FRONT RAKED MECHANICAL SCREEN

OPERATION AND MAINTENANCE MANUAL

DOMINANT WATER TECHNOLOGIES

FRONT RAKED
MECHANICAL SCREEN
Model:SZS-100-800

OPERATION AND MAINTENANCE

MANUAL
 FRONT RAKED MECHANICAL SCREEN
OPERATION AND MAINTENANCE MANUAL

FRONT RAKED MECHANICAL SCREEN

CONTENT

1. NOTICE TO THE CUSTOMER

2. TRANSPORT, RECEPTION, HANDLING AND STORAGE

3. DESCRIPTION OF THE FRONT RAKED MECHANICAL SCREEN

4. SAFETY INSTRUCTIONS

5. INSTALLATION

6. STARTING UP

7. MAINTENANCE AND CONTROL

8. LUBRICATION

9. TROUBLE SHOOTING
 FRONT RAKED MECHANICAL SCREEN
OPERATION AND MAINTENANCE MANUAL

1. NOTICE TO THE CUSTOMER

This “operation and maintenance” manual prepared by us with care, in order to help you
to start up and run the unit with minimum time spend and maximum efficiency.

In this manual sufficient description of the screen, its operation and trouble shooting
instructions are given.

Before starting to installation and commissioning of the equipment, this manual and
attached technical information must be read carefully.

If you are faced with a problem that is not described here, please contact us.

A- Full name of your plant, location, type of equipment and its serial number, your fax
and phone numbers, name of contact person.

B- The exact description of the trouble.

From the praxis we know that most of the troubles can be solved by phone. But if not,
please be sure that, upon being ordered by you, our technicians will be at your service
immediately.
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OPERATION AND MAINTENANCE MANUAL

2. TRANSPORT, RECEPTION, HANDLING AND STORAGE

2.1. TRANSPORT AND PACKING

Dimensions

The dimensions of the equipment parts are shown at the attached drawings.

The equipment must be handled respecting the following guidelines.

Loading / unloading

 The load must be immobilized to avoid any movement during transportation.

 Take all necessary precautions to avoid damage due to imprudent or too rapid
handling.

 Loading /unloading can be done by forklift or crane mechanism, depending on the

size or packing form of the equipment. Use lifting straps to provide the correct
hoisting position. Mount lifting straps to lifting lugs and equilibrate the load. In the
case of using forklift, wooden pallets will be helpful for the operation.

Declaration of damage during transport

If any part of the equipment is found missing or damaged, freight company must be
immediately informed verbally. In addition a written report should be submitted. Photos
of damage are also required.

This declaration must be made within 48 hours of delivery to:

Ø The freight company

KK55/01/27.02.2014/S4/22
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2.2. STORAGE

Any damage caused to the machine by storage that does not comply with the following
recommendations is not covered by the guarantee.

Duration Of Storage Part Of The Equipment Measures To Be Taken

All storage  All parts of the equipment  Store the unit in a dry place, inside a
building.

 The equipment must never be directly

exposed to the weather.

 The storage location should be free

from vibrations, dust, and aggressive
and/or chemical substances.

 Transport to place of installation in sturdy

packing

 Do not attach ropes or hooks to the

package where the lifting point is not
indicated.

 Store in well-ventilated, dry room

 Protect against floor dampness by

storage on a shelf or an a wooden
palette

 Cover to protect against dust and dirt

 Apply suitable corrosion protection

 Material that need ultraviolet agent to bright surfaces
and infrared protection
(rubber, plastic, drive unit  The equipment must not be directly
etc.) exposed to sunlight

 Drive unit  Minimum ambient temperature should

be -5 °C.

6 mounts  Protect bright surfaces especially of

output drive parts and mounting
surface, with long term corrosion
protection agent.

 Check for corrosion approximately

every 6 months. If first signs of
corrosion show apply new corrosion
protection.

KK55/01/27.02.2014/S5/22
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6 months to 2 years  All parts of the equipment  Take measures mentioned above to
protect the equipment.

 Gearbox of the drive  Special care must be taken against

system corrosion.

See attached drive unit documents

 Motor  Check for possible damages on the

cable and also check the tightness of
the cable glands.

See attached drive unit documents

Note: See referred documents for the drive unit (motor &gearbox) transportation and
storage conditions
Tasks to be performed before start of service after a period in storage:

Task Part Of The Equipment

Check and exchange the oil Gearbox (see attached drive unit documents)
(If necessary)
Lubrication All bearings (if applicable)
Replace parts Replace the bearing seals if they appear to have
hardened (if applicable)
Corrosion protection lubrication Grease the shaft ends with protection grease of 6
months
Detailed cleaning All parts that can be reached

Important: Warranty starts with the date of delivery! Remember that your guarantee
rights expire after the contractual guarantee period!
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OPERATION AND MAINTENANCE MANUAL

3. DESCRIPTION OF FRONT RAKED MECHANICAL SCREEN

3.1. PRESENTATION

Front raked mechanical screens are widely used at water and wastewater treatment
plant, power stations, paper factories, leather and food industries, chemicals processing
industries for the screening of waste and clean water.

Front raked mechanical screens are of self-cleaning type of screens. They are mostly
used for screening over 6 mm screen openings. They can be easily assembled to most
of the channels.

3.2. COMPONENTS OF THE SCREEN

Main parts of the front raked mechanical screen are as follows:

3.2.1. Frame
3.2.2. Drive unit
3.2.3. Chains
3.2.4. Screen
3.2.5. Rakes
3.2.6. Counter wiper

3.2.1. Frame
Robust steel construction, which the whole system is constructed on.

3.2.2. Drive Unit

Rakes are driven by the drive unit that assembled on the frame. It consists of motor,
gearbox and torque limiter.

3.2.3. Chains
The motion is conveyed from the drive unit to the rakes by means of chains.

3.2.4. Screen
Screening bars are welded to support and fixing plates. Whole screen body is mounted
to the frame and the bottom of the channel. Screens are rectangular in shape and they
are manufactured as stainless steel or galvanized carbon steel.

3.2.5. Rakes
The rotation motion of the drive unit is conveyed to the rake by means of the chain.
Rakes are mounted on the front rake screen with constant spaces.

3.2.6. Counter wiper

Counter wiper is a construction, which the screenings captured by the rake are scraped
and directed towards the trough in which screenings are transported.
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OPERATION AND MAINTENANCE MANUAL

4. SAFETY INSTRUCTIONS

4.1. SAFETY RECOMMENDATIONS

 In order to use the machine without risk of injury and to avoid unnecessary
breakdowns, the basic safety instructions and recommendations must be
understood.
 The safety instructions and recommendations must be respected by all persons who
work on the machine.
 In addition, the general safety and accident prevention rules must also be respected.
 Installation and maintenance of the equipment should be carried out by qualified
personnel in accordance with recommended and designed regulations and
guidelines.

4.2. OBLIGATIONS OF THE OWNER OF THE EQUIPMENT

The owner of the machine must make sure that all persons who operate the machine;

 are fully aware of the basic safety and accident prevention instructions and that they
have been trained to use the machine,
 have read the “Safety Instructions” section and the warnings given in this manual
and signed the manual to confirm that they red it carefully.
in addition, they must also check at regular intervals that the safety rules are being
properly respected.

4.3. OBLIGATIONS OF THE PERSONNEL

Before working on the machine, all persons must commit themselves to;
 respecting the basic safety and accident prevention instructions.
 read the “safety” section and the warnings given in this manual and sign the manual
to confirm that they have done so.
 Observing :
- the corresponding detailed operating instructions and wiring diagrams,
- the warning and safety signs on the equipment,
- the specific regulations for the system,
national / regional regulations covering safety and the prevention of accidents.
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OPERATION AND MAINTENANCE MANUAL

4.4. RISKS DURING WORK ON THE EQUIPMENT

The equipment is designed to respect normal safety rules. Nevertheless, the machine
presents a risk of death or injury for the operator. In addition, improper operation can
lead to damage of the equipment or connected systems. The equipment must be used:

 only for the purpose for which it was designed,

 only when its operational safety is assured.

Any breakdown that might affect the machine’s safety must be repaired immediately.

Injuries and damages of machine may result from:

 neglects
 wrong installation or operation
 removal of the required protective covers or housing when this is not permitted

4.5. UTILISATION FOR THE INTENDED PURPOSE

The equipment is designed only for the purpose indicated in the contract. It must not be
used for any other application. SİSMAT declines all responsibility for damage resulting
from inappropriate use of the machine.

Correct utilisation of the machine also implies:

 respect of all the recommendations in this manual,
 regular execution of inspection and maintenance tasks.

The choice of materials used in the construction of the machine was guided by our
knowledge and experience and information provided by the customer.
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4.6. SAFETY INSTRUCTIONS

Warning 1: Do not work on the equipment without safety guards and covers.

Warning 2: Do not extract and affect safety guards and covers before shut
off machine.

Warning 3: Rotating parts of machinery can lead to injury. There is danger of

being trapped or pulled in. Keep a sufficient distance to rotating parts of
machinery.

Warning 4: Before any affect, be sure that the equipment is off (switch off the
circuit breaker)

Warning 5: The maintenance should be done by min. two persons in risk of

squeezing.

Warning 6: Only authorized person shall do the maintenance of the electric

system.

Warning 7: The control panels should be locked, and the key must be kept
with authorized maintenance personnel.

Warning 8: Shut off power before any electrical repair.

Warning 9: Do not start working of equipment without earthing precaution.

Warning 10: Touching hot surfaces can lead to burns.

Warning 11: Do not touch the gear reducers if their operating temperatures
are too high, or use suitable safety equipment.

Warning 12: Direct contact with the wastewater or screenings may cause
serious diseases for people. Use suitable personal protective devices to
protect from direct contact.
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OPERATION AND MAINTENANCE MANUAL

Warning 13: During maintenance, authorized personnel should use protective

devices such as gloves and masks.

Warning 14: Use emergency stop buttons in any risk.

Warning 15: Before starts working of equipment check that there are no
foreign materials or tools left near the equipment.

Warning 16: During maintenance work an unintentional start of the equipment

can lead serious accidents. Make sure no one can start the equipment while
you are working on it.

Warning 17: The gearbox oil has a fire risk.

Warning 18: Prevent the flow of the lubricants into drains, sewers, and water
resources.

Warning 19: All the time use personal protective devices (gloves, glasses,
mask, etc.)

Warning 20: During maintenance, the personnel should be secured. If the

channel is empty maintenance should be done with safety belts.

4.7. GUARANTEE AND RESPONSIBILITY

The manufacturer’s “General conditions of sale” are applicable. These are made
available to the customer before the signing of the contract.

Any claim under the terms of the guarantee concerning the responsibility for human
injury or material damage will not be accepted if such injury or damage is due to one or
more of the following:

 use of the equipment for a purpose other than that for which it was designed,
 incorrect installation, commissioning, operation or maintenance of the machine,
 operation of the machine when individual protection equipment is defective, or when
any safety or protection equipment is not correctly installed or operated,
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OPERATION AND MAINTENANCE MANUAL

 non-respect of the safety recommendations made in this manual concerning

transport, storage, installation, commissioning, operation, maintenance or
adjustment of the machine
 modification of the machine without the prior written consent of the manufacturer.
 modification of the drive unit specifications (power, speed etc.) without the
knowledge and confirmation of the manufacturer,
 failure to monitor wearing parts of the machine.
 repairs not carried out with main maintenance rules,
 severe incidents due to foreign bodies entering any part of the machine,
 severe incidents occurred by force major.

4.8. ORGANISATIONAL MEASURES

 The necessary individual protection equipment shall be provided by the customer.

 All protection equipment must be inspected regularly.

4.9. SAFETY EQUIPMENT

 All safety equipment must be correctly installed and fully operational before the
machine is started.
 Safety equipment may be removed from the machine only after is has been stopped
and locked out to prevent accidental starting.
 After fitting individual parts, all safety equipment must be correctly re-installed before
the machine is started.

4.10. INFORMAL SAFETY MEASURES

 This manual must remain permanently available near the location of the machine.
 In addition to the recommendations given in this manual, all local accident
prevention and environmental protection rules must be respected.
 All posted information relating to the machine, hazards and safety must be perfectly
legible.

4.11. STAFF TRAINING

 Only qualified, fully trained persons must be allowed to operate the machine.
 Clearly define the responsibilities of the personal responsible for installation,
commissioning, operation and maintenance of the machine.
 Personnel being trained in the use of the machine must work under the supervision
of a fully trained operator.

4.12. OPERATION OF THE EQUIPMENT

 Never modify the software or the operation sequences imposed by the configuration
of the electrical cabinet.
 Only persons who have been adequately trained may change the controls.
 If the control cabinet was not supplied by SİSMAT, the process software must be
written following the SİSMAT logic drawing.
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OPERATION AND MAINTENANCE MANUAL

4.13. SAFETY MEASURES DURING NORMAL OPERATION

 The machine must not be started to work unless all safety equipment is fully
operational.
 Before operation, check that no person is beside the equipment to avoid any risk of
injury.

4.14. DANGERS OF ELECTRICAL ENERGY

 All work on electrical equipment must be carried out by qualified electrician.

 Check all the electrical equipment regularly, in particular the connections.
 Check the cable isolation at regular intervals against defects and hardening to
prevent electrical leakage.
 The control cabinet must be kept shut. It may be opened only by an authorised
person having the necessary key or tool.

4.15. PARTICULARLY HAZARDOUS SECTIONS OF THE EQUIPMENT

 Chain, gear and rake: Risk of crushing of hands between these parts.
 When working on the machine the motor power supply must be switched off and
locked out to prevent accidental starting.
 Remember that the risks are greater when safety equipment has been removed.

4.16. MAINTENANCE AND TROUBLE-SHOOTING

 Before carrying out any inspection, maintenance or repair works, make sure that all
energy sources are cut down:
- switch off and lock out the main electrical switch,
- attach safety labels at all cut-off points to prevent accidental starting,

 Carry out the adjustment, maintenance and inspection tasks at regular intervals.
 Inform the operators before starting any maintenance work.
 Never stand or work beneath suspended objects and moving parts.
 Systematically check the adjustment of any bolted parts that become loosening.
 After maintenance and/or repair, check the operation of safety systems.
 Any worn out part must be replaced immediately.
 Use only manufacturer’s original spare parts. The manufacturer cannot guarantee
sufficient strong and adequate safety level of equipment, if the spare parts are
supplied from other sources.
 Remember that the risks are greater when safety equipment has been removed.

4.17. MODIFICATIONS OF THE EQUIPMENT

 The equipment must not be modified without the written knowledge and confirmation
of the manufacturer.
 Before performing necessary modification, contact with manufacturer.
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OPERATION AND MAINTENANCE MANUAL

4.18. LEANING THE MACHINE

 Do not apply stream jets directly at electrical switches, motors, bearings or control
cabinets.
 Remove all traces of products and substances used, notably:
- after work on lubrication systems and equipment
- after cleaning operations by use of detergents
- after maintenance work

This manual is intended for use by the personnel in charge of

 installation,
 maintenance,
 surveillance and operation.

All industrial rights of this manual are reserved to SİSMAT. Its content must not be
wholly or partly reproduced, used in any unauthorised way for competitive purposes or
made available to third parties without our agreement. Non-respect of this confidentiality
clause may result in legal action.

5. INSTALLATION
Front raked mechanical screen necessary instructions for installation
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OPERATION AND MAINTENANCE MANUAL

6. START UP
6.1. CONTROLS BEFORE START UP

Following instructions must be obeyed for an operation without any problem:

 Check the cleanliness of the screen and channel. Remove foreign materials that
could damage the equipment during operation.
 Check the oil content of the reducer
 Check whether there is oil leakage on the gearbox
 Check all electrical connections are made.
 Check followings before connecting electric power to your control panel:
- check the voltage and amperage of the electrical supply
- check the diameters of the cables laid between control panel and power supply
- check whether earthing of the unit exists
 All bearing lubrications are to be done according to the lubrication instructions
 Check the bolts and nuts that all are tightened
 Check whether all switches are connected right and working correctly (an qualified
electric technician should check its operation manually)
 Check torque limiter on the drive system and if necessary, adjust it according to the
drive unit maximum torque.
 Check level sensor connected and works properly.

6.2. OPERATION
 Check that the rake travel direction is correct by supplying electrical power for a
short time. If the direction is wrong, change the motor rotating direction.
 Run the front raked screen manually at least 4-5 laps to observe its operation. If it is
O.K., test the unit at automatic operation.
 After all tests are completed properly, front raked screen can be operated.
 There is no need to run the equipment continuously. Such an operation will cause
high-energy cost and rapid wearing. So, run the unit according to the accumulation
in front of the screen.

KK55/01/27.02.2014/S15/22
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7. MAINTENANCE AND CONTROL

7.1. MAINTENANCE DESCRIPTION

7.1.1. Drive Unit

For the effective cooling of the drive unit, the motor must be free of dust and dirt.
Lubrication and maintenance has to be carried out acc. to drive unit instruction manual.

See attached lubrication list and maintenance schedule table.

Note: Synthetic gear lubricants of different types or any synthetic and mineral based
gear lubricants must not be mixed to each other.

7.1.2. Bearings
All bearings are delivered after filling with standard grease Greson LiT EP-2(*). They
have to be lubricated every month. Press grease to the bearings from the lubrication
nipple with grease gun. In periodic re-lubrication application, press small amount of
grease (30 g is enough). During entire renewing operation of the lubrication (after three
re-lubrication) the old grease need to be cleaned until you see fresh grease. Old or
excess quantities of grease are come out from oil seals.

(*) This is a product code of local vendor. Any trademark of EP addicted NLGI 2 grade
lithium soap base grease can meet the requirement.

Note: See attached lubrication list and maintenance schedule table.

Note: Use adhesive sealants during maintenance and repair works. Adhesive sealants
are designed for the locking and sealing of threaded fasteners which require normal
disassembly with standard hand tools. The product cures when confined in the absence
of air between close fitting metal surfaces and prevents loosening and leakage from
shock and vibration.

See “LOCTITE-243” documents at enclosures.

Caution! All bolts are to be tightened according to the “Table-1 bolt tightening torques”
(see enclosures).
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7.2. MAINTENANCE INSTRUCTIONS

 Check the rakes every day. Remove any foreign materials would damage the rake.
 Check the noise level of the machine daily. If noise level is higher than usual check,
find out and resolve the problem.
 Observe whether there is any leakage on the unit daily
 Check the accurate operation of the equipment periodically
 Check the screen, rake and counter wiper daily to observe whether they are covered
with sticky wastes. Clean it, if necessary.
 Check all screws and nuts after 150 working hours and tighten them if necessary
 Check all cabling for their conditions and possible damage every month
 Wash and clean discharge chute monthly
 Check the motor and gearbox according to the drive unit operation and maintenance
manual
 Check the counter wiper PE plate in terms of wearing every 6 months.
 Check the oil content of the gearbox by means of the level indicator plug at least
every 6 months
 Check bearings for sign of wear every month
 Lubricate bearings every month with EP addicted NLGI 2 grade lithium- soap base
grease
 Check all shaft ends without any protection for corrosion, lubricate with grease every
6 months
 Automatic greaser for external environment conditions are used in products that
need to change 1 time per year. (If equipped)
 Check the paint of all points annually (if painted)
 Replace worn out parts with new ones annually
 Check control panel, terminal box, switch etc. (if equipped)
 Protect bright surfaces especially of output drive parts and mounting surface, with
long-term corrosion protection agent.
 Check for corrosion approximately every 6 months. If first signs of corrosion show,
apply new corrosion protection.

Caution! During the lubrication or renewing of the grease, insure that, oil and/or grease
will not drop into the water and cause the water pollution.
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7.3. MAINTENANCE SCHEDULE

at least every 10
at least every 2
operating hour

operating hour
every 10000
semi-annual
at 3 months
every 150

monthly
weekly

annual

years

years
daily
Maintenance Check
1 Motor &Reducer
1.1 Visual inspection x
1.2 Check for running noises x
1.3 General overhaul (see NORD manual x
for details)
1.4 Motor heating and insulation (see x
drive unit manuals for details)
2 Bearings (sign of wear) x
3 Paint x
4 Normal operating function x
5 All cabling in terms of their conditions x
and possible damages
6 Terminal boxes & switches (if x
applicable)
7 General cleaning & replacement of x
worn out parts
8 Check for unusual noises and leakage x
9 Check rakes and counter wiper x
10 Clean discharge chute x
11 Check for loosening fasteners x
12 Check PE plate of the counter wiper x
(sign of wear)
Lubrication
1 Motor &Reducer
1.1 Check oil level x
1.2 Change oil (see drive unit manual for x xx
details)
2 Bearings (general)
2.1 Re-lubrication x
2.2 Renewing of Lubricant x

(*) Oil must be changed after 10.000 hours in operation. Even if operation hour is not
reached to 10.000 hours, it should be changed at least after 2 years.

Note: See referred operation and maintenance documents for details.

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OPERATION AND MAINTENANCE MANUAL

8. LUBRICATION
Equipment / Part Name Type Of Total Qty. To Be Periodical Renewing of
Lubricant Qty. Filled Lubrication Lubricant
(lt)
Drive unit ISO 0,50 as decreased semi-annual after the first 500
SK 12063AZ-80S/4 VG680* operating hour or
at least every 2
years
Bearings (General) Greson - up to 30 g monthly after three re-
LiT EP-2** lubrication

(*) See drive unit operation and maintenance manual for details

(**) This is a product code of local vendor. Any trademark of EP addicted NLGI 2 grade
lithium soap base grease can meet the requirement.

Caution! During the lubrication or renewing of the grease, insure that, oil and/or grease
will not drop into the water and cause the water pollution.
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9. TROUBLE SHOOTING
Problems Possible Cause Tasks
Front raked  Electrical defects  Check the cable connections
screen is out of  Check the fuses, relays and
operation contacts

 Clean foreign material between

 Blocked rake screen and rake

 Repair or change them

 Damaged motor
&gearbox
 Adjust the relays for more
 High waste load frequent operation cycles

 Find out and remove the

 Torque limiter switch the overload problem
circuit off
Broken rakes  Coarse materials in the  Plant must be furnished with
and/or rake tines water another coarse screen which
can hold such coarse particles

Sounds from  Damaged bearings  Change them

drive unit
 A little or no oil  Fill or if necessary change the
oil

 Oil leakage  Change the sealing

Oil leakage on  Worn out sealing  Change the sealing
gearbox
Hot drive unit  A little or no oil  Fill or if necessary change the
oil
High Amperage  Foreign materials on the  Clean the rake and/or the
on motor rake and/or the screen screen

 Loosen electrical  Check and tighten the

connections electrical connections