Somat D5 Installation guide

INSTALLATION INSTRUCTIONS

SP-60S PULPER, D5 DISPOSER &

W/HE-9 HYDRA-EXTRACTORS

165 Independence Court, Lancaster, PA 17601

Telephone 717-397-5100 Fax 717-291-0877

1-800-23 SOMAT (1-800-237-6628)

SAFETY

INSTRUCTIONS

READ THE MANUAL COMPLETELY BEFORE ATTEMPTING TO OPERATE THE

UNIT.

HIGH VOLTAGE! DO NOT PERFORM ANY REPAIRS TO MOTORS OR CONTROL

SYSTEMS WITHOUT TURNING OFF THE MAIN POWER.

ALWAYS TURN THE MAIN POWER OFF AND LET ALL MOTORS COME TO A

STANDSTILL BEFORE DOING ANY MAINTENANCE ADJUSTMENTS OR CLEANING

OF THE UNIT.

BEFORE STARTING, BE SURE ALL PERSONNEL ARE CLEAR OF MOVING PARTS.

KNOW LOCATION AND FUNCTIONS OF ALL START/STOP BUTTONS AND SAFETY

SWITCHES.

DURING PERIODIC MAINTENANCE, CHECK ALL SAFETY SWITCHES TO BE SURE

THEY ARE OPERATING PROPERLY.

DO NOT REMOVE OR ALTER GUARDS.

DO NOT REMOVE SAFETY LABELS. IF LABELS ARE MISSING OR DESTROYED,

CONTACT FACTORY FOR REPLACEMENT.

DO NOT OBSTRUCT ELECTRICAL PANELS OR PUSH BUTTONS.

GOOD HOUSEKEEPING IS THE MOST IMPORTANT SAFETY PROCEDURE.

REV.01/99

1

2

INSTALLATION INSTRUCTIONS

INDEX

SP-60S PULPER, D5 DISPOSER &

W/HE-9 HYDRA-EXTRACTOR

WASTE HANDLING SYSTEMS

GENERAL DESCRIPTION

UNPACKING

PULPER INSTALLATION

HYDRA-EXTRACTOR INSTALLATION

PIPING INSTALLATION

ELECTRICAL INSTALLATION

GENERAL DESCRIPTION

The SOMAT® System prepares solid waste materials for disposal by transforming the materials, mixed

with water, into a pulp. This transformation takes place in a unit called a pulper which is designed to reduce

all forms of paper, plastic, foil, and food waste to small sizes. The waste material is manually fed to the

pulper. The continual flow of water and the rotation of the cutting mechanism create a strong vortex action

which pulls the waste against the cutting blades of the impeller. A portion of the resultant slurry passes

through a perforated stainless steel ring surrounding the pumping impeller. This ring allows sufficiently

small particles to pass through the sizing holes. These particles are carried in the slurry to the extractor

where the water is separated and returned to the pulper. Refer to the pulper section for detail views of the

cutting mechanism.

Items such as tin cans, silverware, nails, bolts and other non-pulpable objects which may be inadvertently

fed into the pulper are separated out by centrifugal force and gravity. These items settle to the bottom of the

tank. These items should be emptied manually while wearing gloves during cleanup.

3

The SOMAT® System is designed to pump the mixture of macerated solids and water, called slurry, to

the extractor where the slurry is reduced to a semi-dry pulp. Within the extractor, the slurry is carried

upward by a helical screw within a perforated tubular screen. The water passes through the screen and

is pumped back to the pulping unit. The solids continue up the screw to a compression chamber, where

additional water is removed. The solids in this area are called the plug. This plug is broken up at the

discharge opening by a cutter. The pulp then falls out of the discharge chute in to a waste container. This

system is capable of reducing the volume of average non-compacted waste by approximately 80 percent.

During the process some water is absorbed by the pulp. Fresh make-up water is supplied to the pulper

automatically through a solenoid valve which responds to a PLC.

The system is powered by electric motors with the associated controls housed in the Som-A-Trol

enclosure (electric control panel).

In addition to the basic system as discussed to this point, numerous additional items of equipment may

or may not be required to comprise a specific system.

4

GENERAL DESCRIPTION

The SOMAT® system prepares solid waste materials for disposal by transforming the materials, with

water, into a pulp. This transformation takes place in a unit called a disposer which is designed to pulp

all forms of food waste. The waste material is fed manually or automatically to the disposer. The

continual down flow of water and the rotation of the disposer impeller create a strong vortex action

which pulls the waste down against the cutting blades of the impeller. The resultant slurry is then fed to

a slurry pump which continues the slurry mixture to the extractor.

TYPICAL DISPOSER

5

The SOMAT® System

is designed to pump the

mixture of macerated

solids and water, called

slurry, to the Hydra-

Extractor where the

slurry is reduced to a

semi-dry pulp. Within

the Hydra-Extractor, the

slurry is carried by a

Helicoid screw within a

perforated tubular

screen. The water

passes through the

screen and is pumped

back to the pulping unit.

The solids continue up

the Helicoid screw to a

compression chamber or

plug area where

additional water is

removed by extrusion.

The solids in this area

are called the plug. This

plug is broken up at the

Hydra-Extractor

discharge opening by a

cutter and the pulp then

falls out of the discharge

chute. This system is

capable of reducing the

volume of average non-

compacted waste by

approximately

80 percent.

TYPICAL HYDRA-EXTRACTOR

The system is powered by electric motors with the associated controls housed in Som-A-Trols (electric

control panels). Since, in the course of operation, some water is absorbed by the pulp, fresh make-up

water is supplied to the Pulper automatically through a solenoid valve which responds to a PLC.

In addition to the basic system as discussed to this point, numerous additional items of equipment may

or may not be required to comprise a specific system. You are provided with Installation Drawings

contained within your Installation Package. These drawings show the equipment comprising your

system.

6

7

UNPACKING

The crate containing your SOMAT equipment will contain the following items:

Pulper W/Slurry Pump Hydra-Extractor w/return pump

Tray, if so equipped Discharge chute w/hardware

Pulper Som-A-Trol Panel Hydra-Extractor Som-A-Trol panel

Pulper return line piping assembly Hydra-Extractor return pump piping assembly

Pulper slurry pump piping assembly

Misc. parts box containing:

ALL UNITS:

Mounting Pads

Installation Drawings

UDT UNITS ONLY:

Stainless Steel Lid

Stainless Steel Cone Adaptor

Rubber Gasket

TRAY ONLY:

Gasket & Hardware

TROUGH ONLY:

Gasket & Hardware

Trough Nozzles & Throttling Valves

(See Installation Drawing for quantity)

OPTIONAL EQUIPMENT:

Remote Push Button Station

Trough Magnet & Hardware

Feed hood

Stainless steel angular stand w/hardware

Weather seals

Through-wall extractor chute

The crate containing your SOMAT equipment will contain the following items:

8

Disposer W/Slurry Pump Hydra-Extractor

Disposer Som-A-Trol Panel Tubular aluminum stand w/return pump

Disposer return line piping assembly Discharge chute w/hardware

Disposer slurry pump piping assembly Hydra-Extractor Som-A-Trol panel

Hydra-Extractor return pump piping assembly

Misc. parts box containing:

ALL UNITS:

Anti-Vibration Pads

Installation Drawings

18” Disposer bowl

Connector Sleeve

Stainless Steel Clamps

OPTIONAL EQUIPMENT:

Remote Push Button Station

PULPER INSTALLATION

NOTE: BE SURE TO MATCH SERIAL NUMBERS AS LISTED ON

PRINTS TO PROPER LOCATION.

HIGH TANK MODELS:

1) Put the Pulper into position as shown on the Installation Drawings.

2) Place the Mounting Pads under each leg of the Pulper.

3) TROUGH FEED UNITS ONLY - Install the provided gasket between the Pulper's inlet and the

trough outlet and secure with the provided hardware.

4) TRAY FEED UNITS ONLY

- Install the tray to the Pulper (if it was not already installed at the

factory) using the provided gasket material and hardware.

UDT MODELS:

1) Cut a hole in the top of the table as shown in the Installation Drawing using the following

diameter: SP-60S Pulper – 18.5" Diameter hole

2) Center the provided UDT Cone beneath the opening and weld it into place as shown per

drawings.

3) Put the Pulper into position.

4) Place the mounting pads under each leg of the Pulper.

5) Install the rubber gasket onto the Pulper tank and around the outside of the adaptor cone as

shown per drawings.

6) Adjust the Pulper legs so that the rubber gasket provides a water tight seal.

7) Install the provided gasket between the Pulper's inlet and the trough outlet and secure with the

provided hardware.

9

DISPOSER INSTALLATION

NOTE: BE SURE TO MATCH SERIAL NUMBERS AS LISTED ON PRINTS TO PROPER

LOCATION.

DISPOSER MODELS:

1) Put the Disposer into position as shown on the Installation Drawings.

2) Place the Anti-Vibration Pads under each leg of the pump stand.

HYDRA-EXTRACTOR INSTALLATION

1) If so equipped, attach stainless steel angular stand to assembled Hydra-Extractor using provided

9/16" bolts.

2) Move the assembled Hydra-Extractor into position as shown on the Installation drawings.

3) Install vibration pads under foot pads.

4) Install discharge chute and optional weather seal.

5) Secure Hydra-Extractor to finished floor.

MOUNTING OF THE GRABBER MAGNETS:

10

Preferred: Locate per detail below and weld into place.

Optional: Drill four 7/32” diameter holes into the trough as shown below. Seal the heads of

the provided screws with silicone and attach the magnet.

RECOMMENDED POSITION OF THE GRABBER MAGNETS

EXAMPLE PULPER FLANGE DETAIL

PIPING INSTALLATION

11

12

*NOTE: In Massachusetts, the Public Water Supplier shall be contaced regarding the proper

backflow prevention device to be installed. *

1) ALL INTERCONNECTING PIPING, FRESH WATER LINES AND DRAIN LINES NOT

SUPPLIED BY SOMAT.

2) PIPE SIZES TO BE IN ACCORDANCE WITH SOMAT RECOMMENDATIONS.

3) SLURRY AND RETURN WATER PIPING TO BE TYPE L COPPER. SCHEDULE 40

GALVANIZED OR EQUAL (PVC PIPING NOT ACCEPTABLE).

4) SLURRY LINES MUST NOT INCLUDE ANY VALVING EXCEPT THOSE AUTHORIZED BY

SOMAT.

5) ALL FITTINGS MUST BE PRESSURE RATED DRAINAGE TYPE (SEE BELOW) AND KEPT

TO A MINIMUM. MAXIMUM TURNS ALLOWED 10 PER 100 FEET. RECOMMEND USE

OF TWO 45°ELBOWS. USE ELBOWS ONLY TO CHANGE DIRECTION. DO NOT OFFSET

AROUND BEAMS, COLUMNS, OR OTHER OBSTRUCTIONS.

6) USE 45 DEGREE Y-BRANCHES OR 90 DEGREE LONG TURN T-Y WHERE TWO LINES

INTERCONNECT. CONNECTIONS SHOULD NOT BE MADE FROM THE BOTTOM.

7) INSTALL ALL VALVES AND CHECK VALVES HORIZONTALLY.

8) CLEANOUTS REQUIRED IN SLURRY LINES ONLY AND MUST BE INSTALLED AT EVERY

90 DEGREE BEND AND EVERY 60 FEET MAXIMUM IN STRAIGHT PIPE RUNS. USE 45

DEGREE Y-BRANCH AND 90 DEGREE LONG TURN T-Y FOR CLEANOUTS. (ALL

CLEANOUTS MUST BE ACCESSIBLE).

9) SOMAT DISPOSERS REQUIRE FLEXIBLE CONNECTORS IN SLURRY AND RETURN

LINES ONLY.

10) COMPANION FLANGE, GASKETS, AND HARDWARE NOT SUPPLIED AT PIPE LINE

TERMINATIONS.

11) KEEP DRAINS ACCESSIBLE TO UNIT. DO NOT INSTALL DRAINS UNDER SOMAT

EQUIPMENT.

12) PIPING MUST BE SUPPORTED AND BRACED INDEPENDENTLY OF SOMAT

EQUIPMENT. ALL INTERCONNECTING PIPING MUST BE SUPPORTED SO THAT NO

MOVEMENT OCCURS DURING OPERATION. USE UNIONS OR FLANGES FOR FINAL

CONNECTIONS.

13) NO EXTERNAL STRAIN TO BE EXERTED ON SOMAT EQUIPMENT.

14) PROTECT ALL SOMAT EQUIPMENT AND PIPING FROM FREEZING AND

CONDENSATION.

15) ALL PIPING TO BE IN ACCORDANCE WITH STATE AND LOCAL PLUMBING

CODES.

16) "F" = FURNISHED BY SOMAT/"NF" = NOT FURNISHED BY SOMAT.

The following are some suggested forms of pipe bracing for a SOMAT waste handling system. There

are many factors involved which require the additional bracing. This system in normal

operation is

subject to surges from air, water and solids. If the piping is not properly supported and “works” during

operation it will only be a matter of time before a failure occurs.

If you have any questions or concerns please call Somat Company and speak with the service or

engineering departments to get clarification.

1. Support horizontal piping and fittings at sufficiently close intervals to maintain alignment

and prevent sagging or grade reversal. Support each length of pipe by an approved

hanger located not more than 18 inches from the joint.

2. Support terminal ends of all horizontal runs or branches and each change of direction or

alignment with an approved hanger to prevent movement. (see below for examples)

See figure # 1 and # 2 below for fastening to prevent movement when using hanger type supports. These

should be installed within 18” inches of each change of direction and every 10’ feet of straight run.

Figure 1 - Horizontal Pipe with Sway Brace (Longitudinal)

Figure 2 - Sway Brace (Traverse)

1

Reprinted with permission of the Plumbing & Piping Industry Council, Inc.

See figure #3 and #4 for examples of horizontal suspension.

13

Figure 3 - Horizontal Pipe Supports

Figure 4 - Horizontal Pipe Supports (continued)

FRESH WATER:

14

*NOTE: In Massachusetts, the Public Water Supplier shall be contaced regarding the proper

backflow prevention device to be installed. *

1) Bring a 1/2" cold water line for the SP-60S, to the pre-piped fresh water assembly. (See

enclosed diagram and Installation Drawings)

2) Bring a 1/2" cold water line for the D5 disposer to the pre-piped fresh water assembly. (See

enclosed diagram and Installation Drawings)

3) Bring a 1/2" hot water line for the Hydra-Extractor to the pre-piped fresh water assembly.

(See enclosed Diagram and Installation drawings)

SLURRY AND RETURN PIPING:

1) Install the Pulper slurry pump piping assembly on to the slurry pump. (See Installation

drawing.)

2) Install the Pulper return line piping assembly on to the Pulper tank. (See Installation drawing.)

15

RETURN PIPING FOR UNITS WITH A TROUGH:

1) Pipe the trough spreader plate and optional side nozzles and silver saver to the tee in the return

line piping assembly as shown in the trough detail on the Installation drawing using the provided

throttling valves and trough nozzles.

NOTE: All Pre-Piped Assemblies are hand tightened for shipping purposes only.

SILVER SAVER (TROUGH UNITS ONLY, IF EQUIPPED):

1) Connect hose (provided by Somat) with hose clamp to ½” x 1” lg. pipe nipple on silver saver.

16

ELECTRICAL INSTALLATION

NOTE: BE SURE TO MATCH SERIAL NUMBERS AS LISTED ON PRINTS TO PROPER

LOCATION.

1) PRE-WIRED CONTROL PANELS, OPERATOR DEVICES & ELECTRIC VALVES BY

SOMAT.

2) INSTALL A PIECE OF CONDUIT FROM PANEL TO PREWIRED JUNCTION BOX, PULL

MOTOR WIRES AND CONTROL WIRES THRU THIS CONDUIT AND DO THE FINAL

HOOKUPS.

2) GROUND ALL ELECTRICAL EQUIPMENT.

3) CONTROL CIRCUIT TO BE 115 VAC AND/OR 24VDC NOMINAL.

4) ALL SOM-A-TROL PANELS ARE TO BE WIRED IN ACCORDANCE TO LOCAL, STATE

AND/OR NATIONAL ELECTRIC CODE (NEC 1993) SPECIFICATIONS.

5) REMOTE PUSH BUTTON STATION TO BE MOUNTED & WIRED AT WORK STATION BY

CUSTOMER. (BRACKET REQUIRED BY CUSTOMER) OPTIONAL INTEGRAL PUSH

BUTTONS ARE LOCATED IN PANEL DOOR AND PRE-WIRED AT FACTORY.

6) THE PUSH BUTTON STATION HOUSES TWO (2) ILLUMINATED PUSH BUTTONS,

INDICATED WITH THE LETTERS "A" AND "B".

PANEL & OPTIONAL REMOTE PBS MOUNTING:

1) Mount both the Pulper and Hydra-Extractor Som-A-Trol in a suitable location (see Diagram and

Installation drawings) so that the bottom of the panel is at least 48" above the finished floor.

2) Install the Optional Remote Push Button Station onto the Dish Table or at another convenient

location. (See Diagram and Installation Drawings.)

MOUNTING PATTERN FOR SOM-A-TROL PANELS AND THREE PUSH BUTTON

STATION

17

SUPPLYING THE SOM-A-TROL WITH POWER

Bring the (4 wire) customer power supply to the top right side of the Som-A-Trol and connect to

the panel disconnect and ground lug. (See Diagram and Installation Drawings.)

All remote systems are prewired, there is a prewired junction box mounted to the side of the

extractor shell. Inside this prewired junction box there will be terminals that are the same as in

the panel. Install conduits from the panel to the pre-wire junction box, pull the motor wires and

control wires thru these conduits separately and do your final wire terminations matching

numbers from panel to pre-wire junction box.

PUSH BUTTON STATION

Mount the push button station, run the conduit from push button station to prewired junction

box, then pull the wires from push button station to prewired junction box and do your final

hookups in the prewired junction box.

INTERCONNECTING WIRES

On the remote system there are interconnecting wires that go from the extractor panel to the

pulper panel. To install run a piece of conduit between the extractor panel and pulper panel.

Pull control wires thru from extractor panel to pulper panel and install the wires to the terminals

which have the same numbers in both panels.

WARNING:

Improper connection of the equipment grounding conductor can result in a risk of electrical

shock. An equipment grounding conductor must be run with the circuit conductors and

connected to the pulper/extractor grounding terminal.

TYPICAL FOR REFERENCE ONLY

18

TYPICAL FOR REFERENCE ONLY

19

Page is loading ...

Somat D5 Installation guide

This manual is also suitable for

Somat D5 Installation guide

Related papers

Other documents