Nilfisk-ALTO 7309021 manual

1 User Manual DEL T ABOOSTER 7309021 (02.2008)[...]

2 Contents 1 Pr oduct description ....................................................... 4 1.1 Model sur v e y and main functions ......................................................................... 6 1.2 Selection of system .............................................................................................. 8 1.3 T echnical data ..[...]

3 3 How to use the DEL T ABOOSTER ...................................... 38 3.1 Saf ety .............................................................................................................. 38 3.2 Model sur v e y ...................................................................................................... 39 3.3 Functional diagram[...]

4 1. Pr oduct Description Lay out of system The DEL T ABOOSTER is a flexib le pump station capable of supplying se ver al simultaneous users with pressurized cold / hot water through a pipeline. The DEL T ABOOSTER has been pre-adjusted f or a cer tain line pressure which is also the maximum w orking pressure. F or the DEL T ABOOSTER a system of ni[...]

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6 1.1 Model survey and main functions The DEL T ABOOSTER comprises 4 different modules: 1. A switc hboard 2. A water tank 3. KEW T echnology C3K pumps 4. Cabinet / frame The DEL T ABOOSTER is made of stainless materials through and through. DEL T ABOOSTER switchboard The s witchboard comprises: - main (emergency) s witch, to which the supply cable [...]

7 W ater tank The water tank of the DEL T ABOOSTER has been constr ucted in accordance with BS 6281 par t 1 (type A air gap). As standard the water tank is mounted f or water connection in the left side (seen from in front) b ut the water tank is also a v ailab le with prepared water connection in the right side. The water tank of the DEL T ABOOSTE[...]

8 1.2 Selection of system The g reat degree of fle xibility , an impor tant characteristic of the DEL T ABOOSTER, means that each individual customer ma y select the system which suits his cleaning needs. The f ollowing solutions are off ered: NUMBER OF PUMPS Choose from 2 to 6 pumps depending on the capacity required at the same time. In other wo[...]

9 1.3 T echnical data Identification of model The model identification appears from the identification plate on the cabinet. The model plate provides the f ollowing data: 1. Model 2. Nilfisk-AL T O No. 3. Nozzle 4. Pump pressure 5. Max. pressure 6. W ater v olume 7. Max. temperature of inlet water 8. V oltage / frequency / nominal input 9. P o [...]

10 1.3.0 Control system Classifica- Country Model Electric Data P o wer Max. tion of absorption capacity tightness B,E,I, DEL T ABOOSTER-3P 230V 3~+ EAR TH, 50Hz 6,7-20,4kW 3x6,7kW IP55 N 20,6-63 A DEL T ABOOSTER-6P 230V 3~+ EAR TH, 50Hz 6,7-40,5kW 6x6,7kW IP55 20,6-125 A DK,S,N, DEL T ABOOSTER-3P 400V 3~+ EARTH, 50Hz 6,7-20,4kW 3x6,7kW IP55 SF ,D[...]

11 1.3.3 Dimensions, weight and total perf ormance per system 1 - water inlet for hot w ater 2 - water inlet for cold w ater 3 - water outlet, ∅ 22 mm No. of pumps 2 3 4 5 6 Model 44C3 44C3 44C3 44C3 44C3 Cleaning power kW 8,8 13,2 17,6 22,0 26,4 Pressure bar 160 160 160 160 160 W ater v olume l/min 34 51 68 85 102 Current cons. A 21,4 1) 32,1 1)[...]

12 1.4 Location of the DEL T ABOOSTER The DEL T ABOOSTER is fitted with vibration absorbing r ub ber suppor ts, so it ma y be placed straight on an e v en surf ace (see section 2.2). The plant must be placed in frost-free premises where the maximum temperature does not e xceed 40°C . LOCA TION SKETCH (dimensions in millimetres)[...]

13 1.5 Installation requirements f or water connection The w ater tank is fitted with two water inlets, one f or cold w ater (BLUE marking) and one for hot water (RED marking). This allows the operator to control the temperature of the water being used. If no temperature control is desired both w ater inlets ma y be attached to the cold pipeline. [...]

14 PE L1 L2 L3 PE max 125 A max 35 SUPPL Y NETWORK DEL T ABOOSTER control system Ground f ault circuit interrupter 1.6 Installation requirements f or mains power connection The power system of the DEL T ABOOSTER is designed in conformity with the common Euro- pean standard: EN 60204-1 (October 1992): Electr ical equipment of machines , P ar t 1: Ge[...]

15 1.7 Pipe system 1.7.1 Location of pipelines/g eneral instructions - The pump station and outlet points should be placed so that the lines become as shor t as possible . - The line should be arranged with as f e w bends as possible . - Sometimes it ma y pa y to split the line close to the pump station so the lengths conducting large volumes of w [...]

16 Rørledningskomponenter - Piping Components - Rohrleitungsk omponenten - Elements De T uy auterie BETEGNELSE BEZEICHNUNG DESCRIPTION DESIGNA TION DIMENSION G R Cu Rø r Rohr G Ø15 x 2 mm X X X Pipe T uyau R Ø15 x 1,5 mm Rø r Rohr G Ø22 x 2,5 mm X X Pipe T uyau R Ø22 x 2,0 mm Rø r Rohr G Ø30 x 4,0 mm X * Pipe T uyau R Ø30 x 3,0 mm Tilslut[...]

17 Rørledningskomponenter - Piping Components - Rohrleitungsk omponenten - Elements De T uy auterie BETEGNELSE BEZEICHNUNG DESCRIPTION DESIGNA TION DIMENSION G R Cu Vinkel Winkel Ø15 x Ø15 X X * Elbow Coude Vinkel Winkel Ø22 x Ø22 X X Elbow Coude Vinkel Winkel Ø30 x Ø30 X * Elbow Coude Stilbar L-f orskruning V erschraubung Ø15 X X Adj. Elbo[...]

18 1.7.3 Fittings, standar ds - 3 Rørledningskomponenter - Piping Components - Rohrleitungsk omponenten - Elements De T uy auterie BETEGNELSE BEZEICHNUNG DESCRIPTION DESIGNA TION DIMENSION G R Cu T -stykke T -Stück Ø22 x Ø15 x Ø22 X X T -Connection Raccord en Té T -Stykke T -Stück Ø30 x Ø30 X X T -Connection Raccord en Té Justerbar T -for[...]

19 1.7.3 Fittings, standar ds - 4 Rørledningskomponenter - Piping Components - Rohrleitungsk omponenten - Elements De T uy auterie BETEGNELSE BEZEICHNUNG DESCRIPTION DESIGNA TION DIMENSION G R Cu Rø rhol der Rohrhalterung Ø15 X X Pipe holder Suppor t tuy au Rø rhol der Rohrhalterung Ø22 X X Pipe holder Suppor t tuy au Rø rholder Rohrhalterung[...]

20 1.7.3 Fittings, standar ds - 5 Rørledningskomponenter - Piping Components - Rohrleitungsk omponenten - Elements De T uy auterie BETEGNELSE BEZEICHNUNG DESCRIPTION DESIGNA TION DIMENSION G R Cu Roset f . murgennemfø r ing Röllchenplat. f . Durch Ø15 X Pipe enclose Enkysté de tuyau Roset f . murgennemfø r ing Röllchenplat. f . Durch Ø22 X [...]

21 1.7.4 Dimensioning of pipe systems The below diag ram shows the current pressure drop g raphs meant f or the dimensioning of pipe systems used in connection with the DEL T ABOOSTER plant. The diagram illustr ates two v er tical divisions f or II ) electro galvaniz ed steel pipes 15x2 mm - 22x2.5 mm - 30x4 mm I ) stainless steel pipes 15x1.5 mm -[...]

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23 50 m 40 m 70 m a b c M 1.7.5 Examples The follo wing examples hav e been worked out on the basis of stainless steel pipes and a 160 bar system, and the dimension requirements are max.15 bar pressure drop from the machine to the outlet points. Example 1 T wo diff erent conditions ma y be used when dimensioning the pipe system: A. Based upon a fi[...]

24 20 20 c 2 c 1 c 20 20 b 2 b 1 b 20 20 a 2 a 1 a 30 m 30 m 10 m 10 m 80 m 60 m M B: If , on the other hand, a green spra y lance is selected = 33 l/min + a standard spr a y lance = 17 l/min the maximum load on the line b-c = 33 l/min. P R E S S U R E DROP Use of 50 m ∅ 15 mm pipe will result in a pressure drop of: 9.3 bar Maximum load on line a[...]

25 80 m 60 m c 2 c 1 b 1 b 2 a 2 a 1 15 m 20 m 20 m 40 m 40 m 20 m 20 m 30 m 20 m 30 m 30 m M Example 3 Ring system Selection of spra y lance: 2 g reen spra y lances each of 33 l/min 2 blue spr a y lances each of 17 l/min If the maximum load is distributed e venly and symmetrically the maximum load on line b1 - c1 = 33 l/min. If ∅ 15 mm pipe is s[...]

26 1.7.6 Mounting requirements and hints T emperature compensation When hot w ater (max. 75°C) is used in the system due regard should be paid to thermal e xpan- sion of the pipes when mounting the system. When raising the temperature from10°C to 75°C the system will e xpand some 0.7 mm/m. In order to allo w for this e xpansion long str aight li[...]

27 FIXA TION A T CORNERS AND TEE CONNECT ORS Standard distance between pipe brac k ets is some 2 m. MOUNTING OF PIPE LINES/GENERAL INSTRUCTIONS - Shor ten the pipes by sa wing off and take off burrs . - When bending the pipe bending radii should not be smaller than those stated in the char t under “U-bends/hose connections” and the bending shou[...]

28 1. Saw the pipe rectangular ly through and take off burrs . 2. It will be most easy f or you to saw the pipe rectangularly through by means of the pipe sawing mechanism shown. NAME:BA V 6/42 (f or pipes of 6-42 mm OD). NO TE: Do not use pipe cutter! The pipe will be cut ov er slantingly and there will be burrs inside as well as outside the pipe [...]

29 1.8 Outlet points and accessories Outlet point A is a high-pressure coc k meant f or per manent mounting. The high-pressure cock should be fitted straight on the pipe line b y means of an ∅ 15 mm cutting ring connection. If a DEL T ABOOSTER spray lance is wanted the quick-coupling for the high- pressure hose should be fitted straight on to o[...]

30 ACCESSORIES Detachable foam injector , to be used in conjunction with outlet station A. Pressure-relieved spray handle with 10 m hose. Hose coil with 20 m hose Single spray lance for DEL T ABOOSTER plant descr ibed in section 1.9 Foam lance T o be used in conjunction with detachab le foam injector and detergent trolle y .[...]

31 1.9 Multipressure spra y lance system Spra y lances with colour coding are used as standard equipment. The colour code indicates the water v olume and pressure supplied b y the specific lance. The different water v olumes and pressures depend on the high-pressure nozzle, pre-nozzle and spra y lance fitted. The spra y lances for 120 and 160 bar[...]

32 2. Instructions f or assemb l y of DEL T ABOOSTER 2.1 Location of the DEL T ABOOSTER The DEL T ABOOSTER is fitted with vibration absorbing rubber suppor ts, so it may be placed straight on an e v en surf ace . The plant must be placed in frost-free premises where the maximum temperature does not e xceed 40°C . LOCA TION SKETCH (dimensions in m[...]

33 2 1 3 2.2 Mounting base If the base is une ven height adjustments may be made by adjusting the counter n ut (1) on the machine f oot (2) as shown on Fig. 1. It is impor tant that the plant is adjusted to hor izontal position. Otherwise it may be a problem opening the cabinet door . Fig. 1 It is advisab le to fix the module frame of the system t[...]

34 filter 2 1 2.3 Connection of inlet water The water tank is pro vided with two 1" w ater inlets: Inlet 1 for cold w ater (BLUE marking) Inlet 2 for hot w ater (RED marking) Fig. 3 W ater is connected at the inlet sock ets of the system by means of two 1" flexib le hose con- nectors. Shut-off cocks should be mounted right ne xt to the [...]

35 4. Main ear th ter minal 2. Sealing connection 1. Cable reliefs 2.4 Mains power connection between the DEL T ABOOSTER and the supply netw ork (cf. Fig. 5) All measurements and connections described below should be carried out by authorized specialists ! 1) The DEL T ABOOSTER should be connected to a three-phase mains supply at the rated voltage [...]

36 2.5 Star ting up/running in Prior to star ting up the customer engineer should be fully confident with sections 3.4 - 3.6 of the Operation Manual describing the instrument panel, settings and star ting up/operation. If any f aults appear during the star ting up and r unning in, sect. 3.10 on trouble-shooting ma y help you. 2.5.1 Oil control Che[...]

37 1 2 3 2.5.4 V enting of pipe system When each pump has been v ented the system is star ted up, and all high- pressure coc ks on the pipeline are opened one at a time until all air has been remov ed. Begin with the remotest high pressure cock. Please note that the cock should be closed f or a shor t time before opening it again. The latter is don[...]

38 3 How to use the DEL T ABOOSTER Users are urgently requested to study these instructions before oper ating the DEL T ABOOSTER. The individual user is personally responsible for handling and using the cleaning system properly and saf ely . It is therefore urgent that all users are instr ucted in detail of how to use the system and they should all[...]

39 3.2 Model survey 1 5 4 3 10 9 2 15 8 12 6 7 14 13 16 11 1. Switchboard 2. Main switch 3. Operation switch 4. Star ting button 5. Switchboard 6. Water tank 7. Motor pump units 8. Water connection 9. Oil control 10. Pressure gauge 11. Outlet sock et 12. Machine feet with vibration absorber 13. Identification plate 14. Water filters 15. Lock 16. [...]

40 3.3 Functional diagram 1 2 3 4 5 6 21 20 22 12 14 17 15 13 10 11 18 25 16 15 19 7 8 9 26 1. W ater filter 2. W ater tank 3. Overflo w pipe 4. Le vel sensor (lack of w ater) 5. - - (star t inlet of water) 6. - - (stop inlet of water) 7. Relief valv e 8. Flow switch (flo w bac k to tank) 9. Excess-pressure valv e (ov erflow valv e) 10. Pressur[...]

41 3.4 Instrument panel The instrument panel is situated on the switchboard of the DEL T ABOOSTER. 1. Main / emergency switch (circuit break er) 2. Operation switch - stopping s witch 3. Star ting switch 4. Switchboard 5. Locks f or the door of the s witchboard 4 2 3 1 5 3.4.1 Main / emergency switc h The main s witch (1) connects the DEL T ABOOSTE[...]

42 3.4.3 The control panel The control panel ( 5 ) is based upon a schematic drawing of the system where a number of control lamps will show the status of the system and possib le f aults. The control lamps hav e been divided into three categor ies: Green indicating a coupled unit (v alve , C3K) Y ellow indicating an activ ated sensor (pressure s w[...]

43 3.5 Setting and reading of DEL T ABOOSTER In the DEL T ABOOSTER the user will only need to make the f ollowing settings and readings: 1. Setting of water temperature 2. Setting of n umber of C3K pumps in operation 3. Reading of hour meters In all three cases the s witchboard (Fig. 3) will hav e to be opened by means of the enclosed special ke y [...]

44 3.5.1 Setting of water temperature The knob f or adjusting the water temperature is placed on the steering A1 in the s witchboard and ma y either be put in the OFF position (click function - vertically) or set on the desired mixing temperature . The yellow diode below the control knob indicates the star ting point of the temperature adjustment. [...]

45 3.5.2 Connection and disconnection of C3K pumps The desired configuration of the DEL T ABOOSTER will deter mine this setting. As the system may hav e 2 to 6 C3K pumps connected, each module location has a specific figure connected to it.: The current configuration is set on the 8-poled transf or mer (cf . Fig. 3); below is a setting f or a c[...]

46 3.5.3 Reading of hour meters On the hour meters you can read for how man y hours each of the motor pump units has been running. Reading as follows: Motor pump unit 1 Hours 1/100 hours Example: 4 hours + 50/100 hour = 4½ hours[...]

47 3.6 Star ting up/running in (cf . Fig. 4) Once the desired settings ha v e been made the cov er of the switchboard should be closed and both locks activ ated. Make sure the w ater supply has been connected. T ur n the main s witch ( 1 ) to position I . T ur n the control s witch ( 2 ), to position I and keep an ey e on the control panel ( 3 ) to[...]

48 The operation of the system ma y be controlled on the control panel. (cf . sect. 3.4.4, Fig. 2) F rom the abo v e figure it appears which pumps and water supplies hav e been connected at the moment ( green ), and the status of the pressure, w ater flow and w ater le v el ( yello w ). Below is an e xample of the indications on the control panel[...]

49 3.7 Multipressure spra y lance system F or each line pressure of 120 and 160 bar a kit of nine diff erent spray lances is av ailable , which hav e been especially dev eloped for the Multipressure spray lance system. Each of the nine spra y lances represents a combination of pressure and water volume . Users may theref ore alwa ys select the job-[...]

50 3.8 Operation after star ting up - outlet points and equipment 3.8.1 High pressure cock with Multipressure spra y lance, Outlet point A 1. Open/close handle on high-pressure cock 2. Quick-coupling 3. T r igger on spra y handle 4. Safety loc k 5. Quick-coupling f or spra y lance 6. Multipressure spray lance Operation after starting up 1. Carefull[...]

51 3.8.2 Outlet point with foam injector and f oam lance, Outlet point B 1. Open/close handle on high-pressure cock 2. Quick-coupling 3. T rigger on spray handle 4. Saf ety lock 5. Quick-coupling f or spray lance 7. F oam lance 10. Dosage scale 11. Dosage valv e 12. Detergent containers 13. W all rac k for detergent containers Operation after start[...]

52 3.8.3 Outlet point with detergent trolle y and f oam lance, Outlet point D 1. Open/close handle on high-pressure cock 2. Quick-coupling 3. T rigger on spray handle 4. Saf ety lock 5. Quick-coupling f or spray lance 7. F oam lance 10. Dosage scale 11. Dosage valv e 12. Detergent containers Outlet point with detergent trolley should be operated in[...]

53 3.9 Maintenance The DEL T ABOOSTER is designed to ensure a minimum of maintenance. The following points should how e ver , be obser ved in order to secure troub le-free operation. 3.9.1 Service intervals/oil change "F requenc y of syste m servicing is dependent upon se ver al f act ors including wate r temper atu re and water quality . W e,[...]

54 3.10 T r ouble-shooting and possib le correction Prob lem P ossible cause Correction System will not star t or stops in mid-operation (no indication of fault) System does not star t or stops in mid-operation with the f ollowing fault indication: C3K C3K W ater tank W ater tank Pipeline / internal hoses Sensors One or more pumps will not stop aft[...]

http://www .nilfisk-alto .com F ax: +358 207 890 601 E-mail: jukka.lehtonen@nilfisk-alto .com www .nilfisk-advance.fi FRANCE Nilfisk-AL TO AL TO F rance SAS Aéroparc 1 19 rue Icare 67960 Entzheim T el.: +33 3 88 28 84 00 F ax: +33 3 88 30 05 00 E-mail: inf o@nilfisk-alto .fr www .nilfisk-alto.com GERMANY Nilfisk-AL TO Division of Nilfisk-[...]

7309021 (02.2008)[...]