OPERATION; the power mains switch must be
LOCKED IN THE ON POSITION (with a padlock) for the safety of
personnel.

It is important to periodically ensure there is no foam in the oil as this is a sign


that air is being incorporated due to cavitation in the oil pump or to bad sealing
of the lubrication circuit. You also need to check for a whitish water/oil emulsion
which is caused by inefficient drainage of condensate or water infiltrations
inside the body (faulty water/oil exchanger or worn guide plunger gaskets).

4c092e0c.doc 4.9.1
Niro Soavi S.p.A

Any type of oil used should have the following specifications:


Suitable for hydraulic circuits, of mineral origin, viscosity ISO VG 150 (150 cSt
at 40C) with non-foaming, antioxidative additives, etc.

Class: ISO VG 150


DIN 51524-2-HLP

BRAND TYPE BRAND TYPE


Agip Oso 150 Texaco Rando oil HP 150

IP Hydrus Oil 150 Gulf Harmony 150 AW

BP Energol HLP-HM Amoco American


150 industrial oil 150

Mobil DTE 19M Total Azolla ZS 150

Mobil DTE Extra Heavy Fina Hyidran 150

Chevron EP Hydr. oil 150 Api Cis 150

Castrol Hyspin AWS 150 Kuwait Petr. Int. Q8 haidn 150

Esso/Exxon Nuto H 150 ELF Olna DS 150

Shell Omala 150 ARAL Motanol HP150

TABLE 4.9.1

MODEL OIL VOLUME (liters) OIL VOLUME (liters)


WITH OIL PUMP SPLASH SYSTEM
NS 1003 1,2
NS 2006 3,0 1,5
NS 3006 4,5 3,0
NS 3011 8,5 6,0
NS 3015 20
NS 3018 20
NS 4022 24
NS 3037 28
NS 3075 30
NS 3110 38
NS 5132 55
NS 5160 55
NS 6200 125
NS 8315 150
TABLE 4.9.2

4c092e0c.doc 4.9.2
Niro Soavi S.p.A

4.9.1 SPLASH LUBRICATION

Splash-type lubrication is used to lubricate the moving parts by effect of their


own movement inside the oil which is contained into the crankcase.
In specific the parts subject to splash lubrication are:
- Conrod bearings
- Sleeve bearings (if present)
- Guiding piston (crosshead)
- Wrist pin and related bearing
- Roller bearings supporting the crankshaft ends

Splashing of oil due to moving parts allows to lubricate the various points for
which lubrication is required to avoid seizing or damage.
Splash lubrication is very simple because there are no mechanical parts to be
checked, but is always required to verify the oil level carefully to keep its
efficiency.
This system is not suitable for machines arranged for variable speed operation,
as at low speed slash lubrication cannot allow the sufficient lubricating effect on
moving parts in slow motion.

The machine is not provided with oil pressure gauge as there is no oil pressure
circuit with splash lubrication.

4c092e0c.doc 4.9.3
Niro Soavi S.p.A

OIL LEVEL CHECK

The oil level needs to be checked every day, before the machine is started; the
oil should reach the mid level indicated on the sightglass located or inside the
machine on the crankcase or on the machine front panel. The oil level must be
checked with the machine stopped for at least 1 hour.
See for reference figure 4.9.3.

FIGURE 4.9.3

It is normal at the start of the machine to observe a lowering of the oil level on
the sightglass.
If oil drops below the required level top it up through the orange filler located
inside the machine on the crankcase lid.
To reach the fill you need to remove the side panel of the machine.

4c092e0c.doc 4.9.4
Niro Soavi S.p.A

OIL CHANGE

The frequency of oil change intervals is given in the "Tables for Regular
Servicing" at Chapter 4.2.
Use only oil as specified in Table 4.9.1.
To change the oil (see figure 4.9.1):
- prepare a reservoir to collect the oil, and of a size that is suitable to contain
the amount of oil found in the machine according to table 4.9.2;
- open the filling tap on the crankase cover
- open the bottom drain plug and let the oil drain out.
- once the oil has drained out completely, close the bottom plug and pour in
the new oil through the filler plug
- check the oil level through the sightglass.

CAUTION: Used oils are extremely harmful to environment and should be


disposed of correctly, in accordance with the local regulations.

VAPOUR CONDENSATE DISCHARGE

Inside the crankase it is possible to have condensation of vapours depending


on the characteristics of the ambient where the machine is working in, therefore
it is necessary to remove regularly the condensate to avoid any mixing with
lubricating oil.
The frequency of the discharge depends on the amount of condensate formed
in the drive unit (which depends on the working temperature, relative humidity,
frequency of starting and stopping the system); however, refer to the "Tables for
Regular Servicing", chapter 4.2.

The condensate drain can be done when the machine is stopped for at least 4
hours.
To drain the condensate:
- Prepare a basin for collection and open the bottom drain valve
- Water is heavier than oil, therefore it is collected at the bottom of the oil
tank; once the oil starts to pour out, close again the drain valve
- Check the oil level again and, if necessary, top it up through the filler plug

Presence of water into the oil may be caused by cooling water entering trough
the crosshead seals; it is recommended to check the surface of crosshead
extensions for scratches, and to replace the crosshead seals in case of oil
leakage or oil into the water, according to what is mentioned in paragraph 4.8.1.

4c092e0c.doc 4.9.5
Niro Soavi S.p.A

4.10. PNEUMATIC PLANT

Machines provided with pneumatic control system of the homogenizing


pressure are supplied with specific hydraulic dampening system of the
homogenizing valve.

The force required to close the homogenizing valve and consequently achieve
the homogenizing pressure is applied through a pneumatic actuator using
compressed air on its upper part; the lower part of the actuator is connected
with the pressurized oil dampening system.

The dampening system is not installed on the machine when the pneumatic
valve installed is type NanoValve.

The pneumatic actuator does not requie any periodical maintenance but it is
recommended to protect it from extreme temperatures (which may damage the
gaskets) and corrosive fluids, as its body is made with Aluminium alloys and not
in stainless steel.
In case the pneumatic actuator is not working properly we recommed its
replacement; its anyway available upon request to Niro Soavi Spare Parts
Dept. the complete gaskets spare kit.

The pneumatic plant can be configured in various versions, according to the


options installed; on figure 4.10.1 it is shown a basic version for single stage
homogenizer with manual pneumatic adjustment of the homogenizing pressure
installed on the machine front panel.

The scheme of the plant actually installed on the machine is given in Section 5
SPARE PARTS CATALOG with components list; you can also check the Flow-
sheet (P&ID) given in Section 1 TECHNICAL SPECIFICATIONS.

4c101e0c.doc 4.10.1
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FIGURE 4.10.1

The components present on the circuit accordino to the scheme presented in


figure 4.10.1 are:
- Inlet air pre-treatment unit (A) with pressure gauge (B)
- One pneumatic switch (C) (or as option a solenoid valve) to give pressure to
the actuator (G)
- One manual pressure regulator (D) (or as option a proportional valve for
remote controls
- Throttle valves (E, H) to achieve a stable operation of the pneumatic system
and to adjust the speed of the raise of the homogenizing pressure by
throttling the oil backflow
- A pressure gauge (F) installed on the machine front panel, indicating the
pressure effectively supplied to the pneumatic actuator
- A damper tank (K) for oil and pressurized air

The effect of dampening of the vibrations induced on the homogenizing valve by


the normal reciprocating movement of the plungers is granted by a suitable
air/oil damper vessel (K) which is connected to the lower part of the pneumatic
actuator of the homogenizing group.
This damper tank is preloaded with compressed air, pressure 0,5 bar.
The gauge (L) allows to check the pressure in the tank, and ina case of need it
is possibile to use the quick connection (M) to restore the correct pressure
inside the tank.

If the pneumatic dampening system is checked on a regular basis for correct


preload pressure and oil level, it is possible to avoid problems of valve

4c101e0c.doc 4.10.2
Niro Soavi S.p.A

vibrations and resonance, which may cause reduction of homogenizing


efficiency and can be dangerous for the machine itself.

Ordinary maintenance operations are listed below:


- Check regularly the oil level inside the damper tank through the sightglass
- Check regularly into the damper tank the correct pressure value: must be
0,5 bar with machine stopped
- In case refilling of oil is required, close the valve (J) and open slowly the
upper filling plug (there is pressure inside); once the pressure is gone, fill
the necessary oil quantity. The pscifications of the suitable oil are listed on
table 4.10.2

WARNING: the damper tank containing oil is under pressare; open


carefuly and slowly to allow air pressare go down and avoid danger
for personnel.

- Close the upper plug and connect a compressed air source to the quick
connection (M) to restore the pressure of 0,5 bar inside the damper tank
- Open the valve (J) and check if the air pressure is still at the set value of 0,5
bar

Pressure inside the camper tank cannot be higher than 0,6 bar when the
machine is stopped.

Oil into this circuit does not requie any change but only refilling in case the level
is low.
If during the above mentioned procedures of filling up, or during the
homogenizing valve maintenance some air bubbles are present into the plastic
pipes, it is possible toeliminate the same by application and release of the
pressure to the actuator through the pneumatic switch (C), with machine
stopped and with the manual pressure regulato set to allow some air to go
through (not at zero).

The presence of air bubbles, anyway, cannot prevent the system to work
properly, even if the dampening effect may be sometimes reduced.

The adjustment of the throttle valve (E, H) allows to regulate the speed of the
homogenizing pressare raise.
Usually the setting of this valve is made during the machine test, in order to
avoid a sudden raise of the homogenizing pressure which may cause the
opening of the overpressure relief valve.
Before making any modification to the setting, please tae note of the original
setting on the scale in order to recover the original setpoint in case of need.
As general information the closing of the valve (H) is slowing down the pressure
raise, its opening is making it faster.

4c101e0c.doc 4.10.3
Niro Soavi S.p.A

CAUTION: Used oils are extremely harmful to environment and should be


disposed of correctly, in accordance with the local regulations.

Class: ISO VG 32
DIN 51524-2-HLP

BRAND TYPE BRAND TYPE


Agip Oso 32 Texaco Rando oil HP 32

IP Hydrus Oil 32 Gulf Harmony 32 AW

Shell Tellus V 32 Amoco American


industrial oil 32

Mobil DTE 24 Total Azolla ZS 32

BP Energol HLP 32 Fina Hyidran 32

Chevron EP Hydr. oil 32 Api CIS 32

Castrol Hyspin AWS 32 Kuwait Petr. Int. Q8 haidn 32

Esso/Exxon Nuto H 32 ELF Olna DS 32

TABLE 4.10.2

4.10.1 PNEUMATIC PLANT WITH LOCAL MANUAL ADJUSTMENT

The pneumatic plant for local and manual pressure adjustment allows to adjust
the homogenizing pressure from the machine front panel through a pneumatic
regulator and pneumatic switch.
No maintenance is required on these components, and in case of evident
malfunctioning replacement of faulty parts is recommended.

4c101e0c.doc 4.10.4
Niro Soavi S.p.A

4.10.2 PNEUMATIC PLANT WITH REMOTE PRESSURE ADJUSTMENT

The pneumatic plant with remote pressure adjustment is using a proportional


valve (or I/P converter) to ad just the homogenizing pressare. This proportional
valve requires a suitable ramp signal on a 420 mA scale; the signal must be
isolated and amplified, with electrical connection to the proportional valve
accordino to the following diagram shown in figure 4.10.3.

FIGURE 4.10.3

It is anyway always recommended to follow the indications in the specific wiring


diagram supplied in the manual, which is showing also the numbering of
terminals on the terminal board for proper connection.
In case of malfunctioning of the system, it is possible to follow the below listed
indications:
- Wrong connection: make sure the wiring is made according to the supplied
diagram
- Not enough air pressure supply (required minimum 7,5 bar air pressure)
- Moisture or oil into the supplied air, which is necessary to eliminate
- Not enough power in the signal coming from valve pilot source (especially if
directly connected to a PLC output): it is necessary to install a suitable
signal amplifier

4c101e0c.doc 4.10.5
Niro Soavi S.p.A

The proportional valve is tested and calibrated durino the machine test run. The
setting is related to the range of pneumatic signal output related to the electrical
signal input; in case of need it is possible to modify the factory settings by
adjusting the ZERO and SPAN screws located on the proportional valve
body under a protection cover (see figure 4.10.4).
The proportional valve is installed inside the machine cabinet, on left hand side,
and it is possible to access to it by removing the left side panel of the machine.

Usually it is not required to have any maintenance on these components, and in


case of faulty operation their replacement is recommended.

FIGURE 4.10.4

4c101e0c.doc 4.10.6
Niro Soavi S.p.A

4.11. ASEPTIC PLANT

The machine, being supplied in SANITARY execution is NOT equipped with


aseptic plant.

4c112e0c.doc 4.11.1
Niro Soavi S.p.A

SECTION 5
SPARE PARTS CATALOGUE - INDEX

5.1. HOW TO USE THE SPARE PARTS CATALOGUE

5.2. HOW TO ORDER SPARE PARTS

5.3. RECOMMENDED SPARE PARTS

5.4. MAINTENANCE BOX

5.5. SPARE PARTS LISTS AND ASSEMBLY DRAWINGS

5C001E0C.DOC 5.1.0
Niro Soavi S.p.A

5.1. HOW TO USE THE SPARE PARTS CATALOGUE

To ensure that effective operation and quality characteristics are maintained


only original spare parts must be used on NIRO SOAVI machines.
The use of non original spare parts shall instantly invalidate the
guarantee.
This catalogue has information on how to order spare parts, selecting the parts
in the attached tables and their code number in the relative tables.

5C001E0C.DOC 5.1.1
Niro Soavi S.p.A

5.2. HOW TO ORDER SPARE PARTS

Spare parts can be ordered directly from NIRO SOAVI, Service Department, or
through your local NIRO SOAVI agent or Authorized Dealer, who can provide
useful advice and forward your request immediately.

When placing an order please specify:


SERIAL NUMBER of the machine
spare part code number
if necessary, a brief description of the component for easier identification
if applicable, the item number on the assembly drawing in the SPARE
PARTS CATALOGUE
the means of transport or dispatch requested; if this is not specified NIRO
SOAVI will arrange suitable transport at their discretion
whether urgent, as this may affect cost
exact address and name of contact person

To order spare parts or request quotations for spare parts, copy the standard
form below and send it by fax.

5C001E0C.DOC 5.2.1
Niro Soavi S.p.A

NIRO SOAVI ORIGINAL SPARE PARTS


INQUIRY FORM
To:
Fax No.
From:
Name:
Reply Fax No.
e-mail:

Model:
Serial No.

! URGENT ! QUOTATION ! ORDER No.

Part CODE Qty Description

Shipping Specs.

5C001E0C.DOC 5.2.2
Niro Soavi S.p.A

5.3. RECOMMENDED SPARE PARTS

.
In order to limit the number of shutdowns during production, and the time
required for maintenance of the machine, we recommend you stock a set of
spare parts to replace elements which are normally subject to wear.

The number of spare parts to be stocked will depend on production needs and
on how important it is to avoid long shutdowns due to unavailable spare parts.
In specific, in case of homogenizing valves, the replacement at due time allows
to keep the homogenizing efficiency and consequently the quality of the
processed product.

NIRO SOAVI cannot guarantee that a given spare part will be in stock either at
their central warehouse or at the Dealers due to problems with material
availability or to special requirements for dispatch.
Please note that shipment is no guarantee of successful delivery and that
delays may occurr due to customs problems or miscarriage.
In any case NIRO SOAVI shall not be responsible for delays occurring due to
the shipment of spare parts.

The following is a list of spare parts which, in our experience, is important to


have in stock:
a complete set of gaskets, two sets in case of VHP high-pressure
compression blocks
two sets of packings, including packing washers and anti-extrusion rings
one or two plungers, if ceramic plungers are used
a homogenizing valve set for each stage (for homogenizers)
a set of balls and valve seats, for VHP high-pressure heads
a set of seats and pumping valves, if the machine is used with abrasive
products
a set of pumping valve springs
a pressure gauge for the compression block
seat and ball for overpressure relief valve
oil filters
a set of guide plunger gaskets
crankshaft oil guard

In addition to the ordinary maintenance operations described in Section 4 -


MAINTENANCE, below you will find a table with checklist for machine
inspection that you can use to check which spare parts are needed before
performing ordinary maintenance on the machine.

5C001E0C.DOC 5.3.1
Niro Soavi S.p.A

NIRO SOAVI - CHECKLIST FOR MACHINE INSPECTION

Machine Type : Serial Number :

Working Hours : Date :

Checke Replace Checke Replace


d d d d
1 Compression head 34 Transmission
2 Suction Valves 35 Main motor
3 Suction Springs 36 Auxiliary motors
4 Suction valve seats 37 Gear box
5 Delivery Valves 38 Gear box tightening kit
6 Delivery Springs 39 Gear box oil level
7 Delivery valve seats 40 Belts
8 Gaskets 41 Pulley
9 Plungers 42 Water plant
10 Plunger Packings 43 Water filter
Overpressure
11 cleaning/seat 44 Water solenoid valve
12 Homogenizing group 45 Water drain check
13 Passage head 1st 46
14 Impact ring 1st 47 Lubrication plant
15 Impact head 1st 48 Lubrication unit
16 Gaskets 1st 49 Pump driven by crankshaft
17 Passage head 2st 50 Heat exchanger (oil/water)
18 Impact ring 2st 51 Suction oil filter
19 Impact head 2st 52 Delivery oil filter
20 Gaskets 2st 53 Condensate discharge
21 54 Gaskets
22 55 Oil level
23 56 Oil piping check
24 Transmission body 58 Dampening system check
Air filter/Pressure
25 Crankshaft 59 regulator
26 Conrods 60 Accessories
27 Guide pistons 61 Tightening of the nuts
28 Conrod bronze bearings 62 Tightening of plungers
29 Main bronze bearings 63 Pressure gauges
30 Pins 64 Aseptic plant
31 Bearings 65 Steam heat exchanger
32 Gaskets 66 Steam valve
33 Oil splash guards 67 Aseptic chambers gaskets

Notes:

5C001E0C.DOC 5.3.2
Niro Soavi S.p.A

5C001E0C.DOC 5.3.3
Niro Soavi S.p.A

5.4. MAINTENANCE BOX

The machine is supplied complete with a set of spanners and tools to be used
during ordinary maintenance; they include special tools for installing or
removing plungers and packings, where required.
The set of spanners DOES NOT INCLUDE a Torque Wrench, which is
recommended for correct tightening of nuts and studs to the torque values given
in Section 4 - MAINTENANCE.
The maintenance box includes a basic set of spare gaskets.
Please find attached a list of the tools supplied for ordinary maintenance.

5C001E0C.DOC 5.4.1
Niro Soavi S.p.A.
Item Description Description Qty Part Code
- CHIAVE COMB 24X24 MIXED WRENCH 24X24 1 810224
- CHIAVE COMB 30X30 MIXED WRENCH 30X30 1 810230
- CHIAVE COMB 19X19 MIXED WRENCH 19X19 1 810219
- CHIAVE ESAGONALE AD " L " 8 EXAGONAL KEY " L " 8 1 810308
- GIRAVITE A CROCE 8X150 SCREWDRIVER 8X150 1 810010
- CHIAVE UNIFAST UNIFAST KEY 1 350229
- FONDELLO PIEDE FOOT BASE 4 350457
- MOLLA SPRING 6 0124804-1
- RONDELLA WASHER 6 0133563
- PACCHETTO PACKING 3 150101CX
- ORING ORING 18 140205PU
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 18 0130254
- ORING ORING 1 140027PU
- ORING ORING 1 140022PU
- ORING ORING 1 140030PU
- ORING ORING 1 140035PU
- ORING ORING 1 140026PU
- ORING ORING 1 140330PU
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130176
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130982
- ORING ORING 1 140013PU
- ORING ORING 3 140030PU
- ORING ORING 1 130031S
- ORING ORING 1 130027PU
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0127432
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130175
- ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0124748
- ORING ORING 1 140022PU
- ORING ORING 1 140205PU
- GUARNIZIONE GASKET 2 140358
- GUARNIZIONE GASKET 1 140353

TOOLS_4537 .xls 1/1


Niro Soavi S.p.A

5.5. SPARE PARTS LIST AND ASSEMBLY DRAWINGS

You will find attached assembly drawings and a list of components and spare
parts.
The first code of each spare parts list indicates the assembly drawing which the
components refer to.

5C001E0C.DOC 5.5.1
Item Description Description Qty Part Code
\ ASS. TESTATA DI COMPRESSIONE COMPRESSION HEAD ASS. DRW. 1 0130237-2
2 PIASTRA PLATE 1 0131376-10
3 PACCHETTO PACKING 3 150101CX
4 RONDELLA WASHER 6 0133563
5 FLANGIA FLANGE 3 0129632-9
6 PRIGIONIERO STUD 12 0122926
7 DADO NUT 12 760006
8 PRIGIONIERO STUD 4 0131063
9 DADO NUT 4 760006
10 PRIGIONIERO STUD 8 0130852
11 DADO NUT 8 760008
12 TESTATA COMPRESSION HEAD 1 0133288
13 ORING ORING 3 140205PU
14 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 3 0130254
15 GRUPPO VALVOLA VALVE GROUP 3 DRW.29112
16 GRUPPO VALVOLA VALVE GROUP 3 DRW.29112
17 PRIGIONIERO STUD 8 0131067
18 DADO NUT 8 760008
19 PRIGIONIERO STUD 8 0131068
20 DADO NUT 8 760008
21 ASSIEME ASSEMBLY DRAWING 3 0201BKB7
22 COLLETTORE MANIFOLD 1 0133689-2
23 COLLETTORE MANIFOLD 1 0133283-2

SPARES_4537 .xls COMPRESSION HEAD


Item Description Description Qty Part Code
1 ASSIEME GRUPPO VALVOLA VALVE GROUP ASS. DRW. 3+3 0130270
2 SEDE VALVOLA VALVE SEAT 3+3 0123059
3 SFERA BALL 3+3 190062
4 MOLLA SPRING 3+3 0124804-1
5 COPERCHIO VALVOLA VALVE COVER 3+3 0130241-2
6 ORING ORING 3+3 140205PU
7 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 3+3 0130254
8 CONTENTITORE SEDE VALVOLA VALVE SEAT HOUSING 3+3 0131064-2
9 ORING ORING 3+3 140205PU
10 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 3+3 0130254

SPARES_4537 .xls VALVE GROUP


Item Description Description Qty Part Code
1 ASS. GRUPPO PISTONE PLUNGER GROUP ASS. DRW. 3 0126664
2 PISTONE PLUNGER 3 0124559-002
3 ANELLO RING 3 0126886
4 ANELLO RING 3 0126887
5 GHIERA NUT 3 0125397-1
6 ORING ORING 3 140008

SPARES_4537 .xls PLUNGER GROUP


Item Description Description Qty Part Code
1 ASS. GRUPPO OMOGENEIZZANTE HOMOGENEIZING GROUP 1 0132338
2 CAMERA OMOGENEIZZANTE HOMOGENEIZING CHAMBER 1 0132320-2
3 ANELLO RING 1 0132321-2
4 ORING ORING 1 140027PU
5 ORING ORING 1 140022PU
6 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130176
7 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130982
8 TESTINA DI PASSAGGIO PASSAGE HEAD 1 0130185
9 ANELLO DI URTO IMPACT RING 1 0126660
10 CONTENITORE ANELLO URTO IMPACT RING HOUSING 1 0132328-2
11 ORING ORING 1 140030PU
12 ORING ORING 1 140035PU
13 DISTANZIERE SPACER 1 0132329-2
14 TESTINA D'URTO IMPACT HEAD 1 0122780
15 ALBERINO SHAFT 1 0132330-2
16 GUIDA GUIDE 1 0132333-2
17 ORING ORING 1 140026PU
18 ORING ORING 1 140330PU
19 BOCCOLA BUSHING 2 260358
20 BOCCOLA BUSHING 1 260359
21 FLANGIA FLANGE 1 0131268
22 PRIGIONIERO STUD 4 0125377
23 DADO NUT 4 760006
24 SUPPORTO SUPPORT 1 0132337
25 VITE SCREW 4 69TE12X30
26 FLANGIA FLANGE 1 0132323
27 PROLUNGA EXTENSION 1 0132339
28 CILINDRO PNEUMATICO PNEUMATIC ACTUATOR 1 0125602
29 VITE SCREW 4 69TCE16X105
30 RACCORDO CONNECTION 1 260468
31 RIDUZIONE REDUCTION 2 260151
32 RACCORDO CONNECTION 1 260271

SPARES_4537 .xls HOMOGENEIZING GROUP 1 ST.


Item Description Description Qty Part Code
1 ASS. GRUPPO OMOGENEIZZANTE HOMOGENEIZING GROUP ASS. DRW 1 0132338
2 CAMERA OMOGENEIZZANTE HOMOGENEIZING CHAMBER. 1 0132320-2
3 ANELLO RING 1 0132321-2
4 ORING ORING 1 140027PU
5 ORING ORING 1 140022PU
6 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130176
7 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130982
8 TESTINA DI PASSAGGIO PASSAGE HEAD 1 0130185
9 ANELLO DI URTO IMPACT RING 1 0126660
10 CONTENITORE ANELLO URTO IMPACT RING HOUSING 1 0132328-2
11 ORING ORING 1 140030PU
12 ORING ORING 1 140035PU
13 DISTANZIERE SPACER 1 0132329-2
14 TESTINA D'URTO IMPACT HEAD 1 0122780
15 ALBERINO SHAFT 1 0132330-2
16 GUIDA GUIDE 1 0132333-2
17 ORING ORING 1 140026PU
18 ORING ORING 1 140330PU
19 BOCCOLA BUSHING 2 260358
20 BOCCOLA BUSHING 1 260359
21 FLANGIA FLANGE 1 0131268
22 PRIGIONIERO STUD 4 0125377
23 DADO NUT 4 760006
24 SUPPORTO SUPPORT 1 0132337
25 VITE SCREW 4 69TE12X30
26 FLANGIA FLANGE 1 0132323
27 PROLUNGA EXTENSION 1 0132339
28 CILINDRO PNEUMATICO PNEUMATIC ACTUATOR 1 0125602
29 VITE SCREW 4 69TCE16X105
30 RACCORDO CONNECTION 1 260468
31 RIDUZIONE REDUCTION 2 260151
32 RACCORDO CONNECTION 1 260271

SPARES_4537 .xls HOMOGENEIZNG GROUP 2 ST.


Item Description Description Qty Part Code
1 ASS. GRUPPO TRASMETTITORE TRANSMITTER GROUP ASS. DRW. 1 0124219-4
2 TRASMETTITORE TRANSMITTER 1 320127
3 RONDELLA WASHER 1 0123486
4 FLANGIA FLANGE 1 0133688
5 ORING ORING 1 130031S
6 ORING ORING 1 130027PU
7 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0124748
8 PRIGIONIERO STUD 4 0126273
9 DADO NUT 4 760008

SPARES_4537 .xls TRANSMITTER


Item Description Description Qty Part Code
1 ASS. VALVOLA DI SICUREZZA RELIEF VALVE ASS. DRW. 1 0130259
2 SEDE VALVOLA VALVE SEAT 1 0130260-2
3 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0127432
4 ORING ORING 1 140013PU
5 ANELLO ANTIESTRUSIONE ANTIEXTRUSION RING 1 0130175
6 SFERA BALL 1 190009
7 ALBERINO SHAFT 1 0130261-3
8 ORING ORING 1 140030PU
9 ANELLO ELASTICO SNAP RING 1 210030
10 ORING ORING 2 140030PU
11 CUSCINETTO BEARING 1 220197
12 MOLLA SPRING 1 0130263
13 CORPO BODY 1 0131526-3
15 DISTANZIERE SPACER 1 0130264
16 COPERCRCHIO VALVOLA VALVE COVER 1 0130266
17 FLANGIA FLANGE 1 0130604
18 DADO NUT 4 760006
19 PRIGIONIERO STUD 4 0122926
20 TUBO PIPE 1 0124722

SPARES_4537 .xls RELIEF VALVE


Item Description Description Qty Part Code
1 ASS:GRUPPO COLLETTORE MANIFOLD ASS. DRW. 1 0131408
2 CODICE NON PRESENTE NOT EXISTING CODE - -
3 ORING ORING 1 140022PU
4 FLANGIA FLANGE 1 0134000-2
5 VITE SCREW 2 69TE10X20
6 MORSETTO CLAMP 1 350901
7 GUARNIZIONE GASKET 1 140358
8 TRONCHETTO FERRULE 1 260389
9 CODICE NON PRESENTE NOT EXISTING CODE - -
10 CODICE NON PRESENTE NOT EXISTING CODE - -
11 ORING ORING 1 140205PU
12 FLANGIA FLANGE 1 0134001-2
13 VITE SCREW 4 69TE16X25
14 MORSETTO CLAMP 1 350901
15 GUARNIZIONE GASKET 1 140358
16 TRONCHETTO FERRULE 1 260389

SPARES_4537 .xls MANIFOLD


Item Description Description Qty Part Code
1 ASS. CORPO DI TRASMISSIONE TRASMISSION BODY ASS .DRW. 1 0120382
2 CORPO DI TRASMISSIONE TRANSMISSION BODY 1 0131400
3 ALBERO A GOMITI CRANKSHAFT 1 0127073
4 CUSCINETTO BEARING 2 220306
5 FLANGIA FLANGE 1 0108927
6 VITE SCREW 16 70TCE10X25
7 ORING ORING 2 140109
8 FLANGIA FLANGE 1 0120222
9 GUARNIZIONE GASKET 1 180051
10 PISTONE DI GUIDA GUIDE PLUNGER 3 0126611
11 SPINOTTO WHRIST PIN 3 250006
12 RONDELLA WASHER 6 0100119
13 BIELLA CONROD 3 0109680
14 BRONZINA BRONZE BEARING 3 0113175
15 FLANGIA FLANGE 3 0133520
16 ANELLO RASCHIATORE ROD SCRAPER 3 160108
17 VITE SCREW 12 70TE6X25
18 PARASPRUZZI SPLASH GUARD 3 0120332
19 COPERCHIO COVER 1 0100092
20 CORDINO GASKET 1 630005
21 VITE SCREW 8 70TE8X25
22 VITE SCREW 4 70TE12X35
23 PULEGGIA PULLEY 1 0121873
24 BUSSOLA BUSHING 1 610609
25 SPINA PIN 2 0111800
26 LINGUETTA FEATHER KEY 1 810868
27 TAPPO PLUG 1 120919
28 CONVOGLIATORE OLIO OIL CONVEYOR 2 0100155
29 CODICE NON PRESENTE NOT EXISTING CODE- - -
30 NIPPLO NIPPLE 1 120859
31 RACCORDO A T TEE CONNECTION 2 120394
32 LIVELLO OLIO OIL LEVEL 1 170017
33 TAPPO PLUG 1 120919
34 TAPPO PLUG 2 170001
35 RIDUZIONE REDUCTION 1 120711
36 ORING ORING 3 140194
37 GUARNIZIONE GASKET 3 160105

SPARES_4537 .xls TRASMISSION BODY


Item Description Description Qty Part Code
1 ASS. MOTORIZZAZIONE DRIVE END ASS. DRW. 1 0122967
2 MOTORE MOTOR 1 MB6111Y2
3 PULEGGIA PULLEY 1 0121879-001
4 DISTANZIERE SPACER 1 0120403
5 RONDELLA WASHER 1 0122966
6 PIASTRA PLATE 1 0133159-9
7 SUPPORTO SUPPORT 1 0133158-9
8 TIRANTE TRUMBUCKLE 1 350026
9 SUPPORTO SUPPORT 1 0121435
10 ANELLO RING 2 0123479
11 CINGHIA BELT 6 40SPZ1900X
12 VENTOLA FAN 1 990011

SPARES_4537 .xls DRIVE END


Item Description Description Qty Part Code
1 ASS. IMPIANTO PNEUMATICO PNEUMATIC PLANT ASS. DRW. 1 0133613-2
2 NIPPLO NIPPLE 1 260189
3 RONDELLA EWASHER 1 680044
4 RIDUTTORE PRESSIONE PRESSURE REDUCER 1 390250
5 MANOMETRO MANOMETER 1 320081
6 DISOLEATORE MIST SEPARATOR 1 390251
7 BLOCCHETTO BLOCK 1 260250
8 PRESSOSTATO PRESSURE SWITCH 1 EF0043
9 CODICE NON PRESENTE NOT EXISTING CODE - -
10 ELETTROVALVOLA ELECTROVALVE 1 390263
11 ELETTROVALVOLA ELECTROVALVE 1 390230
12 DOSATORE FLOW BATCHER 1 390046
13 MANOMETRO MANOMETER 1 320361
14 GIUNTO COUPLING 1 260310
15 GIUNTO COUPLING 2 260313
16 CODICE NON PRESENTE NOT EXISTING CODE - -
17 GIUNTO COUPLING 1 260310
18 GIUNTO COUPLING 1 260314
19 STROZZATORE CHOCKER 1 350167
20 RUBINETTO BALL TAP 1 580002
21 OLIO OIL 2 530006
22 LIVELLO LEVEL 1 170017
23 SERBATOIO TANK 1 261202
24 SUPPORTO SUPPORT 1 261203
25 PROLUNGA XRTENSION 1 261204
26 MANOMETRO MANOMETER 1 320080

SPARES_4537 .xls PNEUMATIC PLANT


Item Description Description Qty Part Code
1 IMPIANTO DELL'ACAQUA WATER PLANT ASS. DRW. 1 0133601-11
2 FILTRO FILTER 1 230014
3 RONDELLA WASHER 1 680044
4 NIPPLO NIPPLE 1 260417
5 ELETTROVALVOLA ELECTROVALVE 1 390035
6 RUBINETTO BALL TAP 1 580010
7 FLUSSOSTATO FLOW SWITCH 1 EFB038
8 PORTAGOMMA HOSE COUPLING 1 260010
9 TUBO PIPE 1 790003
10 PORTAGOMMA HOSE COUPLING 1 260010
12 NIPPLO NIPPLE 1 260300
13 RONDELLA WASHER 1 680045
14 CODICE NON PRESENTE NOT EXISTING CODE - -
15 NIPPLO NIPPLE 1 260300
16 CODICE NON PRESENTE NOT EXISTING CODE - -
17 CODICE NON PRESENTE NOT EXISTING CODE - -
18 CODICE NON PRESENTE NOT EXISTING CODE - -
19 CODICE NON PRESENTE NOT EXISTING CODE - -
20 CODICE NON PRESENTE NOT EXISTING CODE - -
21 CODICE NON PRESENTE NOT EXISTING CODE - -
22 CODICE NON PRESENTE NOT EXISTING CODE - -
23 CODICE NON PRESENTE NOT EXISTING CODE - -
24 CODICE NON PRESENTE NOT EXISTING CODE - -
25 CODICE NON PRESENTE NOT EXISTING CODE - -
26 CODICE NON PRESENTE NOT EXISTING CODE - -
27 CODICE NON PRESENTE NOT EXISTING CODE - -

SPARES_4537 .xls WATER PLANT


Niro Soavi S.p.A

SECTION 6
ELECTRICAL DIAGRAMS - INDEX

6.1. ELECTRICAL DIAGRAMS

6C001E0C.DOC 6.1.0
Niro Soavi S.p.A

6.1. ELECTRICAL DIAGRAMS

In the following pages it is possibile to find the wiring diagrams of the electrical
devices installed on-board the machine, or as an alternative, the complete
electrical diagram of the Electric Power Board if the same or its engineering is
supplied by Niro Soavi.
We recommend to check carefully the wiring diagrams to proceed with correct
connection of the machinhe and its components.
The wiring of the machine and its components must be done by qualified
personnel who must be able to understand properly the supplied electrical
documentation and wiring diagrams.

6C001E0C.DOC 6.1.1
Niro Soavi S.p.A

SECTION 7
SUPPLIERS CATALOGUE - INDEX

7.1. SUB-SUPPLIERS AND COMPONENTS CATALOGUE

7C001E0C.DOC 7.1.0
Niro Soavi S.p.A

7.1. SUB-SUPPLIERS AND COMPONENTS CATALOGUE

We have included copies of the suppliers catalogues and of components


installed in the machine.

In addition to the maintenance guidelines provided in this USE AND


MAINTENANCE MANUAL, you should refer to the specific instructions of any
installed components.

7C001E0C.DOC 7.1.1