Bauer FAN Separator PSS 1.1-300, Operating Manual

Page 1: ...ORIGINAL OPERATING MANUAL FOR FAN PRESS SCREW SEPARATOR PSS 1 1 300 Version II 2019 ...

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Page 3: ...faction for many years to come The content of this operating manual is the intellectual property of the company FAN Separator GmbH and or its supplier companies The available information may only be used in connection with the crea tion of specification compliant documents in the course of an order from the FAN company Without express written permission from the FAN company no reproduction or shar...

Page 4: ...27 938 444 Email info fan separator de www fan separator de Owner or operator Name Address Tel Fax Note Make a note of the type designation and serial number of your press screw separator and its ac cessories Include these numbers along with all contact with your dealer 1 It is very important to include with all guarantee claims and all correspondence related with this ma chine the entire serial n...

Page 5: ...lates Information Signs 9 4 5 1 Information on the Separator Type Plate 9 4 5 2 Information Signs 9 4 6 Separator Technical Data 9 4 7 Setup and Assembly 10 4 8 Complete System 11 4 8 1 Inflow Setup 12 4 8 2 Drainage Line 12 5 ELECTRICAL CONNECTION 13 5 1 Setup and Operation of the Motor 14 5 2 Condensate Hole 14 5 3 Installation Without Switch Cabinet 14 6 PREPARATION FOR INITIAL STARTUP 15 7 INI...

Page 6: ...3 13 3 Inspecting and Reinstalling the screen 25 13 4 Inspecting and Reinstalling the auger 26 13 5 Evaluation Criteria for the auger and screen with Regard to Wear and recoating 27 13 6 Summary of Maintenance and Inspection Intervals 28 14 PROBLEMS TROUBLESHOOTING 29 14 1 Principles of a Normal Operating Condition 29 14 2 Troubleshooting 30 15 ACCESSORIES 33 15 1 Separator Control 33 16 NOTES 34 ...

Page 7: ... or prohibitions to protect against serious injury or property damage WARNING Special information on preventing minor injuries or requirements and prohibitions to prevent damage to the machine NOTE Special instructions to simplify working with the machine or to aid in efficient use of the machine To prevent malfunctions that could directly or indirectly result in serious injuries or property damag...

Page 8: ...rew separator may be used and operated only by persons who are familiar with the system and aware of the hazards involved All relevant rules for accident prevention as well as any other generally accepted rules and regula tions relating to safety occupational medicine and traffic laws must be strictly observed Unauthorized modifications to the machine release the manufacturer from liability for da...

Page 9: ...nt supervision of a person experienced in operation of the system The safety and risk conscious work by the personnel in compliance with the operating manual must be checked at least at certain intervals The personnel assigned to operate the machine may not have Exposed long hair Loose clothing Jewelry including rings and drop earrings Such items could get stuck and or drawn into the machine resul...

Page 10: ... suitable lifting equipment and load handling devices with sufficient car rying capacity and no technical operating defects may be used Standing or working under suspended loads is not permitted Grips steps railings landings platforms and ladders must be cleaned of oil dirt snow and ice before all activity on the system If the FAN press screw separator is installed on an elevated platform this mus...

Page 11: ...e in combination with oxygen Open flame light checks spark creation and smoking are therefore prohibited When using the retention or alternating retention method special care must be taken in the area of the opened sliding gates to the pre pool before the main tank or to cross channels due to the formation of gases In addition special care is required at stirring and withdrawal points while the st...

Page 12: ...ter via gravity inside the screen The interior auger trans ports the pre drained material horizontally toward the solid outlet Along the last section of the transport path the auger presses out additional liquid which escapes the separator through the screen as thin slurry The required contact pressure is applied to the escaping solid by a system consisting of a cap loaded by a weighted lever The ...

Page 13: ...llation of the FAN press screw separator DANGER Work on electrical and electronic components of the system may only be per formed by a trained electrician or otherwise appropriately trained personnel under the guidance and supervision of a trained electrician in accordance with the appli cable electrical and electronic regulations 4 3 REQUIRED TOOLS Special tools are not required for setting up th...

Page 14: ...main separator components for the specific application before it is purchased manufactured assembled and shipped Pos Bezeichnung Pos Bezeichnung 1 Geared motor 8 Auger bolt 2 Screen housing 9 Weights 3 mouth piece 10 Housing protecting ring 4 Double flap with rod 11 Screen 5 Inflow Element 12 Wearing profile 6 Ventilation pipe 13 Screen guide rails 7 Auger 14 Sealing The precise article numbers of...

Page 15: ...he following information signs are located on the FAN press screw separator Red arrow on the mouth piece indicates the correct rotation direction of the auger shaft Yellow text field on the mouth piece warns of a turning part Yellow warning symbols on the housing shell indicate that turning parts should not be touched Yellow text field on the geared motor indicates the lubrication interval for the...

Page 16: ...o remove the auger and the screen for maintenance It must be possible to remove the auger and the screen for regular inspections Width of the setup area No less than 2000 mm Length of the setup area No less than 2900 mm The surrounding clearance around the separator should be at least 1 m Handrail height of the setup area No less than 1000 mm Make sure that the mouth piece and the functioning of t...

Page 17: ...k by means of gravity a flow reg ulator may be required in some circumstances to limit the pressure on the separator In this case an overflow is not required The effluent should be disposed of via an open and thereby ventilated drain channel or collect ed in a drainage pit and then pumped out in or der to avoid generating a suction effect on the separator The ventilation is required because otherw...

Page 18: ...nnect the supply line to the lower horizontal connection socket DN75 of the inflow element A tube of DN75 is re quired for this Connect the overflow line to the upper horizontal connection socket DN75 of the inflow element A tube of DN75 is also required for this On the vertical connection of the overflow line socket 1 must be connected the ventilation tube This prevents the buildup of negative pr...

Page 19: ...rcuit breaker that must be set to the rated current shown on the type plate depending on the motor wiring Only motor protection circuit breakers certified according to the following standards may be used IEC UL CSA WARNING Set the motor protection circuit breaker to the correct value never above the max rated current according to the type plate It is recommended that the corresponding electrical c...

Page 20: ...uthorized starting of the machine 5 2 CONDENSATE HOLE We recommend a condensate hole on motors that are subjected to high temperature fluctuations or extreme climatic conditions DANGER A motor protection circuit breaker or a protection device with overload relay must always be installed to protect the motor winding Fuses do not protect the motor from overloads they only protect the electrical supp...

Page 21: ...y dispose of old oil 8 Check The supply line between the pump and the separator is connected and sealed the over flow line is connected and sealed open discharge into the storage container line for drainage of the separated slurry connected and sealed open discharge into storage container 9 Motor protection circuit breaker set to required rated current after switching on verify the correct rotatio...

Page 22: ...am rubber included in the standard equipment behind the flaps This starter cake is replaced as the separation process continues by a newly formed solid cake made of the separated medium pressing out the starter cake A starter cake should be employed when the solid cake has been removed from the machine for cleaning inspection or maintenance purposes If the machine is not operated for a prolonged p...

Page 23: ...o assess a stable cake not to determine the dry matter content of the solid phase 7 3 CONFIGURATION TO STABILIZE THE SOLID CAKE 7 3 1 Cake Too Firm Move the weights inward on the arms or remove them entirely If the cake is too firm the separator may clog up after prolonged opera tion since the cake can no longer be pushed out of the mouthpiece In order for the cake to be ejected more easily the we...

Page 24: ...eparating to avoid shooting or clogging due to irregularities But also ensure that the slurry is not stirred up and repumped too often especially for small pre pools causing the slurry consistence to change become smooth up to the point when no solid matter is separated at all As a remedy a buffer container should be situated at the separator inflow that is filled by means of a level control 8 WIN...

Page 25: ...g screens with lower gap widths For example if the first separator is operated with a gap width of 0 75 mm the effluent can be introduced to a separator with a gap width of 0 25 mm and so on To determine the possible dry matter content for your application using the separator perform a screen test such as with a screen of gap width 0 50 mm The dry matter content when using the separator will alway...

Page 26: ...he arms is too large you must increase the contact pressure by increasing the leverage of the weights If the contact pressure becomes too high the solid cake will become too hard see section 14 Problems Troubleshoot ing 12 TAKING THE SEPARATOR OUT OF OPERATION 1 Switch off the feed pump to the separator 2 Allow the separator to continue running for about 30 60 seconds until no more solid or separa...

Page 27: ...the in flow housing in order to protect the seals from the medi um being separated This can be accomplished with sealing grease For this purpose a grease press must be used every 125 operating hours or weekly to introduce roughly 3 to 5 cm3 of grease via the lubricating nipple The grease should be supplied while the machine is run ning to ensure that the entire seal area is filled with seal ing me...

Page 28: ...to the housing When dismounting the auger the O rings and the slide ring remain on the auger hub and can be pulled out of the machine together with the auger When reinstalling the auger make sure that the complete auger hub especially the glued bushing and the slide ring are free of dirt in order not to dam age the rotary shaft seal The surface of the slide ring which is in contact with the wear p...

Page 29: ...the main switch against reactivation e g with a padlock 5 Remove the bolt internal brace in the head of the auger The length of the bolt is always the same as the length of the auger Remove the mouthpiece by unscrewing the 6 nuts that hold it in place 6 Loosen the lock nuts of the scraping bolts and turn the scraping bolts roughly one turn counter clockwise see Fig 13 13 7 Remove the rest of the s...

Page 30: ...components that must be handled with care The screen guide rails are aligned during assembly of the sepa rator using a special template then fixed in place with the fas tening bolts and should not be loosened again However if the setting is changed due to an error they must be realigned You can obtain the required alignment template along with instruc tions from your nearest FAN dealer Follow the ...

Page 31: ...riginal installation position is retained it is possible to identify the causes for any uneven wear on the basis of wear marks The screen must have sufficient floating capacity after reinstallation in other words it must not be under axial tension from the housing and the mouthpiece If installed correctly the screen can be moved somewhat by hand A small gap of several tenths of a millimeter must e...

Page 32: ...rt the auger carefully into the separator without striking the feather keys against the axial contact surface of the auger This could cause the auger to exhibit axial eccentricity Turn the auger until the feather keys snap into the feather key grooves of the auger Then press the auger upward and screw it with the auger bolt again tightening torque 81lbf ft Check the auger again for axial eccentric...

Page 33: ...he normal wear of the screen can be observed as an increase in the inner diameter and the screen gap width The wear of the screen and the auger generally affects the proper functioning of the separa tor and can be identified based on reduced throughput and worse drainage of the liquid phase Howev er when observing such changes it must also be ruled out that the supply medium and its consistency ha...

Page 34: ...auger blade would no longer suffice for sufficient bonding of the plating A new auger is therefore required 13 6 SUMMARY OF MAINTENANCE AND INSPECTION INTERVALS Check the operational safety of the machine before every start Daily Visual inspection of the solid cake and the effluent Visual inspection of the machine and gearbox seals see section 13 1 1 Fig 13 3 flange inflow housing inspection openi...

Page 35: ... maintained to ensure optimal operation of the separator The open drainage of the influent takes place in the inflow area of the screen in other words the water not bound up in solid matter via capillary action is removed In the press area where the solid cake forms water bound up via capillary action is pressed out If the influent contains no solid matter no solid cake is formed as well as no tra...

Page 36: ...in the bypass line 2 Lifting effect in the overflow line the medium is being drawn out of the separator 3 Too much contact pressure 4 Excess wear on the screen or au ger 5 Screen positioned incorrectly or clogged 6 Auger channels clogged 7 Screen only worn in certain places guide rails for the screen not set correctly 8 Slurry is pumped stirred too much ground fine 1 Inspect pump rotation directio...

Page 37: ...applies to operation under load 1 Overload 2 Power consumption is too high because the solid cake is too hard 3 The setting for the maximum pow er consumption is not configured correctly or the control unit has been damaged 4 Foreign bodies are blocking the auger 1 Check the motor protection for correct setting set to maximum value if necessary 2 See configuration instructions in the section Initi...

Page 38: ...and or the supply medium is highly abrading 2 The blocking seal has been worn out by the duration of operation 1 Replace the pump with a low pressure pump 2 The blocking seal must be re placed before the second seal is damaged which would lead to damage to the bearing or the geared motor Problems that cannot be cor rected A problem as described above cannot be corrected despite optimal configurati...

Page 39: ...which control the operation of the separator The cir cuit diagrams contained in the switch cabinet explain the individual electrical connections the cabling and the circuits Your electrician requires these circuit diagrams to connect the separator to the switch cabinet and your local power supply Every part and every component in the switch cabinet is numbered and listed in the parts list for the ...

Page 40: ...34 Operating Manual for FAN Press Screw Separator PSS 1 1 300 S 16 NOTES ...

Page 41: ...ective 2006 42 EC Electromagnetic Compatibility Directive 2014 30 EU Low Voltage Directive 2014 35 EU The following standards in the current versions were applied correspondingly EN ISO 12100 2011 03 Safety of machinery General principles for design risk assess ment and risk reduction EN ISO 13857 2008 08 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower...