Somat SPC-60F/S Service Training Manual

Brand: Somat

Model: SPC-60F/S

Type: Service Training Manual

This manual is also suitable for

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).

Somat SPC-60F/S Service Training Manual

Brand: Somat

Model: SPC-60F/S

Type: Service Training Manual

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Somat SPC-60F/S Service Training Manual

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