Somat Company Division of ITW Food Equipment Group LLC 165 Independence Court Lancaster, Pennsylvania 17601 Telephone 717-397-5100 Facsimile 717-291-0877

SPC-60 Service / Training Manual

TABLE OF CONTENTS

General Description Installation Inspection Start up Chemical Pump Difference between close couple and remote units NOTE: For extractor and pumps refer to classic line manual.

GENERAL DESCRIPTION AND OPERATION The pulper will fill with water to the pre-set level when the stop button is released. Once the unit is operating water will be circulating through the pulper to the extractor and back to the pulper to be used again for processing. As the operator begins to add waste to process it is carried into the pulper and down to the cutting mechanism. The cutting mechanism grinds and cuts the waste into small pieces with the rotating blades as they pass closely by the stationary blades on the security ring. As the pieces are cut they will be pumped through the sizing ring and pumped away as “slurry” to the extractor. The single 6 horsepower motor provides the work required for both pulping and pumping. The slurry flow from the pulper to the extractor is about 100 gallons per minute. The slurry is piped to the “ Hydra-extractor” which is a screw press that separates the solids from the liquids in the slurry flow. The solids are carried upwards through the screen barrel by the screw and delivered to the discharge chute for depositing into the waste container. The liquids are released through the screen and are picked up by the return pump to be returned to the pulper via the tray or trough to be used again for processing. This procedure greatly reduces the volume and weight of the waste by removing the liquids as well as the air voids common to food waste.

Extractor

Discharge Chute

Pulper Tank

Pulper Drive Motor

Cutting Mechanism

Pulper Lid

Extractor Drive Motor

Return Water Pump

Screw & Screen

Feed Tray

Return Line

SPC-60S, F/S, TY

PLUMBING

Fresh water supply The fresh water connections are made at the square end of the pulper, behind the drive motor. The unit requires the connection of cold water and hot water. There are labels on the “end plate” indicating the type and locations of the fresh water connections. Make the plumbing connection as required. The connections are made to half-inch female pipe threads. When running the pipe for these connections, do not use less than half-inch pipe and fittings at any location in the fresh water supply lines. Ensure that there is a shut-off valve in the supply line.

Drain pipe connection The drainpipe connection is done with 2-inch pipe, and the connection is made at the bottom of the pulper shell, at the end opposite the fresh water connections. When installing the drainpipe, ensure that the pipe is level or steadily falling. Never position the drainpipe such that it runs up hill at any location. The drainpipe should run to a floor sink. Use of an elbow, at the drain end of the pipe is recommended to divert the pulper drainage downward. The system overflow is internally piped to the pulper drain, at the factory.

Extractor hi level connection There is an extractor high-level connection that needs to be piped to drain. This connection is made to 1-½ inch female pipe threads. This hi level port should also be plumbed to the drain. If desired, this 1 ½ inch line can be tee’ed into the pulper drain line. If convenient it can be run separately to the floor sink.

Junction Box

Trough or Tray Flush Water Hose Connection

Cold Water Connection

Hot Water Connection

Trough flush piping Some pulpers have a “feed tray” for feeding waste into the pulper, in which case, the flush water is piped at the factory. Some models have a “feed trough” which is commonly integrated into a stainless steel table or dishwasher. In this case, the trough flush plumbing must be installed. This connection is also made at the “end plate” behind the drive motor. The trough flush location is labeled on the end plate. This connection is made to a 1-½ inch female pipe thread. The 1-½ pipe diameter should be maintained from the pulper to the trough end flush nozzle. Trough designs can vary and there may be other flush nozzles that branch off from this 1 ½ trunk line. Consult the final installation drawings to confirm the final trough and flush design.

ELECTRICAL This reference will describe the connection of the pulper junction box to the pulper’s control panel. The pulper junction box is located behind the pulper drive motor, and is accessed by removing the junction box cover from the “end plate”, next to the plumbing connections. The specified conduit between the pulper junction box and the control panel is 1 ¼ inch flexible plastic conduit known as Sealtite. There is a penetration cut in the side of the junction box and is designed to receive a 90 degree Sealtite connector. All junction box & control panel wiring is to be contained within this 1 ¼ Sealtite. Also, there is a 3/8-diameter polyethylene tubing, which carries air for the water level control system. This piece of tubing is also run inside this 1 ¼ Sealtite along with the wiring. This Sealtite can be run the entire distance from the pulper to the control panel, or if desired, it can be run to a junction box and the run can be completed with rigid conduit. Within the conduit, there are control wiring and power wiring. The control wiring carries the 120 VAC or 24 VDC control signals, while the power wiring carries the 3-phase power to run the motors. All the control wiring should be 18-gage wire. All the power wiring should be 12-gage wire. The quantity and identification of power and control wire can vary from unit to unit, but the following guideline is correct in all cases. FOR EACH UNIQUE TERMINAL NUMBER IN THE PULPER JUNCTION BOX, THE APPROPRIATE GAGE WIRE SHOULD BE PULLED, LABELED AND LANDED. If there are multiple terminals with the same number in the junction box, only one wire for that terminal need be pulled. For example, there will be multiple terminals labeled #2. Only one #2 wire need be pulled, and can be landed on any #2 terminal. If desired or needed, these instructions can be confirmed on the final installation drawings. In most cases, you will have to wire the start/stop push button station. (Refer to the sketch.) The push button station is wired to the pulper junction box via half-inch sealtite. As always, confirm the exact wiring with the FE drawing that came with the unit.

Start & Stop Push Button Station

To operate the pulper: 1. Ensure the drain valve is closed. 2. Ensure that the pulper and extractor

lids are closed 3. Ensure the “Empty/Run” selector switch

is in the “Run Position” 4. Flip the locking lever to release the

red stop button. The pulper will pre-fill with water.

5. When the pulper is pre-filled, the green button will illuminate.

6. Press the green button to start the Pulper.

The Pushbutton Station may be located under the table, on the wall or if specified may be installed into the control panel door.

START UP CHECK OUT Voltage Check Measure the voltage of the incoming power and confirm that it matches the voltage on the placard on the inside of the control panel door

Air Bubbles / Water Level Control The water level control system functions by pumping air from the control panel into the bottom of the pulper tank. As the water level increases, the pressure in this airline increases proportionally. The pressure switch monitors this airline pressure and turns the fresh water fill valve on when the water level is low. At start up, it is good practice to check the inside of the tank to make sure that there is a flow of air bubbles into the tank. The air enters the tank through the drainpipe before the drain valve.

The proper adjustment of the water level control system must be made before the unit can operate properly. The photo shows the cutting mechanism of the Super 60. The level indicated by the line, about 1 inch above the cutting mechanism, is the level to which the pulper should fill before starting the unit. The pressure control switch should be adjusted, such that, when the pulper stops filling, the water level is within one-quarter inch of this line.

The lid switches must be functioning and the lids closed for the water level system to operate. If you cannot get the system to start filling refer to the lid switch section for probable cause.

The photo shows the pressure switch located in the control panel. The adjusting screw on the pressure switch is rotated counter-clockwise to raise the water level set point, and vice versa. One-quarter turn of this adjustment screw will change the level set point by approximately one inch. When the pulper fills to the pre-set water level, the green start push button will illuminate, indicating that the pre fill level has been reached and the pulper is ready.

Motor Rotation Direction When operating 3 phase motors, it is possible for the motors to turn in the wrong direction when starting up the machine. The close coupled pulper has 3 motors, each of which needs to have the direction of rotation confirmed.

1. The pulper drive motor should turn counter clockwise as viewed from inside the pulping tank.

2. The auger in the extractor drive should turn clockwise, as viewed from above. If the extractor drive is attempting to turn backwards, it will likely stall and cause an overload to trip instead of actually turning backwards.

3. To check the direction of rotation of the return pump, you must remove the top panel from the shrouded area between the pulper and the extractor. (Just below the extractor access door.) The return pump sits vertically within this shrouded area, with the motor fan facing upward. The proper direction of rotation is counter-clockwise, as viewing the motor fan from above.

Amperage Draw of Motors When the pulper is operating, the amperage draw of each of the motors goes a long way in telling whether the unit is installed and operating correctly. The amperage of each motor should be checked below each of the motor overload relays in the main control panel. The following chart shows the amperage readings that should be expected when the pulper is operating on water only.

These readings should be checked before waste is fed into the pulper.

Motor w/ 230-Volt Supply w/ 460 Volt Supply Pulper Drive 10 amps, (+/- 1 amp) 5 amps, (+/- ½ amp) Extractor Drive 3 amps, (+/- 1 amp) 1 ½ amps, (+/- ½ amp) Return Pump Drive 7 amps, (+/- 1 amp) 3 ½ amps, (+/- ½ amp)

Lid / Limit sensors There are (3) types of sensors on the close-coupled pulper. 1. Extractor Chute. (Magnetic proximity sensor.)

This prevents the extractor from operating with the lid on the chute open as this is potentially dangerous should someone reach into the head area. It is mounted on the side of the chute and interfaces with a magnet on the lid.

2. Hinged lid switch. (Inductive proximity sensor.) This sensor is mounted inside the latch keeper, up from the bottom. The top of the sensor will see the latch tang when placed inside the keeper. The sensing range is very small (3mm). If in need of adjustment care must be taken not to raise the sensor too high or the latch will come in contact with the sensor. If this should happen and it is damaged it will fail and require replacing. (Refer to the exploded view section for further clarification if needed.)

3. UDT lid switch. (Magnetic inductive proximity sensor.) The UDT (Under Dish Table) model has a sensor mounted inside a ½” pipe. The sensor is inside the pulper and will detect the presence of the lid as it has a thin magnet located in between two walls of stainless. This sensor operates on 24-volts and extreme care should be taken not to apply 120 volts to it. This will burn out the sensor and it will require replacing.

CHEMICAL PUMP The system comes supplied with a chemical additive pump. This is for reducing odors and adding disinfectants to the return water to be circulated throughout the system. The pump is easily adjusted depending on the needs of the system and for regulating the concentration dependant on the recommendations of the chemical manufacture. Simply turn the adjusting ring. When using SOMAT’s Neutro Plus the dial should be placed on setting 2 or 3. Overdosing of the chemicals may cause excess foam and bubbles in the water that may interfere with the water level control. The pump is wired into the electrical system and will operate whenever the system is operating. There is an additional manual switch to turn off the pump should the user not wish to inject any chemicals.

Extractor Overflow The overflow port on the extractor should not come into play during normal operations. The return pump is sized to have the capability to return more water from the extractor shell than the pulper is capable of delivering to it. Consequently, the water level in the extractor should be very low, and below the elevation of the extractor overflow. The extractor overflow should allow the release of water only during the “Empty Mode.” In the “empty mode,” the extractor rinse system is energized, adding approximately 10 gallons per minute of hot water to the system. The extractor overflow is needed only to allow the discharge, to drain, of this volume of water. If water is flowing down the extractor overflow during normal operation, contact the Somat factory.

System Overflow

One of the means in which the system accomplishes weight and volume reduction, is by removing from the waste, an amount of “free-water” that foodservice waste typically contains. Therefore, the system is designed to divert this volume of “system overflow” to waste in the pulper drain line. Typically, the Somat system will divert 1 to 4 gallons per minute to the drain, as “overflow.” The rate of overflow can be adjusted to match the needs of your particular waste stream. This adjustment is made with the stainless steel “overflow control assembly” that is located under the drive shroud next the pulper

drive motor. Upon system start-up, this adjustment should be made to minimize the system’s use of fresh water. Most applications will operate successfully with a setting of “2”, which is the factory setting If the waste stream has an abnormally high volume of “mushy” food wastes, (mashed potatoes, custards, etc.) the overflow rate may have to be increased. Conversely, if the waste stream contains only disposable plastics and paper, the overflow rate may reduce to “1.” Refer to the photo for adjusting the overflow. The number is roughly the volume of overflow in gallons per minute. If the setting needs to be changed, simply loosen the four flange bolts and change the setting. If the desired setting is to “3” or “4”, one of the flange bolts will have to be removed to allow the tang to pass. When securing the tang, by tightening the flange bolts, ensure that the tang is touching the side of the bolt, to assure proper alignment. The setting number must be visible in the center of the round hole for the assembly to function properly. When tightening the hardware, be sure to tighten all four bolts evenly to assure equal pressure around the plates, which prevents leakage.

PART NUMBERS AND VIEWS SUPER 60 PULPER ASSEMBLY PARTS LIST DESCRIPTION PART NO. QTY.

CUTTING MECHANISM (See Cutting Mechanism Section) 1 SEAL, MECHANICAL 54306 1* MOTOR, 6 HP, TEFC 41660 1

Attaching Parts

Screw, Hex Head, 3/8"-16 X 1" Lg., S/S 4 Washer, Lock, 3/8" Split, S/S 4

VIBRATION ISOLATOR, Rubber 16200 4*

Attaching Parts

Screw, Hex Head, 3/8"-16 X 1" Lg., S/S 4 Washer, Lock, 3/8" Split, S/S 4

LID LATCH 35100 1 LID HANDLE 35220 1 LID GASKET 53410 1 LID STOP 84770 1 LIMIT SWITCH, Magnetic Proximity 54999-1 1 MAGNET 55007 1* TRAY ONLY

Curtain 23011 1 Tray Gasket 33915 1

* Recommended Spare Parts SS - Stainless Steel

SUPER 60 PIPING COMPONENTS PARTS LIST DESCRIPTION PART NO. QTY.

FRESH WATER ASSEMBLY

Backflow Preventor, 1/2" * 11310 1* Shock Arrestor, 1/2" 11303 1 Solenoid Valve, 1/2" * 64710-2 1*

DRAIN ASSEMBLY

Drain Valve, 2" 64840 1

WATER LEVEL CONTROL

Snubber * 59998 1* Diaphragm Check Valve * order by description 1*

* Recommended Spare Parts SS - Stainless Steel

SP-60 Cutting Mechanism

Security Ring

Rotating Blade

Impeller Pumping Vanes

Stationary Blade

SUPER 60 CUTTING AND PUMPING MECHANISM PARTS LIST DESCRIPTION PART NO. QTY.

Rotating Blade 80960 1

Attaching Parts Screw, Hex Head, 3/8"-24 X 1" Lg., S/S 2

Security Ring 87473 1

Attaching Parts Screw, Hex Head, 3/8"-24 X 1/2" Lg., S/S 3 Washer, Flat, 3/8", S/S 3 Washer, Lock, 3/8" Split, S/S 3

Stationary Blade* 80988 3*

Attaching Parts Screw*, Flat Head, 1/4"-20 X 1" Lg., S/S 6* Nut*, Self Locking, 1/4"-20, S/S 6*

Impeller 86600-1 1

Attaching Parts:

Screw, Hex Head, 3/8"-16 X 3/4" Lg., S/S 1 Washer, Lock, 3/8" Split, S/S 1 Washer*, Flat, 3/8" Special, S/S 89201 1* Key* 1/4" x 1/4" x 1" 1*

*Recommended Spare Parts

Remote units only There are a few fundamental differences between the close couple units. Electrical

1. The control power comes from the extractor panel; this panel must be on for the system to work.

2. Interconnecting wires must be connected to correct terminals (dash lines on FE print).

Plumbing

1. The elimination of the overflow assembly at the pulper. Balance of the system is done in a normal Somat fashion (at the extractor).

On one on one units the throttling valve will be located near the extractor in the return line adjust valve while monitoring amps of the return pump motor.

On multiple units the throttling valve will be located near pulpers in the return line adjust to obtain good trough flow and the desired overflow at extractor. (Special attention to not over amping motors) Pressure switch These units will have a dual switch in them. The left side is for setting the “flood” level, this is controlling the operation of the MOV stopping water flow in the return line if pulper is to full. The right side is your normal prefill/operating water level setting (approx 1” above security ring).