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Teknofanghi
Instruction for the TEKNOBAG-DRAIMAD PACKAGE
TPTKN02E-240105
Teknofanghi S.r.l. VIA BRESCIA, 18- 20063 - CERNUSCO S/N (MI) ITALY
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Teknofanghi
Instruction for the TEKNOBAG-DRAIMAD PACKAGE
TPTKN02E-240105
REFERENCE DRAWING
Te n k ofa n ghi S.r . l.

L D G D E WT R G E Q U P E T S U E A E N I I MN
I V A B E S CA 1 8 R I , 2 0 6 3 E R N U S OS N ( ) T A L C C / MI I Y +392924037 0 13 ++30292403 9 13 7
E RI E / SERI S S E
I P O/ T Y P E T MA T R I O L A / / J O B C O D E C A NO / YEAR kg.
MA S S A / M A S S
Teknobag- Dr i m a ad
Teknobag- r i m D a ad
P1 0
P9
P3
P2
P1 2
P10
P9
P3
P2
P1 2
Te U no E R ng P E S. .r l. k G E E fa IN E Q hi T S D L D A T W G U MN I I ARESCI 18 V B A, 2063ERNUSO N M TAL 0 C C S/ ( ) I Y I +390224037 ++90292303 913 3 14 7 SEI E/ SERI S R E

TPO T YPE I / M CO / / J OBCODE ATRI LA ANO / YEAR N M ASSA/ M
AS S
kg.
UNIT IDENTIFICATION PLATE POLYELECTROLYTE PUMP SLUDGE PUMP STATIC MIXER WATER INLET SLUDGE INLET 02B-PACK / 03B-PACK / 03B-PACK-P FEMM. UNI ISO 228-1 06B-PACK / 06B-PACK-P DN40 UNI 1092-1 21 AIR PRESSURE INLET ** 1/8 FEMM. UNI ISO 228-1 23 FILTRATE OUTLET 02B-PACK 2 FEMM. UNI ISO 228-1 03B-PACK / 03B-PACK-P / 06B-PACK / 06B-PACK-P DN100 UNI8320* 25 DEWATERED SLUDGE 26 TEKNOBAG-DRAIMAD DEWATERING BAG 38 POLYELECTROLYTE STIRRER 40 CONTROL PANEL 42 POLYELECTROLYTE PUMP ADJUSTING KNOB 43 INNER INDICATOR TO IDENTIFY THE LEVEL OF WATER INSIDE THE TANK 52 DRAINAGE OF THE POLYELECTROLYTE TANK 70 REACTION TANK (02B-PACK / "03B-PACK" / "06B-PACK" only) 71 POLYELECTROLYTE TANK 200 FRONTAL SAFETY GUARD (6 bags has two of them; 12 bags has four of them) 201 SAFETY GUARD FOR THE POLYELECTROLYTE TANK 300 SAFETY GUARD FOR THE SLUDGE DIST. TANK (02B-PACK / "03B-PACK" /"06B-PACK" only) E FUNNEL EG FUNNEL GASKET EMQE MANUAL EMERGENCY STOPPING DEVICE F CLAMP G CONTAINING BASKET Q0 MAIN SWITCH SFX2 AIR PRESSURE OUTLET ("03B-PACK-P" / "06B-PACK-P" only) SL SLUDGE LEVEL TO ALLOW THE EASY REMOVAL OF THE BAG SND LEVEL SENSOR *FOR GASKETED PLASTIC PIPE D110 DIN19560 DIN4102-B1. ** "03B-PACK-P" / "06B-PACK-P" only: minimum pressure 4 bars; max 10 bars
0 3 5 6 18 20
Teknofanghi
Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00
Page 3
INTRODUCTION
Dear customer, thank you for having chosen one of the Teknofanghi products. The QUICK GUIDE that follows this introduction has the purpose to help the reading of this handbook and to allow the trained operator to install, and run the TEKNOBAG-DRAIMAD PACKAGE units. For every information given, the relevant paragraph of this handbook is indicated. THE HANDBOOK SUMMARY IS AVAILABLE AT THE END OF THIS BOOK. Before carry out any of these instructions, identify and charge the operator/s that will have to carry out the installation, start up and daily use, as indicated in paragraph 1.4. On turn, before beginning, every operator must: Have studied the chapter 1 (general information) Have identified the type of the machine (see chapter 2). Have studied every paragraph related to the instruction to carry out. Teknofanghi will not be held responsible for personal injuries or damages to things and/or the unit itself due to non-observance of the warnings here below and/or tampering, and/or wrong setting and/or installation and/or wrong and/or missing maintenance (even if only partial) to the machine. For that reason, the study of the whole handbook is suggested in any case.
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QUICK GUIDE: INSTALLATION OF THE TEKNOBAG- DRAIMAD PACKAGE

Refer to the reference drawing available on the back of the frontal cover: Connect to point 20 the sludge supply line (use a pipe with the same dimension of the fitting, see paragraph 5.5.1 for much details); Fasten the piping so that the machine does not support them. ("03B-PACK-P" / "06B-PACK-P" only) connect to point 21 the air supply source, using a piping with section at least as the fitting provided. Connect to point 23 the filtrate outlet piping using a gasketed plastic pipe (see paragraph 5.8.2 for much details). The polyelectrolyte pump is delivered already filled with oil, check through the window provided (if it is not present see paragraph 7.2). Prepare a hose connected to the water line, in order to allow the filling of the polyelectrolyte tank and the washing procedure. Potable water is not required, but the use of fresh water is recommended, however. Connect the power supply to terminals R, S and T of the control panel (point 40). Details about the power supply required are available in the electric diagram of chapter 14. During the internal test all the motor are connected in order to rotate properly; every motor has an arrow to identify the proper rotation, therefore it is enough o check one motor to be sure that the connection of the power has been made as foreseen.
Once that all above indicated has been done, the basic installation is completed.
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QUICK GUIDE: BEFORE CARRYING OUT THE FIRST START UP

Before carrying out the first start up it is recommended to consult one or more specialists in the flocculant (or polyelectrolyte) field. Our experience shows big and strong flocks give better results. Ask for all the information regarding: dilution rate, dilute product lifetime, normal usage and safety recommendations. Selection of the proper product is essential to obtain the best results. It is recommended to carry out a series of flocculation tests with significant samples of sludge, in order to establish the proportions between sludge and flocculant. Take into account, that well flocculated sludge shows strong flocks, which do not breakdown, even after many mixings. Do not exceed the flocculant dosage, since adding too much flocculant weakens and sometimes breaks them down; moreover, as the flocculant is very sticky, excess of polyelectrolyte may blind the filter cloth of the bags. Once that the proportion is established it is recommend to take note here below of: The quantity of pure polyelectrolyte to dilute taking in account the dilution percentage and the daily consumption of ready polyelectrolyte (e.g. to prepare 100 litres of solution at 0.1% it is necessary to prepare 100 gr of pure polyelectrolyte; the capacity of the polyelectrolyte tank change on the basis of the model: 02B-PACK / 03B-PACK / 03B-PACK-P have a 100 litres tank while 06B-PACK / 06B*-PACK-P have a 200 litres tank). PURE POLYELECTROLYTE TO DILUTE: Gr. The flowing of the polyelectrolyte pump (proportionate to the standard sludge flowing). POLYELECTROLYTE FLOWING: Knob adjusted on No: Adjust the polyelectrolyte pump flowing by turning its adjusting knob until the correspondent percentage of the delivery flowing is readable on the shaft (on the shaft a scale from 0 to 10, which is correspondent to the percentage from 0 to 100%). E.g. to adjust a flowing of 60litres/hour on the polyelectrolyte pump of 101 litres/hour, turn the knob until the 6 is visible (02B-PACK / 03B-PACK / 03B-PACK-P); to adjust the same flowing to the 321 litres/hour pump, turn the knob to reach the 2, then turn it back a little (06B-PACK / 06BPACK-P).
QUICK GUIDE: FIRST START UP

To carry out the first start up follows this instructions : 1. ("03B-PACK-P" / "06B-PACK-P" only) open the air pressure source and check that the gauge of the main regulator shows 3 bars; should this pressure be different lift the knob, screw/unscrew to increase/decrease it and then push the knob down to lock it (see 6.3.1 & 13); 2. Study all the warning, control and emergency devices described in chapter 14. 3. Ensure that the sludge is available. 4. Ensure that the valve 52 of the tank is closed and then fill it with water up to point 43 (through point 18). 5. Prepare the polyelectrolyte following the producer indication. 6. Release the EMQE (turn it anti-clock wise). 7. Turn on the power and wait until the display visualises EE (about 6 seconds, for much details see chapter 14); If the display visualise another code, push together P2 and P12 and keep them pushed until EE appears (it should blink for 8 times the code P2-P12); if even in this case EE does not appear, contact the nearest dealer or Teknofanghi directly. 8. Open the plastic cover of the digital instrument TKN: 9. Push the right arrow button once (the display turn off and soon after light on again) and then for other two times (the display will visualise 3 dEF); 10. Push the up and down buttons together until appears oK (about 2 seconds) and then push the enter button once to confirm (it will appear memo); 11. Close the plastic windows before proceeding. Now the program has been loaded and will remain in the main memory even if TKN (see paragraph 6.6). 12. Push P9 button to activate the polyelectrolyte stirrer. 13. Pour slowly the pure polyelectrolyte through point 18. 14. Wait until the blending time suggested by the supplier is past, then push P10 button to stop the stirrer. Wait for the ageing time requested by the supplier, if any. 15. Set the polyelectrolyte pump to the flowing reported in the note here above 16. Put a new bag for every funnel of the unit following the table INSTALLATION OF NEW BAGS further on reported.
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BEFORE ACTIVATING THE PROGRAM ENSURE THAT THE POLYELECTROLYTE HAS BEEN PREPARED AND AGED AS INDICATED BY THE SUPPLIER. 17. Start the program by keeping pushed the P3 button until the display shows a decreasing time (about 3 seconds); Check that the incoming sludge is well flocculated and if necessary adjust the flocculation increasing /decreasing the polyelectrolyte rate. 18. Once the bags are full and the program stops the sludge loading and wait until the level of the sludge drops under the level sensor ("03B-PACK-P" / "06B-PACK-P" only have the pressurisation active). When the level sensor does not detect sludge anymore, other sludge is loaded again. 19. Wait near the unit until the bags have been filled up twice (Should one of the alarm trips on, refer to the TROUBLE SHOOTING section further reported). Once the two filling of the bags have been done, it is not necessary to stay nearby the machine, visual checking is suggested, however. Before leaving the unit ensure that: The sludge enters in the bags normally and it is well flocculated; The filtrate is as clear as expected and there are no leakages. The display visualise a decreasing time (program activated). (03B-PACK-P" / "06B-PACK-P" only): when the sludge loading restart the pressure is discharged through SFX2. The program continues to load the bags / wait that sludge drops down, until the WORKING TIME will expire: when this happens the display visualise a blinking _FF_; the sludge will not be loaded and the program waits that the sludge level drops under the level sensor ("03B-PACK-P" / "06BPACK-P" only have the pressurisation active). When the level sensor does not detect the sludge anymore, the TEKNOBAG-DRAIMAD PACKAGE shuts down and the display visualise the code EE. Before removing the bags from the unit, the level of the sludge should drops to level SL (see reference drawing at the back of the frontal cover): this is usually reached within 24 hours, therefore generally the bags are removed the day after the program activation.
QUICK GUIDE: THE DAY AFTER THE FIRST START UP

If the day after the bags will be under-filled or overfilled, carry out the instruction of the related paragraph here below reported: If the bags are under-filled, the program has loaded too little sludge, therefore it is suggested to increase the "WORKING TIME" as it follows (see 6.6.1 for further details): I. (Supply on, program not running) Open the plastic cover of the digital instrument TKN. II. Push the arrow button once: after a second the display visualise 1 05 00 (05=hours, 00=minutes). Push the or button to increase/decrease the WORKING TIME (the value should be modified proportionally to sludge found on the bags). III. Once the value has been set, push the button once (it will appear memo). IV. Proceed with the standard operation of the DAILY USAGE described further on. If the following day the display visualise the code "_FF_", the program has loaded too much sludge, therefore it is suggested to decrease the "WORKING TIME" as above described. To remove the bags proceed as follows (refers to the drawing at the back of the frontal cover): i. Turn off the power and then remove the safety guards "200"; ii. Begins with the bags opposite to the level sensor: open, without completely releasing, the lever closing device of the clamps "F"; slip off the back of the bag so that the sludge overflows in the inner part of the machine; iii. Once that the sludge of this bag is dropped to point "SL", remove the bag and repeat the same process for the next bag. The last bag will be the one with the level sensor. iv. When all the bags has been removed the display should show the code EE, if not carry out the cleaning the level sensor (see paragraph 8.3); clean the inside of the unit (see 8.1); v. Adjust the WORKING TIME as above described, remainding to DECREASE it. Once the day after the sludge level is around the point "SL" no further setting are necessary unless big changing of sludge or polyelectrolyte parameters. CAUTION: Now the machine is ready to operate the DAILY USAGE(See section further on and paragraph 6.4). The
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QUICK GUIDE: BAG REMOVAL AND STORAGE

Refer to the drawing at the back of the frontal cover. OPERATION EFFECT DISPLAY Verify that the program is finished. The bags are accessible. Verify that the display Remove the safety guard that visualise the code "EE" and closes the access to the bags by that the level of the sludge pulling it towards the right then lift it is around point "SL". and extract it from the unit. Lift the fastening rod of one of the The hand cart fork can enter up The shield of the handcart cages "G" and open it. to the bag fork touches the bag. Slide the handcart fork under the The bag is lifted off the bottom The bag does not touch the bag and crank it up. supports. bottom supports. Release the clamp "F". The bag is free. Squeeze the bag together at the The bag is ready to be sealed. top of the sludge line. Wrap two wire ties together at the The wire ties are ready to be top of the sludge line. tightened. Insert the tying tool into the loops The bag is sealed and can be and pull several times. Do not pull easily removed and stacked. too much otherwise they will break. Remove the bag and lay it on a The funnel of the TEKNOBAGpallet. DRAIMAD PACKAGE is free. Stack the bags with one layer The bags are ready to be New bags can be stacked horizontally and the next moved to the storage area on old bags. perpendicularly and so on. before the disposal. Repeat this sequence for every bag. If some sludge drops are spilled, wash them away with the water hose.
QUICK GUIDE: INSTALLATION OF THE NEW BAGS

OPERATION EFFECT Remove the bags from the carton. Verify the bag integrity. Open the cages "G" and the The operator can fit clamp "F"(refers to the drawing at the bag the back of the frontal cover). Slip the bag "S" over the funnel nearly all the way to the top. Place the vertical seal of the bag to the rear. Adjust the bags so that the sewed bottom is perpendicular to the supporting bars. DISPLAY The welding and the sewing are ok. The gasket is visible, check its integrity.
The upper part of the bag touches the top hood. The vertical seal is opposite to the operator The bottom part of the bag is perpendicular to the supporting bars with the bag folded towards the inside. Holding the bag tight against the The bag is ready to be The bags is well tighten all around funnel at the front, pull the loose clamped to the funnel the funnel out and forward, and tuck under, "E" to form a tight seal to the funnel. Bring the clamp "F" around the The bag is sealed to There are no gaps between the bag and tighten the funnel. clamp and the bags, all around the funnel Push the bottom of the bag into The bag is ready to be The bag can be moved without the cage, and slip the cage filled. entanglement in the cage. fastening rod through the loops provided on the cage. Repeat this sequence for every bag. Once all the bags are fitted, replace the safety guard 200 to keep the filtrate splash inside the unit.
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QUICK GUIDE FOR THE DAILY USAGE The operator must Follow the procedures BAG REMOVAL AND STORAGE and INSTALLATION OF THE NEW BAGS of the previous page. Ensure that the sludge is available and enough for a dewatering cycle. Ensure that the polyelectrolyte is available end efficient (they loose power after some days). If necessary prepare the polyelectrolyte as follows: fill the polyelectrolyte tank with water through point 18 up to the point 43. Power on the the unit by turning Q0 to position 1. Push P9 button to activate the polyelectrolyte stirrer. Pour slowly the pure polyelectrolyte through point 18 and waits until the blending time suggested by the supplier is over. Push P10 to stop the stirrer and waits for the ageing time (if any). BEFORE ACTIVATE THE PROGRAM ENSURES THAT THE POLYELECTROLYTE IS READY. Starts the program following this table:
QUICK GUIDE: STARTING UP OF THE PROGRAM

OPERATION ("03B-PACK-P" / "06B-PACK-P"): open the air pressure valve. If the unit is not powered turn the main switch "Q0" to position 1. Keep pushed the green push button P3 until the program starts (about 3 seconds). Once that the program is started, the sludge enters in the bags (The outlets to enable/drive the pumps are activated). Waiting (the sludge is entering) Once the unit is full, the program stops the pumps ("03B-PACK-P" / "06B-PACK-P" activate the pressurisation). EFFECT DISPLAY
The control panel is supplied. The unit will not start until the 3 second are past.
On the display is visible the code EE. The display visualise the flashing code P3 together a beeping sound. The sludge enter in the The display visualise the working bags. time decrease second by second. The level sensor detects sludge The filtrate continue to drain through the bags ("03B-PACK-P" / "06BPACK-P" the bags blow and the drainage is increased). The level of the sludge drops down The display visualise the lowest couple of hyphens. On the display are visible all the three couples of hyphens.
Waiting ("03B-PACK-P" / "06BPACK-P" have the pressurisation active). When the level sensor does not detect the sludge anymore, the program reload other sludge. The loadings / dropping down of the sludge continues until the WORKING TIME is expired, after that the sludge will not be loaded anymore ("03B-PACK-P" / "06BPACK-P" have the pressurisation active). When the level sensor does not detect the sludge anymore, the program stops. Waiting
On the display are visible the lower and middle couples of hyphens. The pumps restart ("03B- On the display all hyphens are PACK-P" / "06B-PACK-P" off. discharge the pressure). The program wait until the The display visualise the flashing sludge drops below the code -FF-. minimum level electrode ("03B-PACK-P" / "06BPACK-P" the bags blow and the drainage is increased). "03B-PACK-P" / "06B- The display visualise the code PACK-P" discharge the EE (program end). pressure. The bags continue to The level of the sludge can be drain by gravity action. detected by sight. Once the program is running the TEKNOBAG -DRAIMAD PACKAGE does not need to be manned continuously, however visual checking is suggested.
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Before leaving the working machine, the operator must ensure that: The plant has no leaks; Both the pumps are regularly running; The sludge enters the bags normally; The filtrate discharging from point 23 is as clear as expected; The sludge does not leak from around the clamps of the bags. The display visualise a decreasing time. (03B-PACK-P" / "06B-PACK-P" only): when the sludge loading restart the pressure is discharged through SFX2. Normally, the bags are left on the unit until the program is over (the display visualise the code "EE"), and the level of the sludge is around the point "SL" (typically the next day). Unless the sludge or the polyelectrolyte does not change, it will not be necessary to change any of the parameters of the program. Should the program sense a fault condition, it shuts down the machine and the display shows the relevant code. In the TROUBLE SHOOTING table further on reported are indicated the problems detectable by the program together to the relevant alarm code. Further more are reported also the problem not detectable by the digital unit, together the action to carry out, to solve them. If problems occur which do not appear in the table, or are not solvable, please contact the nearest distributor or the Teknofanghi technical office.
PROGRAM PAUSING
OPERATION EFFECT DISPLAY Push P2 to put the program in The sludge supply is The "WORKING TIME visualised by the pause. The program remains in cut off. display freezes. pause until it is not restarted manually by pushing P3.
POLYELECTROLYTE STIRRER ACTIVATION

OPERATION Push P9 to start the polyelectrolyte stirrer. This outlet operates even when the program is in pause or is not running. Push P10 to stop the polyelectrolyte stirrer. EFFECT DISPLAY The stirrer starts to On the low right corner of the display rotate. appears a dot.
The stirrer rotating.
stops It light off the dot on the low right corner of the display.
QUICK GUIDE: EMERGENCY STOPPING OPERATION EFFECT DISPLAY
Push the emergency stopping The whole machine The display visualise the blinking alarm immediately device EMQE. To unlock and shuts code: . down. reset the alarm see 6.5.7.
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QUICK GUIDE: TROUBLE SHOOTING

If the operator find the display that visualise one of the code here below, it means that the program detected a faulty condition or that EMQE was activated. If the code displayed change, more alarms are on (every code is displayed in sequence). Refer to the list below to identify the paragraph to look at (in paragraph 6.5 are described the instruction for the alarm resetting): PROBLEM DIAGNOSIS Although the main switch Q0 Auxiliary circuit is cut off, or is in position 1 the display one of the automatic fuses does not show anything. inside the "TKN" digital control unit is tripped in alarm. ACTION Check that the supply source is connected and live; verify that the auxiliary circuit breaker are activated; power off the control panel and wait some seconds to allow the automatic fuses of "TKN" to reset. the The program has taken too Bag damaged or slipped away much to fill/ refill the bags with from the clamp, see 6.5.1 sludge. the one of the circuit breaker inside See 6.5.2 the control panel overloaded or input "IN2" in alarm. the Input "IN3" in alarm. See 6.5.3
The display code:
visualises
The display visualises flashing code: The display visualises flashing code: The display visualises flashing code: The display visualises flashing code: The display visualises flashing code: The display visualises flashing code:
the Input "IN4" in alarm.
See 6.5.4
the Input "IN5" in alarm.
See 6.5.5
the Level sensor "SND" is dirty or See 6.5.6 faulty. the "EMERGENCY STOPPING See 6.5.7 DEVICE" activated.
NOTE: if the alarm code does not flash, the faulty condition is not present anymore.
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PROBLEM The display visualise either no hyphens or only the lower hyphens but no sludge enters in the unit There is leakage between a funnel and a clamp.
DIAGNOSIS The sludge supply line is clogged or there is a problem with the sludge and polyelectrolyte pumps.
The display visualise either all the three couples of hyphens or only the two lowest but not all the bags are full. There is a lot of sludge in the Bad flocculation. filtrate coming from the bags. The filtrate has a lot of foam.
ACTION Check the sludge supply line and the connection of the sludge and polyelectrolyte pumps. Check also the pumps rotation direction) The clamp is not properly At the next bag change, adjust tightened. the clamp grip so it tightens properly. Check whether the gasket is present. Some lumps of dry sludge are Carry out the "UNSCHEDULED stopping the sludge distribution WASHING" (see 8.1) to the bags. Check the sludge polyelectrolyte feeding and the flocculation. Check the sludge polyelectrolyte feeding and the flocculation. and rates and rates
Bad flocculation.
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NOTE
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ERRATA CORRIGE
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GENERAL
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1.1
INFORMATION ABOUT THE LITERATURE
Pictures and/or drawings included in this manual may show fittings and details different from your machine. It is also possible that in order to show these details clearly, some pictures show the machine without the fixed guards and/or with the moveable ones opened; During the normal operating times, the machine must have all the safety guards closed, as specified in paragraph 4.2. The development of the product may have changes not shown in the current handbook. In this case contact Teknofanghi or the nearer distributor for clarification. Teknofanghi reserves the right to modify this handbook and the TEKNOBAG-DRAIMAD PACKAGE at any time without prior notice. 1.2 RECURRENT SYMBOLS
In the text, two symbols are used to draw the reader's attention:
The first one is used to draw the attention to the users safety. The symbol is used together with a warning word plus a reference: SYMBOL WARNING WARNING! REFERENCE TEXT READ THE TEXT CAREFULLY, IT REFERS TO YOUR PERSONAL SAFETY.
The second one refers to the correct use and/or adjustment of the machine. The symbol is used together with a warning word plus a reference: SYMBOL WARNING CAUTION: REFERENCE TEXT Read the text carefully, it refers the correct installation and/or use and/or adjustment of the machine.
When one of these two symbols is found, please read the referring text carefully.
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1.3
USER DUTY
Teknofanghi will not be held responsible for personal injuries or damage to property and/or the machine itself due to non-observance of the warnings specified below and/or tampering, and/or wrong setting and/or installation and/or wrong and/or missing maintenance (even if only partial) to the machine.
WARNING!
All the safety procedures and the warnings specified in this handbook must be followed.
The user must observe the safety regulations in force in the country where the installation has been made. Access to the "AREA OF RESPECT" of the machine must be prohibited to all the people not trained or not instructed in the operation of the TEKNOBAG-DRAIMAD PACKAGE (see 1.4 and 5.1). The characteristics of the sludge generated by the waste water treatment plants make it possible to be exposed to hazardous chemical/biological substances. Users and operators must be aware. All the operators must be informed of the potential hazards connected with the sludge being dewatered, and how to protect themselves. Before carrying out any of the maintenance operations, either scheduled or unscheduled, ensure that all power is isolated and all circuits discharged. . The main switch Q0 must be locked in position 0 using the padlock supplied with the TEKNOBAG-DRAIMAD. Non-observance of this rule can cause damage to property, and / or personal (possibly fatal) injuries to people. Avoid starting the machine by turning the mains switch or inserting the plug in the socket, with bare feet or with feet in water or wet hands. It is forbidden to climb and/or stay on the machine to carry out any operation. Before using the machine, check each time, the condition of the cables and of electrical equipment connected to the machine. The user must follow all the maintenance operations, adhering to the times and methods shown in this handbook.
CAUTION:
Keep this handbook in a safe place. It is recommended that one copy be issued to each user. Before carrying out any operation to the machine, the user must have studied and thoroughly understood all the operations described in this handbook, either for the normal use or for scheduled and unscheduled maintenance.
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1.4
OPERATORS IDENTIFICATION
The TEKNOBAG-DRAIMAD PACKAGE must only be operated by the operators trained in its "DAILY USE ". These operators must satisfy the following criteria: 1 2 3 4 5 6 Who have reached adult age and are in good health. Who have studied and thoroughly understood all the instructions for the "DAILY USE" of the TEKNOBAG-DRAIMAD. Who have been given the authority to operate the TEKNOBAG-DRAIMAD. Who have been trained to operate with waste treatment and sludge dewatering equipment. Who wear the correct clothing, such as rubber boots, gloves and tight overalls without belt and/or loose sleeves. Who have been informed about the chemical/biological hazards connected with sludge dewatering, and that have taken all the necessary protective and precautionary measures.
"INSTALLATION", "ADJUSTMENT", "MAINTENANCE" and "UNSCHEDULED MAINTENANCE" of the TEKNOBAG-DRAIMAD PACKAGE must be carried out only by the operators trained as specialist technicians. These operators must satisfy the followings criteria: 1 2 Who have reached adult age and are in good health. Who have studied and thoroughly understood all the instructions for the specialist "INSTALLATION", " USE", "ADJUSTMENT", "MAINTENANCE", and "UNSCHEDULED MAINTENANCE" of the TEKNOBAG-DRAIMAD. Who have been trained in the specific field for the operations that have to be carried out (mechanical, hydraulic, pneumatic, electrical). Who have been authorised to carry out the installation and/or setting and/or adjustment and/or maintenance to the TEKNOBAG-DRAIMAD. who have been trained to operate with waste treatment and sludge dewatering equipment. who wear the correct clothing such as rubber boots, gloves and tight overalls without belt and/or loose sleeves. who have been informed about the chemical/biological hazards connected with sludge dewatering, and have taken all the necessary protective and precautionary measures.
3 4 5 6 7
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IDENTIFICATION OF THE TYPE OF TEKNOBAG-DRAIMAD
This handbook refers to the TEKNOBAG-DRAIMAD PACKAGE types: 02B-PACK 03B-PACK 06B-PACK 03B-PACK-P 06B-PACK-P To identify your machine, please read the code of the machine written on the line TYPE of the metal label fixed on the frame of the machine, as it is shown on the referring drawing on the back of the frontal ocver. In order to have all the information at hand, it is suggested that all the text on the metal label be copied to this page. Dimensions of all these units are specified in chapter 12.
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TRANSPORT AND HANDLING
Tek nofanghi S.r . .l

S L D G E D WA T R G E U I M E T U E EI N Q P N
V I A B RE S CI , 8 A1 2 0 6 CE RNUS COS / ( MI I A L 0 3 N ) T Y ++30292433 9 1 07 S E RI E / TI O / P ++390921307 2 4 3
SERI S E
TYPE JOB CODE
MA T RI OL A / C A NNO / Y MA S S A /
EAR
kg.
M ASS
T e k n o b a g - Dr a m a d i
P10
P 9
P3
P2
P12
Tek nofanghi S.r . .l

S L D G E D WA T R G E U I M E T U E EI N Q P N
V I A B RE S CI , 8 A1 2 0 6 CE RNUS COS / ( MI I A L 0 3 N ) T Y
++30292433 9 1 07 ++390921307 2 4 3
SERI E/ SERI S E
TI O / P
TYPE JOB CODE
MA T R I OL A / C A NNO / Y MA S S A /
EAR
kg.
M ASS
Teknobag- Dr ai ad m
P10
P 9
P3
P2
P12
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In the adjacent page is available a drawing that shows the dimension, the centre of gravity and how to lift the machine either by tying with rope/chains or by using a fork truck. The same tying points can be used to fix the machine for locking during transportation. WARNING! During loading operations pay attention to the people nearby the handling area. Ensure that nobody passes and/or remains under the suspended machine. Avoid sudden lifts or rough unloading of the machine. TEKNOFANGHI will not be held responsible for injuries to people or damage to the machine itself or other equipment, due to clumsy loading and/ or unloading operations. Ropes and/or chains must be positioned in such a manner that when tensioned they do not damage the nearby cables and / or devices. Keep an adequate distance between the forklift truck and the machine. Pay particular care of the control panel.
CAUTION:
3.1
PACKING
The TEKNOBAG-DRAIMAD PACKAGE is supplied packed by a plastic film. To protect the machine against the small impacts, some plastic pieces are added on the exposed parts. In all cases, it is recommended that great care be taken during all the handling operations. Should the machine be stored for a long time, additional protection is required (see 3.2). 3.2 STORAGE
Should it be necessary to store the TEKNOBAG-DRAIMAD PACKAGE for a long time, protect against humidity, or shocks, by means of cloth and/or appropriate coverings. Before doing this, take care that all the hollow parts of the machine are sealed. If it was used before, even for a short time, ensure that the washing pump and all piping are completely emptied. The program of the TKN digital unit, and its data, remain integer even if it is not powered. The storage must be in a position which ensures protection against the weather; temperature of the air must be between -25 and +55 C and relative humidity between 30 and 90%. It is forbidden to stack other machinery or equipment on the TEKNOBAG-DRAIMAD.
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TEKNOBAG-DRAIMAD PACKAGE UNIT
The TEKNOBAG- DRAIMAD unit is able to dewater the sludge generated by any waste water treatment plant by means of special patented porous bags. Although the TEKNOBAG-DRAIMAD PACKAGE is able to dewater the sludge without the use of flocculant, the best results will be reached integrating TEKNOBAG-DRAIMAD PACKAGE with a polyelectrolyte feeding system (in order to obtain a good dewatering the flocculation must be completed before the sludge enters in the unit). The TEKNOBAG-DRAIMAD PACKAGE unit is controlled by a control panel (see point 40 of the drawing at the back of the frontal cover). On the control panel is the digital control unit "TKN" which operates the dewatering program and informs the operator about its progress (the TKN is supplied complete of the program, for much details see chapter 14 ). On the control panel door are available all the buttons to start / stop and reset the program. On the terminal board are available the inlets and outlets to allow the connection to external devices (see paragraph 5.9 and its under paragraph). The control panel drives the sludge and the polyelectrolyte pump directly: the sludge is sucked through the point "20", then enters in contact with the polyelectrolyte inside the static mixer 6, forms the flocks in the reaction tank 70 and is distributed into the bags "S". The solids part are retained within the bags while the liquid part drains through and is discharged by the outlet gate "23". On the 03B-PACK-P and 06B-PACK-P is also available the pressurisation unit that allows to treat more sludge and to reach higher dryness of the sludge. The program continuously checks the correct operation of the unit; should it detect a fault condition, the machine is immediately shut down and, at the same time, the display shows the related code. The table of the QUICK GUIDE: TROUBLE SHOOTING further on, are reported all the alarm codes and the relative paragraphs to look at. During the operating time the TEKNOBAG-DRAIMAD PACKAGE does not need to be manned continuously, however visual sight checks are recommended. In the ADVANCED USERS section are listed the parameters of the program that can be modified to optimise the TEKNOBAG- DRAIMAD unit with your plant(see 6.6 and under paragraph).
4.1
SAFETY GUARDS AND DEVICES
On the back of the frontal cover are shown the safety guards together with the emergency stop(s) available on the TEKNOBAG-DRAIMAD PACKAGE units: The safety guards are placed to prevent sludge and filtrate splash escaping from the machine. Emergency device(s) are placed to allow the operator to immediately shut down the machine.
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4.2
LOGIC OF THE PROGRAM
Every dewatering program should be run with new bags. Once started, the program begins to load the sludge in the bags. The level of the sludge is detected through the level sensor SND (see reference drawing at the back of the frontal cover). When the maximum level allowed of the sludge is detected for 5 seconds continuously, the program stops the sludge entering and waits that the sludge level drops under the minimum allowed. anymore ("03B-PACK-P" / "06B-PACK-P" activate the pressurisation to increase the draining). As soon as the sludge level drops under the minimum allowed, the program switch back to load the sludge again ("03B-PACK-P" / "06B-PACK-P" deactivate the pressurisation and discharge the pressure). As long as the display visualise a decreasing time (WORKING TIME), the program continues to load the sludge, wait, load, wait and so on (If the program is paused, the display remains frozen, see chapter 14 for much details). When the WORKING TIME expires the program stops the sludge loading and waits until the sludge level drops under the minimum allowed for the last time ( the sludge will be not loaded anymore). Until SND detects sludge, the display visualises the blinking code "_FF_" ("03B-PACK-P" / "06B-PACK-P" have the pressurisation active). When SND does not detect sludge anymore, the program ends and the display visualises the code "EE"("03B-PACK-P" / "06B-PACK-P" deactivate the pressurisation and discharge the pressure). Typically the bags are left on the machine until the sludge inside the bags has drop around to the point "SL" (see the drawing at the back of the frontal cover). As to do that it takes a while, it is suggested to schedule the bag replacing for the next day. Should the next day the bags be overfilled, or under filled, it will necessary to adjust the WORKING TIME: With a shorter time the unit will dewater less sludge, and the bags will be less filled; With a longer time the unit will dewater more sludge, and the bags will be more filled. The original parameter of the WORKING TIME is set to 5 hours, and on average this time is enough to fill the bags correctly. To operate the adjustments see paragraph 6.6.1. Before operate a new dewatering cycle the bags full of sludge must be removed and replaced by new bags. The sludge packed inside the bags will continues to loose humidity by air evaporation, therefore after a certain time of storage, the sludge will have lost most of its volume and weight. The storage of the bags can be made in open area, as the bags are water repellent.
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4.3
INTENDED USES OF THE MACHINE AND PROHIBITED USES
The TEKNOBAG-DRAIMAD PACKAGE are machines for dewatering sludge coming from any waste water treatment plant. The sludge must be stabilised, with neutral pH and with a temperature between 10 and C 30 C. Average treatment capacities of the TEKNOBAG-DRAIMAD PACKAGE are indicated in the table below. Please note that these values can vary on the basis of the different specific characteristics of the sludge to be treated. TEKNOBAG- DRAIMAD PACKAGE 02B-PACK 03B-PACK 03B-PACK-P 06B-PACK 06B-PACK-P Dry solids of the inlet sludge (%) 4 0,5 4 0,5 4 0,5 4 0,5 4 0,5 D.S./day (Kg)
15 - 25 20 - 35 35 - 50 40 - 70 70 - 100
It is not permitted: To treat or use substances with different chemical, physical and biological properties from those indicated above; To tamper with the safety guards and devices; To modify any of the parts of the machine mentioned in this handbook; To use power supply (electric, hydraulic, pneumatics) with different characteristics from the ones shown in this handbook. The TEKNOBAG-DRAIMAD PACKAGE can dewater sludge without a previous treatment with flocculant, but the use of this, with the correct selection, will give the best result. WARNING! The characteristics of the sludge generated by the waste water treatment plants make it possible to be exposed to hazardous chemical/biological substances. Users and operators must be aware. All the operators must be familiar with the potential hazards connected with the sludge being dewatered, and how to protect themselves.
TEKNOFANGHI will not be held responsible for damage to persons and/or property and/or to the machine itself due to non-implemented and/or inadequate safety precautions.
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4.4
AIRBORNE NOISE PRODUCTION
The level of the equivalent and continuous airborne sound (weighted as in A scale) measured at 1m from the surface of the machine and at a height of 1,6 m from the floor, is less than 70dB (A). 4.5 COMPLIANCE WITH APPLICABLE DIRECTIVES
The TEKNOBAG-DRAIMAD PACKAGE is made in accordance with the EC Directive 89/392/CEE and further amendments. It is also made in accordance with the low voltage directive 73/23 and to the electromagnetic compatibility 89/336/CEE. 4.6 RESIDUAL HAZARD
On the TEKNOBAG-DRAIMAD PACKAGE the following standardised pictograms are attached to inform about residual hazards: "ELECTRICAL HAZARD", fixed on the control panel.
"PROHIBITION OF REMOVAL OF THE SAFETY GUARDING", fixed on the control panel and on the safety guarding.
"PROHIBITION OF CARRYING OUT MAINTENANCE PROCEDURES WHEN THE MACHINE IS RUNNING", fixed on the control panel and on the safety guarding. "MANDATORY WEARING OF GLOVES", fixed on the control panel.
"REQUIREMENT TO READ THE HANDBOOK ABOUT THE USE OF THE TEKNOBAG-DRAIMAD", fixed on the control panel.
TEKNOFANGHI will not be held responsible for damages to persons and/or property and/or the machine itself due to non-implemented and/or inadequate safety precautions.
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INSTALLATION
The TEKNOBAG- DRAIMAD unit is shipped pre-assembled and it is ready for the connection to the plant. Sometimes, however, the cages are nested within the unit. In this case it is necessary to remove the cages and slip the brackets of the cages over the pins on the main unit: the upper bracket is the farthest from the cage edge. The TEKNOBAG-DRAIMAD PACKAGE must be connected to the power supply and to the sludge feeding point, following the recommendations and diagrams attached to chapters: 12, 13 and 14. From here onwards, are the operations to follow, in order to properly install the machine. 5.1 AREA OF RESPECT
The access to the area where the TEKNOBAG-DRAIMAD PACKAGE will be installed must be restricted to authorised people only. To allow safe use and maintenance of the machine, the TEKNOBAG-DRAIMAD PACKAGE must be installed in a place with enough clear space around the machine as specified in chapter 12. In this handbook this place will be identified as AREA OF RESPECT. Although the machine is made with materials to allow the installation in an open area, it is suggested that a shelter is provided against the bad weather, to protect the operators and not to compromise the dewatering treatment process.
5.2
INDICATION OF THE WALKING AREA
The walking area all around the machine must be non-slip and be able to easily drain all wash-down water. In chapter 12 are shown the slopes that must be provided together with dimensions of the fixing pads of each machine. 5.3 WARNING! ANCHORING TO THE FOUNDATIONS In cases where the TEKNOBAG-DRAIMAD PACKAGE is exposed to wind loads, additional loads must be calculated and added to the superimposed load due to the lateral and vertical pressure. Maximum values typical for the area of the installation must be considered.
Foundations must be constructed according to the dimensions indicated in chapter 12. The machine must be fixed to the pads using proper fixings (e.g. fix every foot with four fisher fixings (or similar), that have M10 screws). CAUTION: Construct the pads for mounting the TEKNOBAGDRAIMAD PACKAGE dead level.
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5.4
REQUIREMENTS OF THE INSTALLATION ENVIRONMENT
The environment for installation must have the following requirements: Ambient air temperature range between +5 and +55 and the ambient air over a C C period of 24h must not exceed +50 C. Relative humidity range between 30 and 95% (without condensation). 5.5 CONNECTIONS TO THE SLUDGE FEEDING POINT
Refer to the reference drawing available at the back of the frontal cover. CAUTION: Connection must be carried out by qualified technicians in the specific field.
Use fairly stiff plastic or metal pipes and strong joints to avoid their yielding due to the suction pressure. If flexible suction and delivery hoses are used be careful to not bend, twist or stand on them. Fix the piping so that it is not supported by the machine. Connect the sludge piping supply to the inlet 20 . Connect the water supply to a garden hose near the unit, for the TEKNOBAG-DRAIMAD PACKAGE cleaning operation and for the preparation of the polyelectrolyte. Potable water is not required, but the use of fresh water is recommended, however.
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5.6
REMOVAL OF MATERIAL PRODUCED
The dewatering carried out by the TEKNOBAG-DRAIMAD PACKAGE produces dewatered sludge already packed in bags and filtrate coming from the process. The bags full of sludge must be manually removed form the unit and disposed as explained in paragraph 5.6.1. The filtrate outlet must be connected to a sump pit, or to the drainage system, as explained in paragraph 5.6.2. 5.6.1 DISPOSAL OF THE BAGS FILLED WITH DEWATERED SLUDGE CAUTION: In order to properly remove the bags full of dewatered sludge, the use of the trolley cart "CEM" produced by Teknofanghi is recommended.
The bags full of sludge must be manually removed form the unit (see table in the DAILY USE of the QUICK GUIDE) and must be disposed on the basis of its chemical/physical, biological characteristics, and in accordance to the safety regulations in force in the country of the installation. However the longer the sludge remains in the bag the more it loses weight by evaporation, therefore where it is possible, it is suggested to store the bags as long as possible in order to increase the dry solid percentage of the sludge to be disposed. The storage can be done in an open area as the bags are made with a special waterproof material. Note that the bag is made of polypropylene fibre and even though is not biodegradable, it is an inert material that can be disposed of as a normal solid waste material. 5.6.2 FILTRATE DISPOSAL Refer to the drawing at the back of the frontal cover. CAUTION: The installation must be carried out by technicians qualified in the specific field.
Connect the outlet gate 23 to a sump pit or to the drainage system, so that the filtrate is returned to the head of the treatment plant. Provide a connection between the point 52 and the sump, in order to allow the discharging of the exhausted polyelectrolyte.
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5.7 Refer to the chapter 14. WARNING!
ELECTRICAL CONNECTIONS
Connection must be carried out by qualified technicians in the specific field. During the connection and setting of the control panel, take care that the inside of the control panel does not get wet.
CAUTION:
The installation must be carried out by technicians qualified in the specific field. Check that the power supply matches with the required values in terms of voltage, frequency and power consumption.
Use an IEC standard cable with cross section and length appropriate to the power of the motors, bearing in mind the mains voltage and the polarity. It is recommend, though it is not obligatory, to install a residual circuit breaker (0.03A) in the electricity supply line. The supply voltage must have a steady state range of 10% of the voltage stated on the electric diagram in chapter 14. Frequency must not exceed the 1% range of the frequency requested value in the electric diagram. The mains supply should have an adequate grounding connection in compliance with the electricity regulation of the country of the place of installation. Connect power supply to terminals "R" "S" "T" and "PE" following the electrical diagram of chapter 14. Further on are listed all the inputs and outputs available on the control panel, for each type of TEKNOBAG-DRAIMAD PACKAGE unit.
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5.7.1 INPUT "IN2" Refer to the electric diagram attached to chapter 14. CAUTION: The installation must be carried out by technicians qualified in the specific field. Use a sensor with a voltage free contact normally closed, able to accept a voltage of 240 V a.c. and a current of 10 A. Provide the installation of IEC cables with appropriate length and cross section. Provide the installation with an appropriate fuse.
The input IN2 is normally used to shuts down the program when trips on the THERMAL RELAYS ALARM of an external control panel (normally for motors not driven directly by the TEKNOBAG-DRAIMAD PACKAGE control panel). Connect the contact to the terminals 1 and 15. Once installed, the program will be conditioned by the state of the contact used for the connection: Closed contact: (ALARM) Opened contact: (NORMAL) If the program is stopped, it will no possible to start it up; If the program is running, it will be shut immediately down. The machine can be started up normally.
In case of alarm the display visualises the flashing code:
If does not flash the cause has been removed. The program can be started up manually and only if the alarm has been cancelled and reset (see 6.5.2 for further details).
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5.7.2 INPUT "IN3" Refer to chapter 14. CAUTION: The installation must be carried out by technicians qualified in the specific field. Use a sensor with a free of voltage contact normally opened, able to bare a voltage of 240 V a.c. and a current of 10 A. Provide the installation of IEC cables with appropriate length and cross section. Provide the installation of an appropriate fuse.
The IN3 inlet can be used if it is necessary to shuts down the program when an external sensor detects an anomalous condition (e.g. missing of the sludge or tripping of alarm in other machine). Connect the external sensor to the terminals 1 and 9 having cared to remove the bridge factory assembled. Once that the sensor is installed, the program will be conditioned by the state of the contact used for the connection: Opened contact: If the program is paused, it will no possible to start it up; If the program is running, it will be shut immediately down. (ALARM) Closed contact: The machine can be started up normally. (NORMAL) In case of opening of the contact of the external sensor, the program shuts the unit down and visualises the flashing code:
If the code is not flashing, the contact has re closed itself. The program can be started up manually and only if the alarm has been cancelled and reset (see 6.5.3 for further details).
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5.7.3 INPUT "IN4" Refer to chapter 14. CAUTION: The installation must be carried out by technicians qualified in the specific field. Use a sensor with a free of voltage contact normally closed, able to bare a voltage of 240 V a.c. and a current of 10 A. Provide the installation of IEC cables with appropriate length and cross section. Provide the installation of an appropriate fuse.
The IN4 inlet can be if it is necessary to shuts down the program when an external sensor detects an anomalous condition (e.g. missing of polyelectrolyte, or tripping of alarm in other machine). Connect the external sensor to the terminals 1 and 13. Once that the sensor is installed, the program will be conditioned by the state of the contact used for the connection: Closed contact: (ALARM) Opened contact: (NORMAL) If the program is paused, it will no possible to start it up; If the program is running, it will be shut immediately down. The machine can be started up normally.
In case of closing of the contact of the external sensor, the program shuts the unit down and visualises the flashing code:
If the code is not flashing, the contact has re opened itself. The program can be started up manually and only if the alarm has been cancelled and reset (see 6.5.4 for further details).
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5.7.4 INPUT "IN5" Refer to the electric diagram attached to chapter 14. CAUTION: The installation must be carried out by technicians qualified in the specific field. As soon as the program detects the fault the display light on the central dot. The machine trips in alarm only after that the fault is detected for 10 seconds continuously. Use a sensor with a voltage free contact normally opened, able to accept a voltage of 240 V a.c. and a current of 10 A. Provide the installation of IEC cables with appropriate length and cross section. Provide the installation with an appropriate fuse.
The input IN5 can be used if it is necessary to shuts down the program when an external sensor detects an anomalous condition for more than 10 seconds continuously (e.g. pressure switch). Note that if the contact remains open for less then 10 second (e.g. 8 seconds and then it closes again), the program does not shut the unit down. Connect the external sensor to the terminals 1 and 11. Once that the sensor is installed, the program will be conditioned by the state of the contact used for the connection: Opened contact: (ALARM) Closed contact: (NORMAL) If the program is paused, it will no possible to start it up; If the program is running, it will be shut down after 10 second (only if the contact remains open for all this time). The machine can be started up normally.
In case of closing of the contact of the external sensor for more then 10 seconds continuously, the program shuts the unit down and visualises the flashing code:
If the code is not flashing, the contact has re opened itself. The program can be started up manually and only if the alarm has been cancelled and reset (for much details see 6.5.5).
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5.7.5 OUTPUT "OUT3" (COLLECTIVE ALARM) Refer to the electric diagram attached to chapter 14. CAUTION: The installation must be carried out by technicians qualified in the specific field.
Output "OUT3" is a voltage free normally open contact, which closes as soon as the program detects an alarm; the contact remains closed until the alarm has been reset. If the digital unit "TKN" is powered off, "OUT3" remains open. CAUTION: "OUT3" is able to accept a voltage of 240 V a.c. and a current of 10 A., the use of a 24 V signal is however recommended. Provide the installation of IEC cables with appropriate length and cross section. Provide the installation with an appropriate fuse.
Connect terminals 61 & 63" to the external control panel that needs to be informed that the TEKNOBAG- DRAIMAD program has tripped in alarm.
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5.7.6 OUTPUT "OUT4" (PROGRAM END) Refer to the electric diagram attached to chapter 14. CAUTION: Technicians qualified in the specific field must carry out the installation.
Output "OUT4" is a voltage free normally open contact, which closes only when the program is over (the display shows the code "EE", see 4.2). If TKN is powered off, the outlet "OUT4" remains open. CAUTION: "OUT4" is able to accept a voltage of 240 V a.c. and a current of 10 A., the use of a 24 V signal is however recommended. Provide the installation of IEC cables with appropriate length and cross section. Provide the installation with an appropriate fuse.
Connect terminals 61 & 62 to the external control panel that needs to be informed that the program is over.
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USAGE
6.1
INDIVIDUAL SAFETY PROTECTION
Operators must wear rubber boots, gloves and tight overalls without loose belts or sleeves. On the basis of the biological/chemical/physical hazard associated with sludge treatment, the use of additional protection is strongly recommended (e.g. goggles, face mask).
6.2
CONTROL DEVICE DESCRIPTION
In chapter 14 are listed symbols, codes, descriptions and functions of each control device fitted on the TEKNOBAG-DRAIMAD PACKAGE and the control panel. Refer also to paragraph 4.1 to identify the emergency stop mounted on the machine frame. The digital control unit is supplied with a program already loaded and complete of all the necessary parameters to proper operate the TEKNOBAG-DRAIMAD PACKAGE. The program and its original parameter are loaded in the digital unit just before shipping the unit. The digital unit TKN is able to keep integer the data also when is not powered. To re-load the original parameters of the program follows the instruction described in 6.6 and 6.6.2 CAUTION: Loading the original parameters will erase the customisations. To apply also the customisation, first re-load of the original parameters and then enter the modification manually .
Should the plant need particular setting refer to section 6.6.
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6.3
ADJUSTMENT TO CARRY OUT BEFORE THE FIRST START UP
6.3.1 PNEUMATIC ADJUSTMENT (BCAVP / BCAVPK ONLY) Refer to the diagrams shown in chapter 13. CAUTION: These regulation must be carried out technicians qualified in the specific field. by
Open the "VM1" valve by pulling its handle towards the "GCVPC01" group and check that the air pressure gauge "W1" indicates the requested pressure (see chapter 13). If a different pressure is shown, lift the upper knob of the "RK1" air filter/reducer and screw or unscrew it in order to increase or decrease the pressure; once the pressure is set, lock the knob of "RK1" by pushing it down. 6.3.2 RECOMMENDATIONS REGARDING FLOCCULANT It is recommended to consult one or more specialists in the flocculant (or polyelectrolyte) field. Our experience shows big and strong flocks give better results. Ask for all the information regarding: dilution rate, dilute product lifetime, normal usage and safety recommendations. Selection of the proper product is essential to obtain the best results, It is recommend to carry out a series of flocculation tests to establish the proportions between sludge and flocculant. Take into account, that well flocculated sludge shows strong flocks which do not break-down, even after many mixings. Do not exceed the flocculant dosage, since adding too much flocculant weakens and sometimes breaks them down; moreover as the flocculant is very sticky, it may blind the filter cloth of the bags. 6.3.3 FIRST START UP OF THE PROGRAM Operate the first start up following the instructions indicated in the FIRST START UP section of the QUICK GUIDE at the beginning of this handbook. The next day the operator must verify the level of the sludge inside the bags: If the bag are too much under-filled, the "WORKING TIME should be increased (see advanced user section 6.6.1); If, the program has not finished yet (the display visualises the flashing code "_FF_") the "WORKING TIME" should be decreased (see advanced user section 6.6.1); If the operator cannot wait the end of the program to change the bags, follows the instructions given in paragraph 6.4.2. Once a suitable "WORKING TIME" is found, it will not be necessary to carry out further modifications unless the sludge or the polyelectrolyte or the pumps vary.
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6.4 WARNING!
DAILY USAGE
The characteristics of the sludge generated by waste water treatment plants, make it possible to be exposed to hazardous chemical/biological substances. Users and operators must be aware. All operators must be informed of the potential hazards connected with the sludge being dewatered, and how to protect themselves. Before starting up the machine, the operator must have identified and studied the control devices and their functions (see chapter 14).
CAUTION:
First of all the verify that the display shows the code:
so that it will be clear that the program launched the previous time has been completed. If the program is not over follows the instruction given in paragraph 6.4.1 If the program has been completed remove the safety guard in front of the bags and check that the level of the sludge inside the bags is around point "SL" (see drawing at the back of the frontal cover): If yes proceed with the instruction given in the QUICK GUIDE at the beginning of this handbook (BAG REMOVAL and INSTALLATION OF NEW BAGS tables). If some clumps of sludge are present inside the bag enclosure, before starting the new dewatering cycle, open the inspection door 300 and push them inside the new bags them by means of the water hose. Start up the machine, following carefully the sequence described in the "DAILY USE" table of the QUICK GUIDE" at the beginning of this handbook. CAUTION: Avoid too frequent switching on and off.
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CAUTION:
Before leaving the working machine, the operator must ensure that: The plant has no leaks. The sludge enters the bags normally. The filtrate discharging from the outlet is as clear as expected (see point 23 of the picture at the back of the frontal cover). The sludge does not leak from around the clamps of the bags. The display visualise a decreasing time.
CAUTION: 03B-PACK-P 06B-PACK-P
Ensure that during the refilling of the sludge the air pressure is discharged by SFX2 and that when the display shows the hyphens of bags full the pressurisation start blowing the bags and increasing the drainage (see also chapters 13 and 14).
WARNING!
In case of power failure, the main switch Q0 should be turned off (0 position).
Once the program is running the TEKNOBAG-DRAIMAD PACKAGE does not need to be manned continuously, however visual checking is suggested. Normally, the bags are left on the TEKNOBAG-DRAIMAD PACKAGE until the sludge inside the bags drops down to the point "SL" (see the drawing at the back of the frontal cover). Should a fault condition occur during the execution of the program, refer to paragraph 6.5.
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6.4.1 STOPPING OF THE PROGRAM BEFORE THE SCHEDULED END Should it be necessary to stop the program definitely before its scheduled end, push "P2". The level of the sludge will drop down by means of the gravity action. At this stage the sludge is surely above SL, therefore it is necessary to wait that it drops under point SL. If this operation must be carried out immediately follows the instruction of 6.4.2 further on listed When the sludge is not detected anymore, the program will shut the machine down (the display show the code .
Now it is necessary to wait that the sludge drops to the SL point, otherwise to close the removed bags some sludge will have to be extracted manually from their inside.
6.4.2 REMOVAL OF THE BAGS BEFORE THE SCHEDULED TIME If the user cannot wait until the sludge drops down to point "SL", he must follow these instructions (refer to the drawing at the back of the frontal cover): Push "P2" to stop the program; Turn "Q0" to position "0"; Remove the safety guards "200" (see 4.1); Open, without completely releasing, the lever closing device of the clamps "F"; Slip off the back of the bag so that the sludge overflows in the inner part of the machine; Once that the sludge is dropped to point "SL", repeat the same process for the next bag. When all the bags have been removed, carry out the unscheduled washing (see 8.1).
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6.5
TROUBLE SHOOTING
Should the program sense a fault condition, the TEKNOBAG- DRAIMAD shuts down and the display shows a blinking code related to the type of alarm detected. In case of presence of more than one alarm, the display will visualise all the relevant codes one by one. Before reset the alarm the cause of the alarm must be rectified. After that the cause has been removed the code will not blink anymore; in order to re-start the program again, keep the button "P12" pushed until the code here below disappear (about 5 seconds):
Note that the code appears as soon as P12 is pushed, and during this visualisation a beeping sound will be audible. If after 5 seconds this code is no disappeard it means that at least one alarm is still active (if P12 is released, the display visualises it). When the display shows the "WORKING TIME", the program is ready to be started up manually (see the PROGRAM START UP section of the QUICK GUIDE, at the beginning of this handbook).
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6.5.1 ALARM "H-01" (THE SLUDGE LOADING LASTED TOO LONG) The display shows the code:
The program has taken too much time to fill or refill the bags. The program times the length of each sludge loading cycle: when one of these exceeds the related SAFETY TIME parameter, the unit is shut down. The causes of this alarm could be the missing of sludge or polyelectrolyte, the clogging of the piping or the bad positioning of the bags or a bag damaged. The program automatically calculates the SAFETY TIMES during the very first start up of the unit. Unless the sludge is changed or the pumps are set to another delivery flowing, the SAFETY TIMES should not be recalculated. ACTION TO CARRY OUT: Check that: The bags are properly installed and are not damaged; There is no leakage of sludge; The sludge supply line is not blocked or damaged and the sludge is available. CAUTION: Operations must be carried out by qualified technicians in the specific field. These TEKNOBAG-DRAIMAD PACKAGE control directly the sludge and polyelectrolyte by means of the output "M2" and "M3". Check that the connections are properly made and that the pumps can operate normally .
CAUTION:
If everything appears normal, it is possible that this alarm is due to an accident already solved (e.g. a temporarily clogging along the sludge line). Reset the alarm condition and re-start the program again (see paragraph 6.5): remain near the unit until has loaded the sludge another couple of times without problem. If the alarm tripped during the first filling (bags half filled) the loading of the bags should be performed with new ones otherwise it will not be possible to understand whether the safety time is too short. If it is not possible to remove the bags immediately, the next time that the program will be executed from the beginning the operator must stay near the machine. If the alarm continues to came up, it is necessary to set the program in order to let it calculate the SAFETY TIMES again. Proceed as follows (If the control panel is not powered) turn the main switch Q0 to position 1, the display must visualise on of this two codes (otherwise see 6.6): Should the display visualise the WORKING TIME cancel it by pushing the P2 and P12 together until the display visualises one of the two codes above (about 8 seconds). Note that when the display visualise the WORKING TIME frozen, it will be possible to visualise some parameter of the program even though they cannot be adjusted.
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Once that one of the two codes here above is visualized, carry out these instructions: Open the TKN cover; Push once the button so that the display turn off for a second and then visualise (the drawing shows the original value of this visualisation):
Push another time the
button and the display will visualise:
Push together the and buttons until the display change the visualisation (about 14 seconds, here below is indicated the original parameter of this step):

Now push the and buttons until the display visualise the above code. Now push once the button so that it will be visualised the following display (here below is indicated the original parameter of this step): Now push the and buttons until the display visualise the above code. Once reached push once the button so that the display visualises: and soon after come backs to one of these two codes:

CAUTION:
Note before executing the program with the new parameters, replace the bags already used with new one. Remember to close the cover of the "TKN" before starting up and leaving the unit
Now the program is ready to recalculate the SAFETY TIMES. Start the program following the table QUICK GUIDE: STARTING UP OF THE PROGRAM. Once that the program has performed the loading of the sludge twice WITHOUT PROBLEMS, the SAFETY TIMES for will be calculated and recorded inside the TKN. After that the program will continue to use the new SAFETY TIMES unless another adjustment will be applied. If the alarm H-01 trips on up again after the recalculation of the SAFETY TIMES, consult the nearest reseller or the Teknofanghi directly.
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6.5.2 ALARM "H-02" (THERMAL RELAYS ALARM or input " IN2" closed) The display shows the code:
CAUTION: CAUTION:
Operations must be carried out by qualified technicians in the specific field. The tripping on of one of the circuit breakers Q1, Q2 or Q3 on the control panel can cause the alarm condition (for much details see also chapter 14).
ACTION TO CARRY OUT: CHECK THE CIRCUIT BREAKER: Turn the main switch Q0 to position 0, open the control panel and look for the circuit breaker with the "STOP" red button tripped and the word "OFF" clearly visible. Refer to the electrical diagram in chapter 14 to identify the associated equipment. Check that the circuit breaker rating matches the values indicated on the electric diagrams and also to the metal label fixed to the associated equipment. Check if there are any problems with the equipment (e.g. damage, bad connections). To release the tripped circuit breaker push the "START" black button so that the writing "ON" is clearly visible. Close the control panel door and turn the main switch Q0 to position 1: The display should show what remains of the "WORKING TIME", otherwise the display will show the code related to the alarm.
CHECK THE DEVICE CONNECTED TO IN2 INLET (if any): the device connected to the IN2 inlet should have the contact open; investigate about the closing of its contact and remove the anomaly (see also 5.9.1). Once that the cause of the alarm has been removed (the code does not blink anymore) re-start the program again, keeping the button "P12" pushed until the code here below disappear (after it has blinked for 8 times):
(if the code does not disappear, refers to paragraph 6.5). When the display shows the "WORKING TIME", the program is ready to be started up manually (see the PROGRAM START UP section of the QUICK GUIDE, at the beginning of this handbook). CAUTION: Before leaving the machine check that the program run properly at least for 30 minutes. If the circuit breaker continues to trip DO NOT CHANGE THE SETTINGS and call the technical service of the manufacturer.
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6.5.3 ALARM "H-03" (device connected to input "IN3") The display shows the code:
CAUTION:
Operations must be carried out by qualified technicians in the specific field.
The device connected to the input "IN3" has opened the contact (see 5.9.2). ACTION TO CARRY OUT: Check the external device connected to "IN3" and remove the cause of the alarm. If no device is connected to IN3, it should be bridged. Once that the cause of the alarm has been removed (the code does not blink anymore) restart the program again, keeping the button "P12" pushed until the code here below disappear (after it has blinked for 8 times):
(if the code does not disappear, refers to paragraph 6.5). When the display shows the "WORKING TIME", the program is ready to be started up manually (see the PROGRAM START UP section of the QUICK GUIDE, at the beginning of this handbook).
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6.5.4 ALARM "H-04" (device connected to input "IN4") The display shows the code:
CAUTION:
The device connected to the input "IN4" has closed its contact (see 5.9.3). ACTION TO CARRY OUT: Check the external device connected to "IN4" and remove the cause of the alarm. Once that the cause of the alarm has been removed (the code does not blink anymore) restart the program again, keeping the button "P12" pushed until the code here below disappear (after it has blinked for 8 times):
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6.5.5 ALARM "H-05" (device connected to input IN5) The display shows the code:
CAUTION:
The device connected to the input "IN5" has opened its contact (see 5.9.4). CAUTION: The program shuts down after that "TKN" detects the fault for 10 seconds continuously. During this delay the display visualises a dot in its centre. Independently from the visualisation displaied.
Refer to the electrical diagram attached to chapter 14. ACTION TO CARRY OUT: Check the external device connected to "IN5", and remove the cause of the alarm. If no device is connected to IN5, it should be bridged. Once that the cause of the alarm has been removed (the code does not blink anymore) restart the program again, keeping the button "P12" pushed until the code here below disappear (after it has blinked for 8 times):
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6.5.6 ALARM "H-06" (SND) The display shows the code:
CAUTION:
The level sensor "SND" has a problem: the signal sent by the electrode ECOM arrives to the EMAX electrode but not to the EMIN one: being this impossible, the program consider this situation an alarm.
Refer to the electrical diagram attached to chapter 14. ACTION TO CARRY OUT: Check the connections of "SND" and carry out the instructions in paragraph 8.3 "LEVEL SENSOR "SND" CLEANING OR REPLACEMENT". After that restart the program again, keeping the button "P12" pushed until the code here below disappear (after it has blinked for 8 times):
(if the code does not disappear, refers to paragraph 6.5). When the display shows the "WORKING TIME", the program is ready to be started up manually (see the PROGRAM START UP section of the QUICK GUIDE, at the beginning of this handbook). CAUTION: If after the cleaning the alarm is still active either the digital unit TKN or the level sensor SND is faulty. DO NOT CHANGE ANYTHING and call the technical service of the nearest dealer or the Teknofanghi directly.
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6.5.7 ALARM "H-99" (EMQE activated) The display shows the code:
The program detects that the emergency stop "EMQE" has been activated (see drawing of chapter 4 and chapter 14). ACTION TO CARRY OUT: Verify why it has been activated , and correct the problem. To remove the alarm condition release the self locking button by turning its head clockwise (the code should stop blinking); After that re-start the program again, keeping the button "P12" pushed until the code here below disappear (after it has blinked for 8 times):
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6.6
ADVANCED USERS
The program can be adjusted through five buttons available on the TKN digital unit (see the picture here below). CAUTION: Only the expert operator should apply this modification.
In this handbook this 5 buttons will be identified as follows: LEFT = ; RIGHT = ; DOWN = ; ENTER = .
UP = ;
In order to have the access to the data of the program the display must visualise one of these two codes stand still:
Should the display visualise the WORKING TIME cancel it by pushing the P2 and P12 together until the display visualises one of the two codes above (about 8 seconds). Note that when the display visualise the WORKING TIME frozen, it will be possible to visualise some parameter of the program even though they cannot be adjusted. CAUTION: Note before executing the program with the new parameters, replace the bags already used with new one.
During the manual adjusting of the program, the P3 push button is disabled, therefore the TEKNOBAG- DRAIMAD cannot be started up. In the following paragraphs are listed the operation to carry out for each adjustable parameter.
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6.6.1 HOW TO ADJUST THE WORKING TIME The WORKING TIME is the parameter that allows regulating the amount of sludge to dewater during a dewatering cycle (amount of sludge loaded in the bags). This parameter should be changed only if the program is not over within the scheduled time or though it expired, the bags are found under-filled or overfilled. In any case before operating the adjustment ensure that the under-filling /overfilling was not due to an accident (e.g. pump defect or piping blockage or missing of sludge / polyelectrolyte). Adjust the WORKING TIME proportionally to the level of sludge found using this rules: With a shorter time less sludge enters the unit will , therefore the next day the bags will be less filled; With a longer time more sludge enters the unit, therefore the next day the bags will be more filled. The standard WORKING TIME is 5 hours and 0 minutes (original parameter). To adjust the WORKING TIME operate as it follows: (If the control panel is not powered) turn the main switch Q0 to position 1, the display must visualise on of this two codes (otherwise see 6.6):
Push the or button to reach the desired value (remember that these two couples of digits indicate hours and minutes). Once that the desired value has been reached push once the button so that the display visualises: (Even if nothing has changed) and soon after come backs to one of these two codes:

CAUTION:
Open the TKN cover; Push once the button so that the display turn off for a second and then visualise (the drawing shows the original value of this visualisation):
Remember to close the cover of the "TKN" before leaving the unit In order to have the new WORKING TIME at hand, it is recommended to write it here below.
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6.6.2 HOW TO LOAD THE PROGRAM WITH ITS ORIGINAL PARAMETERS In the TKN digital unit is recorded a copy of the program and its original parameters, so that, in case of accident, it will be always possible to re-load the program with its original parameters in the main memory of the TKN. This data are stored in a chip that unlike the main memory does not need to be powered therefore its data cannot be lost or modified in any way. CAUTION: Before carry out these instructions ensure to have at hands also all the necessary adjustment to replace, since during the reloading of the original parameters all the manual adjustment previously applied will be lost.
Follows this instructions here below: (If the control panel is not powered) turn the main switch Q0 to position 1, the display must visualise on of this two codes (otherwise see 6.6):
Push twice the button and the display will visualise:
Push together the buttons & until appear confirmations that the parameters are completely loaded (about 2 seconds, the display visualises the following code):

Now the program and its original parameters have been re-loaded. All the previous manual adjustment has been deleted. Push once the button so that the display visualises (even if the data have not been loaded):
and soon after come backs to one of these two codes:
CAUTION:
On average the data loaded in the main memory remains integer for at least six months without powering on the control panel. Therefore should be foreseen a longer period of powering off of the machine, in order not to corrupt the program , it is recommended to power the control panel on for a couple of minutes at least once every 6 months.
Open the TKN plastic cover; Push once the button so that the display turn off for a second and then visualise the following code (the drawing shows the original value of this visualisation):
Remember to close the cover of the "TKN" before leaving the unit
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6.6.3 AUTOMATIC SHUT DOWN OF THE POLYELECTROLYTE STIRRER. This program allow the automatic stopping of the polyelectrolyte stirrer after a scheduled time (the stirrer of the polyelectrolyte is driven through the M1 OUTLET). The standard parameter disable this function, to enable it proceed as follows: (If the control panel is not powered) turn the main switch Q0 to position 1, the display must visualise on of this two codes (otherwise see 5.10): Open the TKN cover; Push once the button so that the display turn off for a second and then visualise (the drawing shows the standard visualisation, see 5.8.1):

Push for 9 times the original parameter):

button and the display will visualise (here below is indicated the
Push the button to enable this function and the display visualises : Push to record it in the digital unit (it appears the following code): Now the program will stop M1 after 15 minutes that has been activated. To change this time, the operator have to: Push once the button so that the display visualise: Push for 9 times the original parameter): button and the display will visualise (here below is indicated the
Push the and buttons continuously until the display visualise (about 6 seconds):

Pushing the or the button the time on the right will increase / decrease (the time is in minutes). Once reached the desired mixing time, push once the button so that the display visualises:

(Even if nothing has been modified) and soon after come backs to one of these two codes:
CAUTION:
Remember to close the cover of the "TKN" before leaving the unit In order to have all the values at hand, it is recommended to write this value here below.
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7
WARNING!
SCHEDULED MAINTENANCE
All maintenance operations must be carried out by operators trained as specialist technicians. (See paragraph 1.4). During the scheduled and unscheduled maintenance operations, the area of respect of the machine must be restricted to the authorised operators only (see 5.1). Carry out all the scheduled maintenance operations following the instructions as shown in this handbook. All the scheduled and unscheduled maintenance operations must be carried out with all power isolated from he machine and all circuits discharged. Operators must wear all the required individual protection.
CAUTION:
Before carrying out any of the maintenance or adjustment to the TEKNOBAG-DRAIMAD, the operators must have studied this entire handbook. The maintenance operation frequency, shown further on, is to be considered indicative only, and will vary from plant to plant. Any obvious deviation from this recommended frequency should be apparent after the first period of use and the specific application of this machine. Set the maintenance frequency suitable for the application. During the manual washing operations, do not point the water jet directly at the control panel.
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7.1
EVERY 5 WORKING DAYS: BAGS EQUALLY FILLED
Follow the "START UP OF THE PROGRAM" table of the QUICK GUIDE and stay nearby the machine to check that the bags are equally filled of sludge. If the operator notices that the sludge is not equally distributed in all the bags, or the "DRAINING CYCLE" starts when one or more bags are not completely filled, carry out the instruction of the paragraph 8.1 "UNSCHEDULED WASHING" and if this doesn't correct it, also the instruction of the paragraph 8.3 "LEVEL SENSOR "SND" CLEANING AND REPLACEMENT". 7.2 EVERY 60 WORKING DAYS: OIL LEVEL
Check that the level of the oil in the polymer pump (point PD2). In case of necessity unscrew the breath plug 1 and refill it with one of the following oils: ESSO SPARTAN EP 320 MOBIL MOBILGEAR 632 SHELL OMALA OIL 320
7.3
EVERY 3 YEARS: OIL REPLACEMENT (or 10.000 WORKING HOURS)
Change the oil in the polymer dosing pump (0.40 litres): unscrew the plug PD3 and discharge the old oil; then close PD3, unscrew the breath plug PD1 and pour the new oil. Once done screw again the breath plug PD1. The gearbox of the stirrer is long life lubricated and it does not need maintenance.
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8
WARNING!
UNSCHEDULED MAINTENANCE
All the maintenance operations must be carried out by operators trained as specialist technicians. (See paragraph 1.4).
During the scheduled and unscheduled maintenance operations, the area of respect of the machine must be restricted to the authorised operators only (see 5.1). All the scheduled and unscheduled maintenance operations must be carried out with all power isolated from the machine and all circuits discharged. Operators must wear all the required individual protection
CAUTION:
Before carrying out any of the maintenance or adjustment, operators must have studied this entire handbook. Before carrying out any of the scheduled or unscheduled maintenance operations, the main switch Q0 must be locked in position 0 by using the padlock supplied with the machine. Before carrying out any of the part replacements described here, note the positions of the worn out items. In order to assemble the new parts properly, it is advisable to take note of all the references available. During the manual washing operations, do not point the water jet directly at the control panel.
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8.1 WARNING!
UNSCHEDULED WASHING Ensure that all the energy sources are cut off from the machine and all its circuits are discharged. For the specific hazards, the operators must wear all the required individual protection.
In order to ensure the correct distribution of the sludge in all the bags, it is necessary to remove the build-up of sludge that sometimes remains between the funnels inside the hood. Using a hose, wash away the sludge accumulated between the holes of the funnels. If necessary clean also the drainage picking up tank below the bags: open the safety guard 200, and always using the hose, remove all the sludge drops. Once the washing is finished, replace the "200" safety guard. After the cleaning operation, the program can be started using these bags: even though they have the sludge fallen during the cleaning operation, the dewatering cycle will not be compromised.
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8.2
DIGITAL CONTROL UNIT "TKN" REPLACEMENT All the operations described here must be carried out with all the energy sources cut off from the machine and all circuits completely discharged. Operators must wear all the required individual protection. Before carrying out the operations described here, lock the main switch Q0 in position 0 by using the padlock supplied with the machine. Before carrying out any of the maintenance or adjustments, operators must have read and understood this handbook. Note the positions of the pieces to replace. It is recommended to take note of all the settings, in order to replace the new parts properly (e.g. customised timer settings).
WARNING!
CAUTION:
The control panel is solid state and has no user accessible parts. A replacement panel must be ordered. To replace the "TKN" unit follow these instructions: CAUTION: Operations must be carried out by qualified technicians in the specific field.
Open the control panel; Disconnect the green terminal connectors from the back of "TKN"; Unscrew the two fixing screws to extract them from the body of "TKN"; Open the plastic cover on the front of the control panel; Extract the whole "TKN" from the door of the control panel; Install the new "TKN" following the above instructions in reverse order. Once that everything is connected remove the padlock.
If some of the parameters of the program of the former digital have been manual adjusted, proceed to apply the same adjustment with the new digital unit before start up the unit (all the information should have been written in the relevant paragraph, see 6.6 and under paragraph). Start the unit following the table QUICK GUIDE: FIRST START UP, so that the program will be able to calculate the safety times for the H-01 alarm.
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8.3
LEVEL SENSOR "SND" CLEANING OR REPLACEMENT All the operations described here must be carried out with all the energy sources cut off from the machine and all the circuits completely discharged. Operators must wear all the required individual protection. Before carrying out the operation described here, lock the main switch Q0 in position 0 using the padlock supplied with the machine. Before carrying out any maintenance or adjustments, operators must have read and understood this handbook. Note the positions of the pieces to replace and take note of every reference possible in order to re-assemble the new parts properly (e.g. screw positions).
WARNING!
CAUTION:
To clean the level sensor "SND" follow these instructions: Unscrew the PVC bolt "SNDB" (see adjacent page); open the cover of the raceway and remove the sheath of the level sensor; Lift out the level sensor from the hood; Clean off all the electrodes. Once the electrodes are cleaned, replace the level sensor on the unit proceeding in reverse order. CAUTION: If after the cleaning the alarm is still active either the digital unit TKN or the level sensor SND is faulty: DO NOT CHANGE ANYTHING and call the technical service of the manufacturer.
Once sure that the level sensor has to be replaced, proceed as follows: CAUTION: Operations must be carried out by qualified technicians in the specific field.
Open the control panel; Unplug the wires of the level sensor "SND" according to the appropriate circuit diagram (see 14). Slacken the cable clamp on the control panel; Extract the wires from the control panel box and remove the old level sensor as described above; Install the new level sensor following the above instructions in reverse order.
Before powering on the machine, go around the machine to ensure that everything is properly connected. Unlock the padlock, take it from the main switch Q0 and follow the "START UP OF THE PROGRAM" table of the QUICK GUIDE. Once the machine is operating, check that everything works properly.
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8.4 WARNING!
SLUDGE AND POLYELECTROLYTE PUMPS All the operations described here must be carried out with all the energy sources cut off from the machine and all the circuits completely discharged. Operators must wear all the required individual protection. Before carrying out the operation described here, lock the main switch Q0 in position 0 using the padlock supplied with the machine. Before carrying out any maintenance or adjustments, operators must have read and understood this handbook. Note the positions of the pieces to replace and take note of every reference possible in order to re-assemble the new parts properly (e.g. screw positions). Operations must be carried out by qualified technicians in the specific field.
CAUTION:
In case of lower or irregular sludge flow rate or presence of noises in the sludge pump, follows the here below instruction (for much details refer to the drawing in chapter 10): 8.4.1 SLUDGE PUMP FOR 02B-PACK / 03B-PACK / 03B-PACK-P The motor of the pump available on the 02B-PACK / 03B-PACK / 03B-PACK-P has the following characteristic: 0.55 kW, 8 poles, 680 RPM (50Hz), IEC 90 B5 INSPECTION AND REPLACEMENT OF STATOR OF THE SLUDGE PUMP For disassembling the stator, unscrew the four tie-rods, remove the end flange connection and extract the stator turning it anticlockwise. Reassemble the stator following the operation inversely, after having lubricated the terminal part of it to make easier the assembling operation. Use Vaseline or silicon oil. ROTOR REPLACEMENT (dismantling) OF THE SLUDGE PUMP Follow the procedure described above, then remove also the pump body (The transmission shaft is visible). Clean the transmission carefully. Push back the rubber sleeve (33), remove the pin (44.04): not the rotor has been released (for much details see drawings available in chapter 10).
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ROTOR REPLACEMENT (re-assembling) OF THE SLUDGE PUMP Before re-assembling clean all the dismantled parts. Lubricate now the rotor with Vaseline or with silicon oil, re-making then all operations described above. Deep all rubber sleeves in hot water, making so easier the re-assembling of joint. The operation is concluded reassembling body pump, stator, tie rods and finally out-let flange. ATTENTION: All the time that this operation is carried out, it must be replaced the O-rings of the stator (2 pieces), and of the body pump (1 piece). INSPECTION AND REPLACEMENT OF JOINT SHAFT OF THE SLUDGE PUMP The joint of transmission at the end of the shaft, has to be considered as one of the most important parts of the pump, and for that reason needs a correct and regular inspection. The rubber sleeve should be replaced even for light damaging, even when the pump is working normally. This simple norm allow to have a much longer life of the joint and making necessary only the replacing of few parts instead of the complete shaft. Before replacing the sleeves, deep them for few minutes in hot water, in order to softer the rubber and easier the operation. To replace the complete joint shaft, proceed follows: repeat the instruction of INSPECTION AND REPLACEMENT OF THE STATOR and also ROTOR REPLACEMENT described above; Remove both the pins of the rotor and of the drive motor as below described: push the rubber sleeve, in order to take it back (33); remove the pin (40.04).
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OTHER DETAILS OF THE 02B-PACK and 03B-PACK SLUDGE PUMP
REF 01 11 12 15 23
DESCRIPTION HOLLOW SHAFT (C40/AISI1040) ROTOR (C40+CRHCP) JOINT SHAFT (X2 TYPE) RETAINING STUD MECHANICAL SEAL (CER/GRA NBR ) ITS SHAFT=C40/AISI1040 STATOR (NBR) O RING STATOR O RING (BODY PUMP) RUBBER SLEEVE SEE POINT 40.04 LONG PIN SHORT PIN SEAL PLATE
No 01 01 01 02 01
REF 51 52 53.03 57 75
DESCRIPTION OUTLET FLANGE BODY (G20) MECHANICAL SEAL HOUSING (C40/AISI1040) COUPLING FLANGE B3 SCREWED PLUG
No 01 01 01 01 01
31 32.03 32.17 33 40.02 40.03 40.04 45.01
01 02 01 02 01 01 01 01
73.34 79.34 79.82 80.03 82.04
WASHER WASHER GRUB SCREW CAP NUT STUD
04 04 02 04 02
Note that point 40.02 is substituted by the below 40.04 (JOINT SHAFT).
JOINT SHAFT X2 TYPE
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8.4.2 SLUDGE PUMP OF 06B-PACK / 06B-PACK-P
The motor of the pump of the above units has the following characteristic: 2.2 kW, 2 poles, + reducer i= 3.87, pump speed 724 RPM (50Hz), IEC 90 B5 (the power supply of the match the data available on the sheet 4 of the electric diagram of the chapter 14). INSPECTION AND REPLACEMENT OF STATOR OF THE SLUDGE PUMP remove the port by unscrewing the four blocking nuts; unscrew and remove the four tierods; extract the stator by turning it in the opposite way of the arrow marked on the body pump. ROTOR REPLACEMENT (dismantling) OF THE SLUDGE PUMP after having removed the stator, remove the screws which fasten the pump casing to support and the screws of the mounting flange. After that withdraw the pump casing, remove the housing from the rotor, the pin on the impeller head using a pin driver, and in the end the rotor itself. TRANSMISSION SHAFT REPLACEMENT (dismantling) OF THE SLUDGE PUMP withdraw the two hoses clamps from the drive shaft (pos. 76.03), remove the rubber sleeve (pos. 33) then remove the two pin circlip (pos. 71.02). Now take away the pin, the cross and extract the transmission shaft. GLAND PACKING REPLACEMENT (dismantling) OF THE SLUDGE PUMP Unscrew the nuts (pos. 80.33) and divide the gland from the housing (pos. 54.01 53.01). Remove the old packing (pos. 21.01) and clean the hallow drive shaft (verify whether is necessary its replacing). Do not use pointed tools because there is the possibility to seriously damaged either shaft and / or packing. Set down the new packing, at the beginning push it only with the simple hands, making in the way to place the packing between shaft and housing. SLUDGE PUMP ASSEMBLING Assemble all pump group followings the dismantling instruction in reverse order. Use always new pin to assemble the jointed transmission shaft. Lubricate rotor and stator before inserting one into the other( if the stator is made with EPDM rubber use soapy water or silicon oil avoiding to use any other type of oil or grease). CAUTION: not to over tighten the packing gland bush as this could damage the drive shaft and the packing, causing leaking from the sealed area. Packing gland seal limits the leaking of the pumped product but it should not stop it completely; few drops of leaking are necessary to cool the drive shaft, avoiding the overheating. During first start up screw lightly the gland packing (pos. 54), allowing 100-200 drops/min of leaking for the first 10-15 minutes. After that close the packing gently in order to reach as minimum leakage as possible.
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DETAILS OF THE SLUDGE PUMP OF THE 06B-PACK / 06B-PACK-P
POS. 01 11 12 15 31 32.04 32.17 51 52 57
DESCRIPTION FEMALE DRIVE SHAFT ROTOR TRANSMISSION SHAFT RETAINING STUD STATOR O RING OF THE STATOR O RING HOUSING OUTLET FLANGE PUMP BODY COUPLING FLANGE
No 01 01 01 04 01 02 01 01 01 01
POS. 75 79.34 79.35 79.82 80.03 80.04 81.05
DESCRIPTION DRAIN PLUG WASHER
WASHER
GRUB SCREW CAP NUT CAP NUT SCREW
No 01 04 04 01 04 04 04
TRANSMISSION SHAFT Y TYPE
GLAND PACKING
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POLYELECTROLYTE PUMP In case of lower or irregular polyelectrolyte flow rate or noises in the polyelectrolyte pump, it is suggested to check the its valve units. Here below are reported the instruction to dismantle them (Refer first to the pump head section drawing):
VALVES UNITS Pay attention to the arrangement of the valve components; each valve ball (see point 15) rests by gravity on its seat (see point 5). Unscrew, one at the time, the housing of the suction and discharge valve units (see 14). Take note of the arrangement, of the various components of the valve unit. Extract the valves and clean carefully their seat, balls, guides and housings. Check the integrity and cleanliness of all the components. If necessary replace worn or damaged seats or valves. Reassemble valve unit exactly as before noted. DIAPHRAGM (pos. 32): Take off pump head screws (pos. 29). Open the pump head (pos.21). Unscrew the diaphragm (pos.32) by turning it counter clock-wise. Before screwing up the diaphragm, grease its thread (pos.102) (threaded top end of the slide). Screw up the diaphragm and make sure that it reaches its end position. Re-assemble the pump head (pos. 21), checking valves, groups arrangement. Gradually screw back in pos. 29 the pump head screws. Do not over tighten.
In case of problem contact the Teknofanghi or the nearest distributor (more details regarding this pump are reported in the paragraph 10).
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8.5
PNEUMATIC SLEEVE VALVE REPLACEMENT (03B-PACK-P / 06B-PACK-Ponly) All the operations described here must be carried out with all the energy sources cut off from the machine and all circuits completely discharged. Operators must wear all the required individual protection. Before carrying out the operations described here, lock the main switch Q0 in position 0 by using the padlock supplied with the machine. Before carrying out any of the maintenance or adjustments, operators must have read and understood this handbook. Note the positions of the pieces to replace. It is recommended to take note of every reference possible, in order to reassemble the new parts properly (e.g. screw positions). Operations must be carried out by qualified technicians in the specific field.
WARNING!
CAUTION:
Refer to diagrams and drawings of chapter 13. If necessary, clean the unit by means of a hose. Cut off the air supply source by pulling the handle of "VM1" towards the outside of the "GCVPC01" group; Lift the knob of "RK1" air reducer; Unscrew it in order to bring the pressure to 0 bar; Unplug the plastic pipe "XV1" from the pneumatic sleeve valve; Unscrew the nuts of the flexible pipe connected to the outlet of the valve; Unscrew the valve from the piping connected to the sludge pump; Replace the sleeve valve with the new one repeating the above steps in reverse order. Follow the pneumatic setting described in paragraph 6.3.1 (if necessary). Before powering on the machine, go around the machine to ensure that everything is properly connected. Unlock the padlock, take it from the main switch Q0 and follow the "START UP OF THE PROGRAM" table of the QUICK GUIDE; once the machine is operating, check that everything works properly.
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8.6
PRESSURE UNIT "XV02-2" REPLACEMENT ( 03B-PACK-P / 06B-PACK-P only) All the operations described here must be carried out with all the energy sources cut off from the machine and all circuits completely discharged. Operators must wear all the required individual protection. Before carrying out the operations described here, lock the main switch Q0 in position 0 by using the padlock supplied with the machine. Before carrying out any of the maintenance or adjustments, operators must have read and understood this handbook. Note the positions of the pieces to replace. It is recommended to take note of every reference possible, in order to reassemble the new parts properly (e.g. screw positions). Operations must be carried out by qualified technicians in the specific field.
WARNING!
CAUTION:
Refer to diagrams and drawings of chapter 13. If necessary, clean the machine by means of a hose. Cut off the air supply source by pulling the handle of "VM1" towards the outside of the "GCVPC01" group. Lift the knob of "RK1" air reducer; Unscrew it in order to bring the pressure to 0 bar; Unplug the plastic pipes "XV2" and "P01" from "XV02-2". Unscrew the "XV02-2" from the unit replace it with the new one repeating all the above steps in reverse order.
"XV02-2" is factory set and does not need adjustment. Before powering on the machine, go around the machine to ensure that everything is properly connected. Unlock the padlock, take it from the main switch Q0 and follow the "START UP OF THE PROGRAM" table of the QUICK GUIDE; once the machine is operating, check that during the sludge loading the air escape from "SFX2" ("XV02-2" keeps it open).
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DISPOSAL OF THE MACHINE
Should the TEKNOBAG-DRAIMAD PACKAGE be disposed, follow the instructions below: Clean the whole machine taking care to remove all the sludge deposits (follow also the instructions of paragraph 8.1). Cut off all the power supply sources. Disconnect all the wiring and connections from the machine (electrical, pneumatic and the sludge and polyelectrolyte piping and also the filtrate disposal piping). Ensure that all the hollow parts of the machine are empty and then seal the inlets & outlets. If future use of the machine is foreseen, follow the instructions in paragraph 3.2 The user must observe the disposal safety regulations in force in the country where the installation has been made.
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10
MOTORS
available one sludge pump,
On the TEKNOBAG-DRAIMAD PACKAGE are polyelectrolyte pump and one polyelectrolyte stirrer. 10.1 SLUDGE PUMP
On the basis of the TEKNOBAG-DRAIMAD PACKAGE type two type of sludge pump are available: 02B-PACK, 03B-PACK and 03B-PACK-P are completed of a sludge mohno pump able to supply 1200 litres / hour of sludge (0.55 kW, 8 poli, 680 rpm (50Hz) IEC90 B5); 06B-PACK and 06B-PACK-P are completed of a sludge mohno pump able to supply 4000 litres / hour of sludge (2.2 kW, 2 poli + riduttore i:3.87 = 724 rpm (50Hz) IEC90 B5); Both the pump is connected and ready for the use. 10.2 POLYELECTROLYTE PUMP Also for the polyelectrolyte pump are available two models: 02B-PACK, 03B-PACK and 03B-PACK-P are completed of a polyelectrolyte pump able to supply 101 litres / hour of sludge (0.20 kW, 4 poles 50 Hz); 06B-PACK and 06B-PACK-P are completed of a polyelectrolyte pump able to supply 321 litres / hour of sludge (0.30 kW, 4 poles 50 Hz); Both the pump is connected and ready for the use. They are assembled with a PP pumping head, diaphragm in Teflon and AISI 316 ball valves. Lubrication times and data are available in paragraphs 7.2 and 7.3. Adjust the polyelectrolyte pump flowing by turning its adjusting knob until the correspondent percentage of the delivery flowing is readable on the shaft (on the shaft a scale from 0 to 10, which is correspondent to the percentage from 0 to 100%). E.g. to adjust a flowing of 60litres/hour on the polyelectrolyte pump of 101 litres/hour, turn the knob until the 6 is visible (02B-PACK / 03B-PACK / 03B-PACK-P); to adjust the same flowing to the 321 litres/hour pump, turn the knob to reach the 2, then turn it back a little (06B-PACK / 06B-PACK-P).
10.3 STIRRER. The TEKNOBAG-DRAIMAD PACKAGE is completed of a polyelectrolyte stirrer already connected and ready for the use. All the type of TEKNOBAG- DRAIMAD PACKAGE type use a motor with the following characteristic: 0.20 kW, 4 poles, IEC 63 B5 (the power supply of the match the data available on the sheet 4 of the electric diagram of the chapter 14). The stirrer is long life lubricated and does not need any maintenance.
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11
SPARE PARTS
11.1 SPARE PART ORDER CODE To order a spare part the user must specify the series number of the machine, the type of unit and the code of the part to change. Proceed as follows: Read the Job Code (series number) on the metal label fixed to the machine; Read the machine model on the same metal label; Use the reference code used in this handbook (see 11.2) Send to the nearest supplier, or directly to Teknofanghi a fax showing the resulting code and the number of pieces that will need replacing. Example 1 Spare part: level sensor of the TEKNOBAG-DRAIMAD PACKAGE unit. Looking into the handbook this item has the code SND (see the drawing on the back of the frontal cover). On the metal label of the TEKNOBAG-DRAIMAD PACKAGE is written: TYPE: 02B-PACK JOB CODE (SERIAL NUMBER): C99/64 Resulting code is: C99/64-02B-PACK-SND Example 2 Spare part: containing basket. In this handbook the containing basket is named G (see the drawing on the back of the frontal cover). On the metal label of the TEKNOBAG-DRAIMAD PACKAGE it is written: TYPE: 03B-PACK JOB CODE (SERIES NUMBER): C99/75 Resulting code is: C99/75-03B-PACK-G
11.1.1 SUGGESTED SPARE PARTS FOR TWO YEARS OF OPERATION Since the components of the TEKNOBAG-DRAIMAD PACKAGE units do not have any specific wear, it is not possible to indicate which parts will need to be replaced after two years. 11.1.2 SUGGESTED SPARE PARTS FOR FIVE YEARS OF OPERATION Since the components of the TEKNOBAG-DRAIMAD PACKAGE units do not have any particular wear, it is not possible to indicate which parts will need to be replaced after five years.
However it would be safer to keep in stock some spare parts, so that in case of accidents, it would be possible to repair the damaged parts in a short time. On the basis of the location of the plant, choose the spare to have in stock from the listed parts below.
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11.2 REFERENCE LIST

REF. ITEM 0 UNIT IDENTIFICATION PLATE 3 POLYELECTROLYTE PUMP 5 SLUDGE PUMP 6 STATIC MIXER 18 WATER INLET 20 SLUDGE INLET 21 COMPRESSED AIR INLET 23 FILTRATE OUTLET 25 DEWATERED SLUDGE 26 TEKNOBAG-DRAIMAD DEWATERING BAG 38 POLYELECTROLYTE STIRRER 40 CONTROL PANEL 42 POLYELECTROLYTE PUMP ADJUSTING KNOB 43 REFERRING MARK OF THE POLYELECTROLYTE TANK (100 L) 52 DRAINAGE OF THE POLYELECTROLYTE TANK 70 REACTION TANK 71 POLYELECTROLYTE TANK 200 SAFETY GUARD TO STOP THE FILTRATE DROPPING FROM THE BAGS 201 SAFETY GUARD OF THE POLYELECTROLYTE TANK 300 DISTRIBUTION TANK INSPECTION PORT ASC OUTLET OF THE CONDENSATE WATER TRAP E FUNNEL ECOM COMMON ELECTRODE EG FUNNEL GASKET EMAX ELECTRODE OF MAXIMUM LEVEL EMIN ELECTRODE OF MINIMUM LEVEL EMQE CONTROL PANEL EMERGENCY STOP DEVICE EVA SOLENOID VALVE N.C. (TO DRIVE THE "XV01") EVF SOLENOID VALVE N.C. (TO DRIVE THE "XV02-2") F CLAMP FN FOUNDATION G CONTAINING BASKET GCVPC01 AIR CONTROL GROUP K23 - K31 MEASURE OF THE CENTRE OF GRAVITY IN2 INPUT FOR EXTERNAL SENSOR (see 5.9.1) IN3 INPUT FOR EXTERNAL SENSOR (see 5.9.2) IN4 INPUT FOR EXTERNAL SENSOR (see 5.9.3) IN5 INPUT FOR EXTERNAL SENSOR (see 5.9.4) M1 POLYELECTROLYTE STIRRER M2 SLUDGE PUMP M3 POLYELECTROLYTE PUMP OUT2 "SLUDGE PUMP ENABLING" OUTPUT (see 5.9.5) OUT3 "PROGRAM RUNNING" OUTPUT (see 5.9.8) OUT4 "PROGRAM END" OUTPUT (see 5.9.9) P01 PIPING TO SUPPLY THE PRESSURISATION (WHITE PIPE) P2 "PROGRAM PAUSE" PUSH BUTTON P3 "PROGRAM START" PUSH BUTTON P9 "STIRRER STOP" PUSH BUTTON P10 "STIRRER START" PUSH BUTTON P12 "RESET" PUSH BUTTON
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REF. PD1 PD2 PD3 PE PL PL1 Q0 RK1 SF SFA SFX2 SL SND SNDB TKN TEKSC-4 VM1 VFM W1 W2 X01 X02 XV02-2 XV1 XV2 Y01 Y14 Z01 Z12
ITEM BREATHER PLUG OF THE DOSING PUMP OIL LEVEL WINDOW OF THE DOSING PUMP DRAIN PLUG OF THE DOSING PUMP DRAWING OF THE BOTTOM VIEW OF THE MACHINE FEET CONCRETE PAD OF THE FOUNDATION MAIN SWITCH AIR FILTER/REDUCER (SET TO 3 bar 5%) AIR DISCHARGE OUTLET OF THE UNIT AIR DISCHARGE OUTLET OF THE "XV02-2" THEORETICAL SLUDGE LEVEL TO EASY REMOVE THE BAG LEVEL SENSOR OF THE TEKNOBAG-DRAIMAD PACKAGE UNIT FIXING BOLT OF THE LEVEL SENSOR "SND" DIGITAL CONTROL UNIT TKN02 - td 3 WAY PNEUMATIC VALVE ISOLATION AND DISCHARGE VALVE SLUDGE SLEEVE VALVE AIR PRESSURE GAUGE (0-4 bar) AIR PRESSURE GAUGE (0-1 bar) FOUNDATION DIMENSION PRESSURE UNIT PIPING COMING FROM EVF FOR VMF (GREEN PIPE) PIPING COMING FROM EVA FOR "XV02-2" (BLUE PIPE) FOUNDATION DIMENSION FOUNDATION DIMENSION
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12
GENERAL DIMENSION
12.1 FOUNDATION
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12.2 DIMENSION
Teknof an i S .r g h
L U S E G D E D A I V T A W E R B I R E C S E G N 1 , A I I U Q 8 E M P T N
. l
0 2 +
3 6 0 0 9 3
E C 2 9
N R 3 4 1
C S U 7 3 0
O / S +
( ) M T N I 9 3 + 2 0
Y L A 1 2 9 0 3 4 7 3
E I / E I S S E R S E R P O / P E T I T Y
M A I T R O A C L /
J B O E O C D
N A M A
O / N S / A
E R Y A M S S A
g .
T e n b g D ma d k o a - r a i
P1 0
P9
P3
P2
P1 2
In order to identify the correct machine refer to the metal label fixed to the machine (see paragraph 2). CAUTION: The short dashed-line around the TEKNOBAG-DRAIMAD PACKAGE shown in the drawings of this section, together with the area of the foundations, identify the AREA OF RESPECT of the machine (See5.1).
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13
PNEUMATIC DATA (03B-PACK-P / 06B-PACK-P only)
ASC EVA EVF GCVPC01 P01 RK1 SFA SFX2
OUTLET OF THE CONDENSATE WATER TRAP SOLENOID VALVE N.C. (TO DRIVE THE "XV01") SOLENOID VALVE N.C. (TO DRIVE THE "XV02-2") AIR CONTROL GROUP PIPING TO SUPPLY THE PRESSURISATION THROUGH "XV02-2-2" (WHITE PIPE) AIR FILTER/REDUCER (SET TO 3 bar 5%) AIR DISCHARGE OUTLET OF THE UNIT AIR DISCHARGE OUTLET OF THE "XV02-2"
TEKSC-4 VM1 VFM W1 W2 XV02-2 XV1 XV2
3 WAY PNEUMATIC VALVE ISOLATION AND DISCHARGE VALVE SLUDGE SLEEVE VALVE AIR PRESSURE GAUGE (0-4 bar) AIR PRESSURE GAUGE (0-1 bar) PRESSURE UNIT PIPING COMING FROM EVF FOR VMF (GREEN PIPE) PIPING COMING FROM EVA FOR "XV02-2" (BLUE PIPE)
AIR REDUCER OF THE XV02-2 IS FACTORY SET DO NOT CHANGE THIS SETTING (0.3 bar 20%)
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3 5 6 20
POLYELECTROLYTE PUMP SLUDGE PUMP STATIC MIXER SLUDGE INLET (SEE REFERRING DRAWING)
21 SF SP
AIR PRESSURE INLET (SEE REFERRING DRAWING) SLUDGE SOURCE AIR PRESSURE SOURCE
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14
ELECTRICAL DATA WARNING DEVICE
The control panel uses the TKN digital unit to inform about the state of the program. Further on are listed the codes visualised by the display together with the relatives state of the program. WORKING CODES (during the execution of the WORKING TIME) Code Display State of the program The code blinks quickly The operator is pushing together "P2" and "P12" push buttons (after 8 seconds the program will have re-loaded the whole WORKING TIME and the display will visualise EE). The code is static The program is ready to be started. The code blinks The operator is pushing the push button P3 (after 3 seconds the program starts) The code decreases The program is running and the TEKNOBAG- DRAIMAD is loading sludge. second by second. The level sensor is not detecting any sludge. The code decreases The program is running and the TEKNOBAG- DRAIMAD is loading sludge. second by second. The level sensor is detecting the sludge level at the minimum allowed. The code decreases The program is running and the TEKNOBAG- DRAIMAD is loading sludge. second by second. The level sensor is detecting the sludge level at the maximum level (after 5 second will light on even the middle hyphens). The code decreases The level sensor has detected sludge at the maximum level for more then 5 seconds. second by second. The program is running and the TEKNOBAG- DRAIMAD is waiting for the dropping down of the level sludge. The code decreases The program is running and the TEKNOBAG- DRAIMAD is waiting for the dropping down of the level second by second. sludge. The level sensor detects sludge at the minimum level, when it does not detect any sludge the program will switch back to the code of the second line of this table.
If any of these 5 visualisations here above is not decreasing it means that the program has been paused by means of button P2. Pushing P3 the program will start again from the same point reached before the pausing.
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WORKING CODES (execution of the FINAL DRAINING) State of the program If the code is blinking the program is running the "FINAL DRAINING CYCLE". The level sensor detects sludge only at the minimum level, when it does not detect any sludge the program will switch back to the code of the first line of this table (even if paused). The code blinks If the code is blinking the program is running the FINAL DRAINING CYCLE. The level sensor detects sludge only at the minimum level, when it does not detect any sludge the program will switch back to the code of the first line of this table (even if paused). If the code does not blink, the program has been paused by means of button P2. Pushing P3 the program will start again "FINAL DRAINING CYCLE". Note: when the polyelectrolyte stirrer is active on the right side of the display the program will light on a dot (this visualisation is the same either the WORKING TIME is not expired or during the execution of the FINAL DRAINING). In case of H-02 or H-99 alarms the stirrer is shut down, therefore even the dot light off. Code Display The code blinks
ORIGINAL PARAMETER OF THE PROGRAM Here below are reported all the visualisation of the display after that the original parameter of the program.
If your digital unit is new or has just been carried out the instruction of paragraph 6.6.2 and the parameters visualised does not match from the above reported, call for the nearest reseller or to Teknofanghi directly (Note visualisation if the digital unit has worked for some time, visualisation 8 and 9 will be surely different since the program always increase these values and the instructions of 6.6.2 does not reset them, therefore it is ok even if only zeros are not visualised ).
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ALARM CODES Code Display The code is static The code is blinking The code is blinking The code is still The code is blinking The code is still The code is blinking The code is still The code is blinking The code is still The code is blinking The code is still The code is blinking State of the program This code indicates that the program has taken too long to load the sludge (see 6.5.1). This code indicates that the input "IN2" detects an alarm condition or one of the circuit breaker is tripped in alarm (see 6.5.2). This code indicates that the input "IN3" detects an alarm condition (see 6.5.3). This code indicates that the input "IN3" detected an alarm but now the cause has been removed (see 6.5.3) This code indicates that the input "IN4" detects an alarm condition (see 6.5.4). This code indicates that the input "IN4" detected an alarm but now the cause has been removed (see 6.5.4). This code indicates that the input "IN5" has detected an alarm condition for more then 8 seconds and that now is still active the cause of the alarm (see 6.5.5). This code indicates that the input "IN5" detected an alarm but now the cause has been removed This code indicates that the level sensor is sending faulty signals to the digital unit TKN (see 6.5.6). This code indicates that the level sensor has sent faulty signal to the digital unit TKN (see 6.5.6) This code indicates that the "EMQE" has been locked to shut immediately down the unit and its devices (see 6.6.7). This code indicates that the "EMQE" has been locked and released (see 6.5.7). The operator is pushing P12 to reset an alarm (if within 8 seconds the code does not change, it means that one alarm is still active).
Until the display visualise one of the above codes, the outlet OUT3 is active (see 5.9.8 OUTPUT OUT3 COLLECTIVE ALARM). Soon after that the reset procedure is completed, OUT3 will go off.
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CONTROL DEVICES
FUNCTION When "P2" is pushed, the program is immediately paused (the displayed code will be frozen). Keeping P3 pressed continuously for five seconds, starts up the program. WARNING: if any of the alarms are tripped the machine will not start. P9 Black push button When P9 is pushed, the polyelectrolyte stirrer starts. P10 Black push button When P10 is pushed, the polyelectrolyte stirrer stops. P12 Blue push button* Keeping "P12" pressed continuously for three seconds resets the alarm (see 6.6). Q0 Black/grey two position main When Q0 is in position 0 the power source is disconnected from control panel; turning it to switch (0-1) position 1 connects the power source to the control panel. Pushing P2 and P12 together for eight seconds, the WORKING TIME will be re loaded from the beginning (see 6.6) Ref. P2 P3 DESCRIPTION Red push button Green push button
EMERGENCY STOP DEVICE

Ref. EMQE DESCRIPTION FUNCTION Self-locking push button with Pushing this device trips the self-locking switch shutting the unit and its devices down (see 6.5.7). red mushroom head on Turning the red head of the activated device anti-clock wise releases the self-locking switch. yellow field.
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14.1 ELECTRICAL DIAGRAM "QCDRCE### (D.03001 rev 1)
The TEKNOBAG-DRAIMAD PACKAGE units use the control panel QCDRCEK03 which is made according to the TEKNOBAGDRAIMAD general electric diagram here below; all the section identified as K are included. Note that the 06B-PACK uses a Q2 different from the standard (for much details see sheet 4 and 7).
Teknobag-Draimad
P10
P9
P3
P2
P12
Teknofanghi S.r.l. - ITALY- Tel. ++39 02 92143037 Fax ++39 02 92143038
Teknofanghi
Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105
SUMMARY Ref. Page
2 3
REFERENCE DRAWING .................................................................................................................................................................................................... 2 INTRODUCTION ................................................................................................................................................................................................................. 3 QUICK GUIDE: INSTALLATION OF THE TEKNOBAG- DRAIMAD .................................................................................................................................. 4 QUICK GUIDE: FIRST START UP ...................................................................................................................................................................................... 5 QUICK GUIDE: THE DAY AFTER THE FIRST START UP.................................................................................................................................................. 6 QUICK GUIDE: BAG REMOVAL AND STORAGE............................................................................................................................................................... 7 QUICK GUIDE: INSTALLATION OF THE NEW BAGS ........................................................................................................................................................ 7 QUICK GUIDE: STARTING UP OF THE PROGRAM .......................................................................................................................................................... 8 QUICK GUIDE: EMERGENCY STOPPING ......................................................................................................................................................................... 9 QUICK GUIDE: TROUBLE SHOOTING............................................................................................................................................................................. 10 GENERAL...................................................................................................................................................................................................................... 15 1.1 INFORMATION ABOUT THE LITERATURE ......................................................................................................................................................... 16 1.2 RECURRENT SYMBOLS...................................................................................................................................................................................... 16 1.3 USER DUTY.......................................................................................................................................................................................................... 17 1.4 OPERATORS IDENTIFICATION ........................................................................................................................................................................... 18 IDENTIFICATION OF THE TYPE OF TEKNOBAG-DRAIMAD ................................................................................................................................. 19 TRANSPORT AND HANDLING ..................................................................................................................................................................................... 20 3.1 PACKING .............................................................................................................................................................................................................. 21 3.2 STORAGE............................................................................................................................................................................................................. 21 TEKNOBAG-DRAIMAD PACKAGE UNIT ................................................................................................................................................................... 23 4.1 SAFETY GUARDS AND DEVICES ....................................................................................................................................................................... 23 4.2 LOGIC OF THE PROGRAM.................................................................................................................................................................................. 24 4.3 INTENDED USES OF THE MACHINE AND PROHIBITED USES......................................................................................................................... 25 4.4 AIRBORNE NOISE PRODUCTION ....................................................................................................................................................................... 26 4.5 COMPLIANCE WITH APPLICABLE DIRECTIVES ................................................................................................................................................ 26 4.6 RESIDUAL HAZARD............................................................................................................................................................................................. 26
Teknofanghi
SUMMARY Ref.
5
Page
INSTALLATION ............................................................................................................................................................................................................. 27 5.1 AREA OF RESPECT............................................................................................................................................................................................. 27 5.2 INDICATION OF THE WALKING AREA................................................................................................................................................................ 27 5.3 ANCHORING TO THE FOUNDATIONS................................................................................................................................................................ 27 5.4 REQUIREMENTS OF THE INSTALLATION ENVIRONMENT............................................................................................................................... 28 5.5 CONNECTIONS TO THE SLUDGE FEEDING POINT .......................................................................................................................................... 28 5.6 REMOVAL OF MATERIAL PRODUCED ............................................................................................................................................................... 29 5.6.1 DISPOSAL OF THE BAGS FILLED WITH DEWATERED SLUDGE .................................................................................................................. 29 5.6.2 FILTRATE DISPOSAL....................................................................................................................................................................................... 29 5.7 ELECTRICAL CONNECTIONS ............................................................................................................................................................................. 30 5.7.1 INPUT "IN2"....................................................................................................................................................................................................... 31 5.7.2 INPUT "IN3"....................................................................................................................................................................................................... 32 5.7.3 INPUT "IN4"....................................................................................................................................................................................................... 33 5.7.4 INPUT "IN5"....................................................................................................................................................................................................... 34 5.7.5 OUTPUT "OUT3" (COLLECTIVE ALARM) ........................................................................................................................................................ 35 5.7.6 OUTPUT "OUT4" (PROGRAM END)................................................................................................................................................................. 36
Teknofanghi
SUMMARY Ref.
6
Page
USAGE .......................................................................................................................................................................................................................... 37 6.1 INDIVIDUAL SAFETY PROTECTION ................................................................................................................................................................... 37 6.2 CONTROL DEVICE DESCRIPTION...................................................................................................................................................................... 37 6.3 ADJUSTMENT TO CARRY OUT BEFORE THE FIRST START UP...................................................................................................................... 38 6.3.1 PNEUMATIC ADJUSTMENT (BCAVP / BCAVPK ONLY) ............................................................................................................................. 38 6.3.2 RECOMMENDATIONS REGARDING FLOCCULANT....................................................................................................................................... 38 6.3.3 FIRST START UP OF THE PROGRAM ............................................................................................................................................................ 38 6.4 DAILY USAGE ...................................................................................................................................................................................................... 39 6.4.1 STOPPING OF THE PROGRAM BEFORE THE SCHEDULED END ................................................................................................................ 41 6.4.2 REMOVAL OF THE BAGS BEFORE THE SCHEDULED TIME......................................................................................................................... 41 6.5 TROUBLE SHOOTING.......................................................................................................................................................................................... 42 6.5.1 ALARM "H-01" (THE SLUDGE LOADING LASTED TOO LONG)...................................................................................................................... 43 6.5.2 ALARM "H-02" (THERMAL RELAYS ALARM or input " IN2" closed)................................................................................................................. 45 6.5.3 ALARM "H-03" (device connected to input "IN3")............................................................................................................................................... 46 6.5.4 ALARM "H-04" (device connected to input "IN4")............................................................................................................................................... 47 6.5.5 ALARM "H-05" (device connected to input IN5)............................................................................................................................................... 48 6.5.6 ALARM "H-06" (SND) ........................................................................................................................................................................................ 49 6.5.7 ALARM "H-99" (EMQE activated) ...................................................................................................................................................................... 50 6.6 ADVANCED USERS ............................................................................................................................................................................................. 51 6.6.1 HOW TO ADJUST THE WORKING TIME ....................................................................................................................................................... 52 6.6.2 HOW TO LOAD THE PROGRAM WITH ITS ORIGINAL PARAMETERS .......................................................................................................... 53 6.6.3 AUTOMATIC SHUT DOWN OF THE POLYELECTROLYTE STIRRER. ........................................................................................................... 54
Teknofanghi
SUMMARY Ref.
7
Page
SCHEDULED MAINTENANCE ...................................................................................................................................................................................... 55 7.1 EVERY 5 WORKING DAYS: BAGS EQUALLY FILLED ........................................................................................................................................ 56 7.2 EVERY 60 WORKING DAYS: OIL LEVEL............................................................................................................................................................. 56 7.3 EVERY 3 YEARS: OIL REPLACEMENT ............................................................................................................................................................... 56 8 UNSCHEDULED MAINTENANCE ................................................................................................................................................................................. 57 8.1 UNSCHEDULED WASHING ................................................................................................................................................................................. 58 8.2 DIGITAL CONTROL UNIT "TKN" REPLACEMENT ............................................................................................................................................... 59 8.3 LEVEL SENSOR "SND" CLEANING OR REPLACEMENT.................................................................................................................................... 61 8.4 SLUDGE AND POLYELECTROLYTE PUMPS...................................................................................................................................................... 62 8.4.1 SLUDGE PUMP FOR 02B-PACK / 03B-PACK / 03B-PACK-P.................................................................................................................... 62 8.4.2 SLUDGE PUMP OF 06B-PACK / 06B-PACK-P ............................................................................................................................................ 65 POLYELECTROLYTE PUMP ............................................................................................................................................................................................ 67 8.5 PNEUMATIC SLEEVE VALVE REPLACEMENT................................................................................................................................................... 68 8.6 PRESSURE UNIT "XV02-2" REPLACEMENT....................................................................................................................................................... 69 9 DISPOSAL OF THE MACHINE...................................................................................................................................................................................... 70 10 MOTORS .................................................................................................................................................................................................................. 71 10.1 SLUDGE PUMP .................................................................................................................................................................................................... 71 10.2 POLYELECTROLYTE PUMP ................................................................................................................................................................................ 71 10.3 STIRRER............................................................................................................................................................................................................... 71 11 SPARE PARTS ......................................................................................................................................................................................................... 72 11.1 SPARE PART ORDER CODE............................................................................................................................................................................... 72 11.1.1 SUGGESTED SPARE PARTS FOR TWO YEARS OF OPERATION ............................................................................................................ 72 11.1.2 SUGGESTED SPARE PARTS FOR FIVE YEARS OF OPERATION............................................................................................................. 72 11.2 REFERENCE LIST................................................................................................................................................................................................ 73 12 GENERAL DIMENSION ............................................................................................................................................................................................ 75 12.1 FOUNDATION....................................................................................................................................................................................................... 75 12.2 DIMENSION .......................................................................................................................................................................................................... 76 13 PNEUMATIC DATA (03B-PACK-P / 06B-PACK-P only) ....................................................................................................................................... 77 14 ELECTRICAL DATA.................................................................................................................................................................................................. 79 14.1 ELECTRICAL DIAGRAM "QCDRCE### (D.03001 rev 1)...................................................................................................................................... 83
Teknofanghi
Instruction for the use and maintenance of the B-pack
TPTKN02E-240105
Cernusco S/N 10. Februar 1997
Dichiarazione di conformit CE.

Con la presente la Teknofanghi S.r.l. dichiara che la macchina modello, tipo e numero di serie riportati in targa, conforme alle disposizioni della Direttiva Macchine 89/392/CEE e successive modifiche, ed conforme alla direttiva bassa tensione 73/23. Inoltre dichiara che sono state applicate le seguenti norme armonizzate:
EN 292/1, EN 292/2, EN 294, EN349, EN 418, EN 60204-1.
EC declaration of conformity for machinery.

We Teknofanghi S.r.l. herewith declares that our machinery model, type and serial number shown on the name plate, is in conformity with the previsions of the Machinery Directive 89/392/EEC, as amended, and that is in conformity with the low voltage Directives 73/23. Furthermore declares that the following harmonised standards have been applied:
EN 292/1, EN 292/2, EN 294, EN349, EN 418, EN 60204-1. CE-Konformittserklrung fr Maschinen

Teknofanghi S.r.l. erklrt hiermit, da die gelieferten Maschinen wie auf dem Typenschild gekennzeichnet mit Ausfhrung, Typ, und Serien-Nummer, den einschlgigen Bestimmungen der EG-Maschinenrichtlinie 89/392/EEC entspricht und auch mit der Richtlinie 73/23 fr Niederspannung im Einklang ist. Weiterhin wird erklrt, da folgende harmonisierten Normen angewendet wurden, und zwar:
EN 292/1, EN 292/2, EN 294, EN349, EN 418, EN 60204-1. Declaracin de Conformidad CE.

Con la presente Teknofanghi S.r.l. declara que la mquina modelo, tipo y nmero de serie indicada en la placa de caractersticas es conforme a las disposiciones de la Directiva Mquina 89/392/CEE y sucesivas modificaciones, y es conforme a la directiva de baja tensin 73/23, adems declara que son aplicadas las siguientes normas armonizadas:
EN 292/1, EN 292/2, EN 294, EN 349, EN 418, EN 60204-1.
GRAZIANO LAGRECA Amministratore unico Managing director Geschftsfhrender Gesellschafter
Teknofanghi
Instruction for the use and maintenance of the B-pack
TPTKN02E-240105

++ 39 02 92143037 ++39 02 92143038 WWW - Teknofanghi.it

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++ 39 02 92143037 ++39 02 92143038 WWW - Teknofanghi.it

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Teknofanghi

Instruction for the TEKNOBAG-DRAIMAD PACKAGE

Instruction for the TEKNOBAG-DRAIMAD PACKAGE

Te n k ofa n ghi S.r . l.

Te U no E R ng P E S. .r l. k G E E fa IN E Q hi T S D L D A T W G U MN I I ARESCI 18 V B A, 2063ERNUSO N M TAL 0 C C S/ ( ) I Y I +390224037 ++90292303 913 3 14 7 SEI E/ SERI S R E

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

QUICK GUIDE: INSTALLATION OF THE TEKNOBAG- DRAIMAD PACKAGE

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

QUICK GUIDE: BEFORE CARRYING OUT THE FIRST START UP

QUICK GUIDE: FIRST START UP

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

QUICK GUIDE: THE DAY AFTER THE FIRST START UP

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

QUICK GUIDE: BAG REMOVAL AND STORAGE

QUICK GUIDE: INSTALLATION OF THE NEW BAGS

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

QUICK GUIDE: STARTING UP OF THE PROGRAM

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

POLYELECTROLYTE STIRRER ACTIVATION

The stirrer rotating.

QUICK GUIDE: EMERGENCY STOPPING OPERATION EFFECT DISPLAY

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

QUICK GUIDE: TROUBLE SHOOTING

The display code:

the Input "IN4" in alarm.

the Input "IN5" in alarm.

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

INFORMATION ABOUT THE LITERATURE

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

IDENTIFICATION OF THE TYPE OF TEKNOBAG-DRAIMAD

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

TRANSPORT AND HANDLING

Tek nofanghi S.r . .l

V I A B RE S CI , 8 A1 2 0 6 CE RNUS COS / ( MI I A L 0 3 N ) T Y ++30292433 9 1 07 S E RI E / TI O / P ++390921307 2 4 3

TYPE JOB CODE

Tek nofanghi S.r . .l

TYPE JOB CODE

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

TEKNOBAG-DRAIMAD PACKAGE UNIT

SAFETY GUARDS AND DEVICES

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

LOGIC OF THE PROGRAM

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

INTENDED USES OF THE MACHINE AND PROHIBITED USES

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

AIRBORNE NOISE PRODUCTION

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

INDICATION OF THE WALKING AREA

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

REQUIREMENTS OF THE INSTALLATION ENVIRONMENT

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00

REMOVAL OF MATERIAL PRODUCED

Instruction for the TEKNOBAG- DRAIMAD PACKAGE TPTKN02E-240105/00