SM 25 Wx C2U2 GB 1

Via Cellini,33 - 35027 NOVENTA PADOVANA (PD) - ITALY

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Technical Assistance +39 049 8084 816

INSTRUCTIONS FOR

USE AND MAINTENANCE

OF THE DISTILLER

SM 25 Wx C2U2

MICROPROCESSOR BOARD HSE 002 / V30

SOLUTEX

All rights reserved. Nothing from this publication is allowed to be copied in any way, whether electronically, mechanically or by photocopy or in any other way, without prior permission of the constructing company. Information in this manual can be changed without prior notice.

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INDEX CE CONFORMITY DECLARATION ................................................................................................................... 3 1. REQUESTED SERVICES ....................................................................................................................... 4 2. FRONT OF THE CONTROL BOARD ...................................................................................................... 5 3. Legend of scheme 95.04 ......................................................................................................................... 7 4. START UP ............................................................................................................................................... 9 5. VAPOURS AND DISTILLED SOLVENT CIRCUIT .................................................................................. 9 6. DIATHERMIC OIL HEATING SYSTEM................................................................................................... 9 7. OIL AND HEATER REPLACEMENT ....................................................................................................... 9 8. RESET OF THE HOUR COUNTER FROM THE MICROPROCESSOR BOARD AFTER 2000 WORKING HOURS. ......................................................................................................................................... 10 9. PNEUMATIC CIRCUIT .......................................................................................................................... 10 10. OPERTING AFTER A LOSS OF ELECTRICAL POWER ................................................................. 11 11. EMERGENCY STOP ......................................................................................................................... 11 12. MAINTENANCE ................................................................................................................................. 11 13. SAFETY DEVICES ............................................................................................................................ 12 14. SCHEME MICROPROCESSOR HSE 002 ........................................................................................ 13 15. HSE 002 Parameters ......................................................................................................................... 16 16. WIRING DIAGRAM E 589 ................................................................................................................. 17

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CE CONFORMTY DECLARATION

GB CERTIFICATE OF CONFORMITY F CERTIFICAT DE CONFORMITE D KONFORMITÄTSBESCHEINIGUNG E CERTIFICADO DE CONFORMIDAD NL CONFORMITEITSCERTIFICAAT I CERTIFICATO DI CONFORMITÀ

FORMECO srl Via Cellini, 33 35027 Noventa Padovana (Pd) - Italy GB Declares in keeping with its responsibility that the distillation unit: F Déclare sous sa propre responsabilité que le Distillateur: D Erklärt in alleiniger Verantwortung, daß die Anlage: E Declara bajo su propia responsabilidad que el Destilador NL Verklaart onder haar eigen verantwoordelijkheid, dat het destillatie-apparaat: I Dichiara sotto la propria responsabilità che il Distillatore:

GB F D E NL I

TYPE TYPE TYP TIPO TYPE TIPO SM 25 Wx C2 U2

SERIAL NUMBER

N° DE SERIE SERIEN NR. N° DE MATRICULA

SERIE NR. MATRICOLA

PRODUCTION YEAR

ANNEE DE PRODUCTION

HERSTEL-LUNGSJAHR

AÑO DE PRODUCCION

PRODUKTIE-JAAR

ANNO DI PRODUZIONE

GB Is in compliance with European directives concerning safety: F il est conforme aux normes de sécurité prévue de les directives Européens D In Übereinstimmung mit den europäischen Sicherheits-Richtlinien: E Está conforme a lo que prevén las normas Europeas de seguridad: NL In overeenstemming is met de Europese veiligheids-richtlijnen: I Risponde alle requisiti essenziali di sicurezza previsti dalle Direttive Europee:

98/37/CE - 89/336/CEE - 73/23/CEE

GB And in compliance with the following regulations: F Et conforme aux suivantes normes harmonisées D Und konform mit folgenden Normen ist: E Y está conforme con las siguientes normas: NL En conform de volgende normen is: I Ed è conforme alle seguenti Norme armonizzate:

EN 292-1-2/92 - EN 294/93 - CEI EN 60204-1/98

CEI EN 50014/A1/A2/99 - CEI EN 50015/99 - CEI EN 50018/01 - CEI 64-2/01

GB The General Manager Signature

F Le Président Directeur général Signature D Der Präsident Unterschrift E El Presidente Firma NL De algemeen directeur Handtekening I Il Presidente Firma

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1. REQUESTED SERVICES

TECHNICAL DATA Installed electrical power Heaters kW 2 Control Board kW 0.75

Installed total power kW 21

Electrical supply Three phase Volt 400 Frequency Hz 50 Electrical supply for boiler lamp Fuses A --- Electrical box for aux. supply Fuses A 6.3 Installed power Tot. A 6

LOADING VOLUME Boiler loading Maximum volume Litres 25 Max. % of residue 15% NB. 1 bar = 0,1 MPa

BSP Measures in inches

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2. FRONTAL OF THE CONTROL BOARD Ref. Scheme: ...95.05

1) Compressed air pressure control gauge PI-AC.

Shows the pressure in the compressed air circuit of the unit. 2) Distillate vapours thermometer TI-VS.

Shows the temperature of the vapours produced during the distillation. 3) Diathermic oil thermometer TI-O.

Shows the temperature of the diathermic heating oil. 4) Control board QC.

On the control board are the Main Switch and the program buttons for setting the process parameters.

5) Cooling water pressure control gauge PI-W.

Shows the pressure in the cooling circuit

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3. Legend of scheme 95.04

AL-VE Stick for level - Expansion vessel SL 04 Max. level controller on distilled solvent tank

AP - HSE Command microprocessor board SL 12 Max. level controller on distilled solvent tank (TASS)

BOLL Boiler SL 10 Min. level controller on distilled solvent tank (TASS)

BPAC Pressure control gauge in case of loss of compressed air

SL 40 Min. level controller on distilled solvent tank (TASD)

COW Water condenser SL 42 Max. level controller on distilled solvent tank (TASD)

EH-B Electrical heaters for boiler heating SOOD PT 100 probe for diathermic oil

FTS Solvent filter SSD Distilled solvent collection tank

IN-AC Compressed air inlet ST-MO Max. thermostat for diathermic oil.

IN-E Electrical power inlet ST-VC Safety thermostat on inlet of condenser

IN-S Solvent to be distilled inlet TAO Residue oil collection tank

LG Visual level TAR Residue oil storage tank

VMRP Delivery regulating manual valve TASD Distilled solvent storage tank.

IN-W Cooling water inlet TASS Dirty solvent storage tank.

OUT-AC Compressed air outlet for PMCS pump TI-O Diathermic oil thermometer

PI-AC Compressed air pressure control gauge TI-VS Solvent vapours thermometer

PMCS Solvent to be distilled loading pump TSFO Oil jacket bleeding tap ( for oil replacement)

PMEO Residue oil extraction pump TSIO Oil jacket unloading tap

PMES Solvent extraction pump VE Expansion vessel

OUT-W Cooling water discharge VMI Cut-off Manual Valve

VMSI Manual valve for winter’s discharge. VPCB Pneumatic boiler loading valve

SCFU Smokes discharge VPES Pneumatic SSD tank unloading valve

SCO Residue oil discharge VPSB Pneumatic boiler unloading valve

SCS Distilled solvent unloading VS Expansion vessel bleeding valve

SFA Air Bleeding YV 01 Solenoid valve for boiler loading

SL 01 Boiler’s loading level controller YV 02 Solenoid valve for boiler unloading and SSD tank unloading

FTW Water filter YV26 Solenoid PMES command valve

YV10 Solenoid valve for cooling water

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4. START UP Ref. Scheme: ...95.04

Before start-up the following operations have to be performed:

a) Fill up 1/3 (one third) the oil collection tank TAO or shut-down the unloading solenoid valve YV02 for two cycles, in order to give the necessary time to the collection tank to self-trigger (to have a certain quantity of oil so that the pump starts to extract without a problem)

b) Open the compressed air supply.

c) Check the correct functioning of the valves and the pneumatic pumps.

d) Switch on the unit by means of the knob QF1, the indicator light HLV turns ON.

N.B.: These phases are performed only during the installation phase or when checking the unit.

5. VAPOURS AND DISTILLED SOLVENT CIRCUIT 1) Boiler loading.

The loading of the boiler occurs by means of loading pump PMCS and through pneumatic valve VPCB, both activated from working level controller SL01 inside the boiler. The timer TT1 inside the microprocessor board acts as a max. time for loading phase (10 minutes). The unit is equipped with a cartridge filter FTS of 2” It is advisable to use a filter placed inside the solvent suction tube.

2) Distillation.

The vapours produced from the evaporation of the solvent inside the boiler BOLL are conveyed in the condenser COW, cooled by air.

6. DIATHERMIC OIL HEATING SYSTEM

1. The oil is heated by means of the electrical element EH-B placed on the bottom of the boiler. 2. An expansion vessel VE, equipped with a bleeding valve VS, and a level tap AL-VE, allows the

expansion of the oil during the heating phase. The caps AL-VE also acts as a loading point for the oil replacement.

3. Located near the electrical elements is the housing of the temperature probes of the thermostats

ST-DP, ST-OD, ST-MO and the probe SOOD for the control of the oil temperature.

7. OIL AND HEATER REPLACEMENT Replace the diathermic oil every 1000 h. The unloading of the diathermic oil occurs through the tap TSIO placed under the boiler BOLL, bleeding through TSFO and AL-VE. The loading of the oil occurs from the caps AL-VE, bleeding by means of the tap TSFO. By means of a funnel fill up the oil to half of expansion vessel. Note.: If over filled, during heating at 200°C the oil can overflow from the bleeding valve VS. Collect

the oil in an appropriated tank. The residue oil has to be disposed according to norms of your country.

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Types of oil: Formeco LT 200-Mobiltherm 605 - Essotherm 500 - Shell Thermia B - Total Seriola 2100 For different trade marks use diathermic oil with a cracking temperature higher than 320° C and with a viscosity of about 31 cSt at 40°C and 5,3 cSt at 100°C. In order to maintain the heaters proceed in the following way:: 1 Unload the oil as explained previously 2 Unscrew the aluminium cover of the heaters paying attention to unscrew the screw M4.

Disconnect the electrical feeding cables. Remove the heaters and proceed with the cleaning or the replacement with the defected one.

3 Screw the heaters using a teflon band for tightening. 4 Refill with oil as described in the paragraph “Oil replacement”. N.B.: Pay particular attention during cleaning to not contaminate the oil circuit with solvent or water

substances which are able to vaporise inside the oil circuit and which can create over pressures which can not be controlled.

8. RESET OF THE HOUR COUNTER FROM THE MICROPROCESSOR BOARD AFTER 2000 WORKING

HOURS. - In sequence turn on and turn off 3 times the thermostat-Switch ST5/SA3

(see paragraph dedicated to the microprocessor board) - Wait for 8 flashes of the indicator light HLR2 (see paragraph dedicated to the microprocessor

board) - At the end of the flashing, turn on and off again 7 times the same switch - At the end of 16 flashes of the same indicator light the hour counter is reset..

9. PNEUMATIC CIRCUIT 1) Compressed air feed (IN-AC).

From the line of the compressed air feed provide: - pressure 7-8 bar - diameter of the tubes 8 mm On the inlet of the pipe provide a pressure reducer and a lubricating filter. It is advisable to have dried air in order to avoid humidity inside the solenoid and pneumatic valves

2) Compressed air connection.

Connect the compressed air with a feed sleeve placed on the higher part of the frame (IN-AC). The compressed air pressure control gauge PI-AC indicates the pressure in the circuit.

3) Compressed air circuit safety device

In case of loss of compressed air the pressure control gauge BPAC intervenes.:

- The dirty solvent loading valve VPCB (normally closed) is not opened then the loading stops.

- The unit shuts down and the indicator light HLR3 turns on.

When the pressure is restored the normal operation is also restored.

If the unit is fed, turn-off the electrical power (QF1 on position OFF) and turn-on (QF1 on position ON) to deactivate the shut-down relay.

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10. OPERTING AFTER A LOSS OF ELECTRICAL POWER (restart after the emergency stop or after an interruption of the electrical power)

When, for whatever reason, the emergency switch is activated or if there is a loss of electrical power the unit will immediately stop. When electrical power is restored the unit starts from the beginning of the working cycle. In order to resume the working cycle which was interrupted the process parameters have to be reset again.

11. EMERGENCY STOP Reference Drawing E733 “Front of the control panel” The activation of the EMERGENCY switch (QF1) stops the unit. The intervention of safety devices will stop the unit deactivating the operating functions. All the alarms remains operative and remain displayed (the alarm indicators will continue to operate normally). To restore the unit, reset the main switch (QF1) and push the button START (SB1). When the unit is re activated, the cycle will start from beginning

12. MAINTENANCE Assign the maintenance operations to skilled staff. It is possible to contact the manufacturer for a programmed maintenance performed by qualified staff 1) Weekly maintenance. 2)

- Check the filter of the dirty solvent loading (FTS). - Check and clean the boiler bottom (BOLL).

2) Monthly maintenance.

- Check the level on the diathermic oil expansion vessel (AL-VE) - Check for leakage on the oil pump (a minimal leakage is negligible) - Check for layers of dried residues on the bottom of the boiler (TAO)

3) Maintenance after 1000 working hours.

- Replacement of the diathermic oil (see the oil circuit), check the efficiency of the heating circuit. - Open the control box and verify the connections on the terminals and on the various devices, verify

the usage state of the contacts of the relays and eventual efficiency of the connections on fuse holders.

- Check the state of the filter and of the valves of the loading line, clean with solvent or replace them if necessary.

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13. SAFETY DEVICES

DEVICE INDICATOR LIGHT

EFFECT CHECK

BOILER HEATING SAFETY THERMOSTAT (ST-MO)

HLR 3 STOP: HEATING

RIA

Check the operation of the microprocessor board and the working

thermostats

DISTILLATE OUTLET SAFETY TEMPERATURE (ST-VC)

HLR 3 STOP: HEATING

Check the condenser and/or the correct operating of the fan motor (absorbtion) or

ambient temperature too high

PHASE TIME SAFETY TIMER (INSIDE THE MICROPROCESSOR

BOARD)

HLR 1 HLV2

STOP: OF UNIT R

Check the electrical functions and eventually ask for technical assistance

DISTILATE STORAGE TANK MAX. LEVEL CONTROLLER

(OPTIONAL) SL42

HLR 2 STOP: OF UNIT R

Discharge tank TASD

DISTILATE STORAGE TANK MIN. LEVEL CONTROLLER

(OPTIONAL) SL40

HLR 2 STOP: OF UNIT R

Before discharging the tank TASD wait for the emptying of the tank SSD

SOLVENT TO BE DISTILLED STORAGE TANK MIN. LEVEL

CONTROLLER (OPTIONAL) SL11

HLR 2 STOP: OF UNIT R

Before loading the tank TASS wait for the loading of the boiler BOLL

DISTILATE COLLECTION TANK MAX. LEVEL CONTROLLER

(OPTIONAL) SL12

HLR 2 STOP: OF UNIT R

Before discharging the boiler wait for the loading of the TASS

COMPRESSED AIR PRESSURE GAUGE - BPAC

HLR 2 STOP: OF UNIT R

Check the presence of the compressed air on pressure control gauge BPAC

R => Reset the unit to re-establish the normal operating conditions RIA => Manual reset device

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14. SCHEME MICROPROCESSORE HSE 002 This distiller is equipped with microprocessor board HSE 002, program V30 - 3 PHASES

Wiring diagram The microprocessor board HSE 002 allows operations with different programs. For the identifications in brackets ( ) see the reference.

12.1 Time for loading of the solvent to be distilled

• The loading is effected up to: a. Reaching the level on the level controller SL01 in the boiler b. Or at the end of the max. time which can be set between 0’ and 10’ through the trimmer TT1

DISTILLATION

Atmospheric pressure distillation The working temperature of the diathermic oil heating is set on the thermostat (ST1) while the time of the phase is set on timer (RP1). It is possible to regulate the heating power between 50% and 100% by means of the trimmer TT3 placed on the microprocessor board located inside the control board.

COOLING

Temperature reduction phase for diathermic oil. This phase is necessary in case of over boiling or foam formation at the beginning of the cycle “Distillation” after the loading of a Multi-cycles . Time can be regulated between 0 ÷ 120 minutes by means of the trimmer (TT2) on the microprocessor board.

1 Batch 2 Batch 3 Batch Power

regulation.

Loading 1 • • • TT1

Distillation 1 • • • TT3

Distillate unloading • • TT5

Loading 2 • • TT1

Distillation 1 • • TT3

Distillate unloading • TT5

Loading 3 • TT1

Distillation 1 • TT3

Cooling • • • TT2

Distillate unloading and residue • • • TT4

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12.2 Settings

Control board opening

Switch off the main power by means of the Main Switch (P QF1) and open the Control Board by removing the screws.

Heating power

The distiller is set to the maximum power. In case foaming occurs during multi-cycle loading reduce the heating power between the interval of 50 and 100%, by means of the trimmer TT3 placed on the microprocessor board.

12.3 Trimmer Regulating

See table “Parameters HSE 002”

To modify the values : a. Shut down the power from distiller by means of the emergency button (SB1). b. By means of a small screwdriver set the white screws as indicated on the figure B. Clockwise : increasing of the value

Counter clockwise: decreasing of the values

Close the control board by fixing all the screws.

+-

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12.4 Setting of the process parameters

Distillation Time

Set the index of the Timer (RP1 or RP3) to the end of the stroke (5 hours). Check during the first distillation cycle the time passed from the start and the moment at which the distillate comes out in a very small quantity or stops. The time taken to this point is the optimal one to set the successive cycles. Normally it will be about 3-4 hours. In case of more consecutive cycles, the time of the successive cycles has to be reduced by 30 minutes.

Temperature for Distillation"

Turn on and turn off in sequence three times the Thermostat-Switch (ST5/SA3) terminating the operation by setting the desired temperature. This operation has to be performed within 8 seconds during which the red indicator light (LR9) flashes.

This operation memorises the process parameters. If the values on the thermostats or on the timers are varied, the modifications will be only accepted if confirmed with the procedure described above.

Starting of the distillation cycle

Push the start button (SB1).

Stop of the distillation unit

For stopping of the distillation unit set the main switch (QF1) to zero.

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15. HSE 002 Parameters

PROGRAM

TRIMMERS VALUE PERCENTAGE MINUTES

TT1 (0-12 minutes) 30% 4 LOADING

TT2 (0-120 minutes) 40% 60 COOLING

TT3 (50-100%) 100% POWER

TT4 (0-20 minutes %)

15% RESIDUE UNLOADING

TT5 (0-20 minutes) 15% DISTILLATE UNLOADING

WORKING TIMERS

TIMERS VALUE RP1 (0-300 minutes) 70% 210 DISTILLATION

WORKING THERMOSTATS

THERMOSTATS VALUE ST1 (0-200°C) 70 °C DISTILLATION

AUX. THERMOSTATS

THERMOSTATS VALORE ST-MO 225° C MAX. OIL

ST-VC 60° C MAX. DISTILLATE

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16. WIRING DIAGRAM E 589