Bauer S655, Original Operating Manual

Page 1: ...ORIGINAL OPERATING MANUAL FOR PLUG PLAY SEPARATOR SYSTEM Version I 2020 ...

Page 2: ...operation and service On this condition the BAUER Plug Play Separator System will operate to your satisfaction for many years The content of this operating manual is the intellectual property of the company BAUER GmbH and or its sup plier companies The available information may only be used in connection with the creation of specification compliant documents in the course of an order from the BAUE...

Page 3: ..._________________ Producer of the machine Röhren und Pumpenwerk BAUER GmbH Kowaldstraße 2 A 8570 Voitsberg Tel 43 3142 200 0 Fax 43 3142 200 320 340 Email sales bauer at com www bauer at com Owner or operator Name ___________________________________ Address ___________________________________ ___________________________________ Tel fax ___________________________________ Note Make a note of the ty...

Page 4: ...2 Operating Manual for BAUER Plug Play Separator System S ...

Page 5: ...AL STARTUP 16 7 INITIAL STARTUP 17 7 9 1 Automatic operation 22 7 9 2 Adjusting the pressure set point 22 7 9 3 Shutdown of the plant at excess pressure 22 7 10 1 Automatic Operation 23 7 10 2 Manual Operation 23 7 10 3 Automatic operation with clear effluent pump 24 7 10 4 Automatic operation without clear effluent pump 25 7 10 5 Manual operation with clear effluent pump 26 7 10 6 Manual operatio...

Page 6: ...ng pressure sensor 19 Figure 13 reset button fault lamp 20 Figure 14 OPERATION SWITCH 20 Figure 15 remote control 20 Figure 16 AUTO 0 HAND switch 21 Figure 17 switch feed pump 21 Figure 18 switch pressure set point 22 Figure 19 switch pump speed 23 Figure 20 lever and switch position in Automatic operation with clear effluent pump 24 Figure 21 lever and switch position in Automatic operation witho...

Page 7: ...rohibitions to protect against serious injury or prop erty 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 damage it...

Page 8: ...R Plug Play Separator System 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 regulations relating to safety occupational medicine and traffic laws must be strictly observed Unauthorized modifications to the machine release the manufacturer from li...

Page 9: ...ant 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 resu...

Page 10: ...mance of such work The work area must be blocked off and secured by a wide margin during such work if necessary Unauthorized persons must be prevented from entering As a rule maintenance and cleaning work as well as repairs of malfunctions may take place only with the drive switched off and the motor at rest switch off and lock the main switch or disconnect the supply of electricity Watch out for ...

Page 11: ...able electrical and electronic regulations With regard to an ATEX 95 zone 22 certification see the special remarks Never touch rotating or moving parts of the machines with hands or feet Never reach with hands tools or other parts into the inflow or hopper in the area of the screw while the machine is running In handling slurry always remember that the gases produced by the slurry are highly toxic...

Page 12: ...nim paired in a temperature range of 0 to 40 C in event of freezing temperatures it must be ensured that the separator feed pump and discharge pump as well as all pipelines are cleaned completely each time before being taken out of operation The eccentric screw pump is controlled by a pressure sensor and feeds the slurry to the separator In the inflow area of the separator the mixture is drained o...

Page 13: ...tronic regulations Required Tools Special tools are not required for setting up the Plug Play Separator System Standard assembly and electrical tools are required for assembly setup and disassembly Transport Improper transport could cause the device to fall or tip Severe injuries could result The customer must check based on the dimensions and weight of the Plug Play Separator System whether the a...

Page 14: ...le numbers of the wearing parts and replacement sets as well as the exploded view of the main components can be found in the replacement parts list No Name 1 Separator 2 Helix Drive eccentric screw pump 3 Rotary discharge pump clear flow pump 4 Switch cabinet 5 Frame with doors 6 Slide plate 7 Helix suction line eccentric screw pump 8 Separator supply line Helix pressurized line 9 Separator overfl...

Page 15: ...is the year 07 the month 001 is a three digit incremental number Required connected power 17 2 kW P PS655 S655HD S855 19 2 kW P PS855HD S855GB Year of manufacture e g 2018 Weight Depends on separator type 4 5 2 Information Signs Information signs can be found on the individual main components such as the Bauer separator Bauer ec centric screw pump and rotary discharge pump and are explained in the...

Page 16: ...or System for determining the dimensions of the setup location are shown in Fig 5 PP655 PP855 A in transportposition 2940 3010 B 2005 2005 C support inside 190 190 D 1180 1180 E 80 340 F 400 470 G 990 990 H 1165 1165 I 980 980 J 1705 1705 K 2515 2515 L 3640 3640 Figure 5 dimensions Plug Play Separator System all dimensions in mm ...

Page 17: ...ines or switching systems from damage in event of a short circuit WARNING Set the motor protection circuit breaker to the value specified on the motor type plate IRated IN I In forward motion the screw shaft turns counterclockwise As viewed from the discharge regulator toward the geared motor This can be checked with the phase monitoring relay 1F2 in the switch cabinet Direction of rotation correc...

Page 18: ...sed ball valve open Operation without clear flow pump gate valve open ball valve closed 7 Fill the feed pump eccentric screw pump suction line completely with liquid to prevent damage to the rotor and stator of the pump 8 Make sure that the press head and the functioning of the separator can be seen clearly from the switch cabinet it must be possible to watch the solid cake and its discharge speed...

Page 19: ...fter making a change and only make changes in small steps NOTE Before the initial startup and after prolonged downtime the separator should be flooded before switching it on by starting the pump briefly in order to pre vent possible damage from dry running NOTE In order to achieve good separating results it is necessary to mix the pumped medium well before separating Motor circuit breakers All mot...

Page 20: ... Bridging switch for break through control For starting the unit the break through control can be bridged manually Switch Position ON After the plug has been built and the flaps are in working position the bridging can be ended Switch Po sition OFF after that the break through control is active Figure 11 Bridging switch for break through control Indicator light light ELECTRICAL CABINET MAIN SWITCH...

Page 21: ...tion OFF see position A 2 OPERATION choice Turn off the switch position 0 see position B 3 PRESSURE SENSOR BRIDGING turn it on position ON see postion C 4 Turn on the MAIN SWITCH position ON see position D 5 Press RESET see position E 6 Turn OPERATION choice switch to hand mode position HAND siehe Pos F After installing a new pressure sensor the switch PRESSURE SENSOR BRIDGING must be turned to OF...

Page 22: ...ND please refer fig 14 Press the switches of the respective components separator feed pump clear effluent pump conveyor belt if available on the remote control please refer fig 15 to check the function Figure 14 OPERATION SWITCH Figure 13 OPERATION choice AUTO OFF HAND RESET fault lamp Figure 15 remote control DIRECTION OF ROTATION OK OPERATION OK RESET OPERATION AUTO O HAND BREAKTROUGHT SWITCH BR...

Page 23: ...the Operation choice switch on switch cabinet to HAND please refer fig 16 3 Set the feed pump switch on the remote control on position FORWARD to operate the feed pump manually until the separator inflow housing is completely filled 4 Switch on separator 5 During separator operation must be ensured that sufficient liquid is present in the inlet housing this is realized by temporarily on and off sw...

Page 24: ... 0 3 bar 7 9 3 Shutdown of the plant at excess pressure On the one hand the built in disconnection with overpressure serves for the protection of the pressure sensor and the system and on the other hand the overpressure discon nection prevents the separator from a breakthrough The disconnection with over pressure is only active during automatic operation In manual operation the operator must make ...

Page 25: ...r regulates the pump speed up or down until the preset target pressure is reached again Moreover in the automatic mode a shut off for over pressure chapter 7 9 3 and a wire break monitoring of the pressure sensor cable are active If the pressure in the inlet rises or the cable of the pressure sensor is damaged the system automatically switches off 7 10 2 Manual Operation The manual operation is de...

Page 26: ...ter 7 10 3 1 The automatic operation can only be started after a starter cake is formed starter cake formation must done manually and is described in chapter 7 8 After the starter cake is formed the Operation choice switch on the electrical cabinet must be switched to AUTO Moreover in the automatic mode the 1 ball valve in the inlet T pipe and the overflow must be closed Automatic operation with c...

Page 27: ... 3 ball valve in the base must be closed see chapter 7 10 4 1 The automatic operation can only start after a starter cake has built up starter cake formation must be done manually and is described in chapter 7 8 After the starter cake has built up the operation choice switch on electrical cabinet must be switched to AUTO Moreover in the automatic mode the 1 ball valve in the inlet T pipe and the o...

Page 28: ... pumps off the effluent In order that the effluent can be pumped off the gate valve 4 of the effluent pipe must be closed and the 3 ball valve in the stand must be opened see chapter 7 10 5 1 The system can be started after a starter cake has built up starter cake built up chapter 7 8 Manual operation with clear effluent pump switch and lever position Gate valve for effluent closed limit switch ac...

Page 29: ...ration mode manual operation without clear effluent pump the effluent is not pumped off that means that the effluent pipe must be moved in such a way that the effluent can flow back to the reservoir liquid manure pit In order that the effluent can run off the gate valve 4 of the effluent pipe must be opened and the 3 ball valve in the base must be closed see chapter 7 10 6 1 The system can only be...

Page 30: ...tive motor has been exceeded System pressure set point was adjusted incorrectly When starting the system in automatic mode the feed pump does not start no system pressure adjusted The feed pump switches off after a few minutes target pressure set too low The feed pump conveys too much material Separator breaks through target pressure set too high Adjusting the pressure set point see chapter 7 9 pr...

Page 31: ...d 9 Foreign bodies are blocking a com ponent 1 up to 7 Check motor protection for correct setting 8 The switch off limit should be ad justed again by a qualified electri cian according to the instructions see attached circuit diagram and documentation 9 Check Separator Helix pump Clear effluent pump Belt conveyor and re move foreign bodies important remove foreign bodies only when cabinet is disco...

Page 32: ...e inlet pipe too high Status LED on pressure switch lights up red 2 Break through protection triggered 3 Level switch triggered 4 PT 100 Sensor from Helix pump triggered 1 not the correct screen for this ap plication installed use screens with larger or smaller slots 2 Check break through protection switch possibly build up a new starter cake see chapter 7 8 in case of repeating check wash or chan...

Page 33: ...D INSPECTION NOTE For maintenance intervals and inspection activities for the individual compo nents of the Plug Play Separator System such as the separator feed pump discharge pump and control please see the enclosed operating manuals of these components DANGER Before doing maintenance work or inspecting electrical cabinet the machine must be disconnected from power supply on all sides and all po...

Page 34: ...32 Operating Manual for BAUER Plug Play Separator System S 11 NOTES ...

Page 35: ... The following standards in the current versions were applied correspondingly EN ISO 12100 2011 03 Safety of machinery General principles for design risk assessment and risk reduction EN ISO 13849 1 2016 06 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 13849 2 2013 02 Safety of machinery Safety related parts of control systems Part 2 Valida...