1. Manuals
  2. Brands
  3. SMOKI Manuals
  4. Cleaning Equipment
  5. JUNIOR
  6. Instruction manual

SMOKI JUNIOR Instruction Manual

Soot abatement system
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
SOOT ABATEMENT SYSTEM
JUNIOR
INSTRUCTION MANUAL
(TRANSLATION OF THE ORIGINAL INSTRUCTIONS)
Smoki srl:
Via Cella Raibano, 16C – 47843 MISANO
ADRIATICO (RN) ITALY
Tel 0541.833748
www.smoki.it – info@smoki.it – commerciale@smoki.it

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the JUNIOR and is the answer not in the manual?

Questions and answers

Related Manuals for SMOKI JUNIOR

Summary of Contents for SMOKI JUNIOR

  • Page 1 SOOT ABATEMENT SYSTEM JUNIOR INSTRUCTION MANUAL (TRANSLATION OF THE ORIGINAL INSTRUCTIONS) Smoki srl: Via Cella Raibano, 16C – 47843 MISANO ADRIATICO (RN) ITALY Tel 0541.833748 www.smoki.it – info@smoki.it – commerciale@smoki.it...
  • Page 2 FOREWORD JUNIOR | SOOT ABATEMENT SYSTEM PAGE LEFT INTENTIONALLY BLANK Rev: 0 /134...

  • Page 3: Foreword

    JUNIOR SOOT ABATEMENT SYSTEM FOREWORD Rev: 0 /134...

  • Page 4: Use Of The Instructions

    FOREWORD JUNIOR | SOOT ABATEMENT SYSTEM Use of the instructions This instruction manual and all the attached documents are an integral part of the purchased machine, and provide useful instructions on how to operate it correctly. IMPORTANT USE OF THE INSTRUCTIONS...

  • Page 5: General Index

    JUNIOR SOOT ABATEMENT SYSTEM GENERAL INDEX Rev: 0 /134...

  • Page 6: Table Of Contents

    GENERAL INDEX JUNIOR | SOOT ABATEMENT SYSTEM FOREWORD ........................3 Use of the instructions ....................4 GENERAL INDEX ......................5 IDENTIFICATION ......................8 Purpose of the chapter ....................9 Identification of the instruction manual ................ 9 Manufacturer identification ..................9 Identification plate ....................
  • Page 7 JUNIOR SOOT ABATEMENT SYSTEM 6.7.3 Danger zones ....................48 6.7.4 Zones layout ....................49 6.7.5 Residual risks ....................50 TRANSPORT AND UNLOADING ................. 82 Purpose of the chapter ..................... 83 Transport information ....................83 Equipment required for unloading ................84 Unloading from the vehicle ..................

  • Page 8: Identification

    IDENTIFICATION JUNIOR | SOOT ABATEMENT SYSTEM IDENTIFICATION Rev: 0 /134...

  • Page 9: Purpose Of The Chapter

    READ CAREFULLY THE CHAPTER The chapter contains information on the identification of this publication, the manufacturer of the machine, the machine itself and its certification. Identification of the instruction manual Document: MUM_SMOKI JUNIOR ABBATTITORE DI FULIGGINE_0_it Edition: 01/2023 Revision:- Date:...

  • Page 10: Identification Plate

    IDENTIFICATION JUNIOR | SOOT ABATEMENT SYSTEM Identification plate The identification data of the machine can be found on the identification plate (1), the position of which is shown in the figure below. CAUTION STORAGE OF PLATE DATA The identification data must always accompany any request for information, for spare parts or other.

  • Page 11: Ec Declaration Of Conformity

    JUNIOR SOOT ABATEMENT SYSTEM EC Declaration of conformity Rev: 0 /134...
  • Page 12 IDENTIFICATION JUNIOR | SOOT ABATEMENT SYSTEM Rev: 0 /134...

  • Page 13: Information For The User

    JUNIOR SOOT ABATEMENT SYSTEM INFORMATION FOR THE USER Rev: 0 /134...

  • Page 14: Purpose Of The Instruction Manual

    IMPORTANT READ THE CONTENTS AND ENSURE YOU UNDERSTAND THEM In this manual, SMOKI s.r.l. provides the technical elements for correct use of its systems, indicating any possible risks. This manual examines the most general cases. For particular information and better understanding of the directives described here, we recommend that you contact our technical personnel.
  • Page 15 JUNIOR SOOT ABATEMENT SYSTEM IMPORTANT READ THE CONTENTS AND ENSURE YOU UNDERSTAND THEM This instruction manual is indispensable and necessary to train and inform the personnel assigned to operate the machine. Due to the specificity of the machine's use, the instructions have been written for professional operators, thus taking into account the level of general training and insight that can reasonably be expected from these operators.

  • Page 16: Receipt And Storage Of Instructions

    INFORMATION FOR THE USER JUNIOR | SOOT ABATEMENT SYSTEM 4.1.1 Receipt and storage of instructions The customer and/or employer is responsible for training and informing the personnel assigned to work on the machine and must pass on the information in the instruction manual to the end users.

  • Page 17: Consultation Instructions

    JUNIOR SOOT ABATEMENT SYSTEM Consultation instructions Warnings involving personal safety and proper use of machinery are represented in the following style: “TYPE” DESCRIPTION Consequence • Action to take. • ... The word 'TYPE' can take on the following meanings: HAZARD Indicates an imminently dangerous situation which, if not avoided, could result in death or serious injury.

  • Page 18: Glossary

    INFORMATION FOR THE USER JUNIOR | SOOT ABATEMENT SYSTEM Glossary 4.3.1 Glossary of safety terms In accordance with the EU Machinery Directive (Directive 2006/42/EC), the following definitions (Annex I, paragraph 1.1.1.) are given, which are used within the instruction manual.
  • Page 19 JUNIOR SOOT ABATEMENT SYSTEM In accordance with the current European Directives on the safety and health of workers in the workplace, the following definitions used within the instruction manual are provided. PERSONAL PROTECTIVE EQUIPMENT (PPE) Personal protective equipment (PPE) means any equipment intended to be worn and held by the worker for the purpose of protecting him against one or more risks likely to threaten safety or health at work, as well as any complement or accessory intended for that purpose.
  • Page 20 INFORMATION FOR THE USER JUNIOR | SOOT ABATEMENT SYSTEM INTERLOCKING GUARD A guard associated with an interlocking device, so that:  The hazardous functions of the machine 'affected' by the guard cannot be performed until the guard has been closed;...

  • Page 21: Illustrations

    JUNIOR SOOT ABATEMENT SYSTEM Illustrations The illustrations in the manual may show the structure or parts of the machine in different colours to the one in your possession. Differences in colour do not invalidate the correctness of the information provided, with the exception of colours strictly related to the safety of exposed persons and the machine.

  • Page 22: Warranty

    INFORMATION FOR THE USER JUNIOR | SOOT ABATEMENT SYSTEM Warranty The manufacturer guarantees its machine and equipment against defects and/or faults in material and/or workmanship up to a contractually agreed period, and in any case in accordance with the applicable legal warranty provisions. Any disputes shall be settled exclusively by the contractually agreed court of law.

  • Page 23: Component Replacement

    JUNIOR SOOT ABATEMENT SYSTEM HAZARD MODIFICATION OPERATIONS The manufacturer accepts no liability in the event of injury due to disassembly, tampering (modification) or exclusion of guards and/or safety devices, or in the event of injury due to operations carried out by personnel with less specific training than defined in the instruction manual.
  • Page 24 INFORMATION FOR THE USER JUNIOR | SOOT ABATEMENT SYSTEM PAGE LEFT INTENTIONALLY BLANK Rev: 0 /134...

  • Page 25: Description And Technical Data

    JUNIOR SOOT ABATEMENT SYSTEM DESCRIPTION AND TECHNICAL DATA Rev: 0 /134...

  • Page 26: General Description Of The System

    In this connection, the "JUNIOR" equipment is designed and made using carefully selected materials to ensure long life. The “JUNIOR" system uses water as a natural filter; any other use than as indicated in this manual is strictly prohibited. Soot abatement is achieved by having the exhaust smoke pass through a sheet of water generated by a spray unit inside the “JUNIOR"...

  • Page 27: Main External Components

    JUNIOR SOOT ABATEMENT SYSTEM 5.1.1 Main external components Rev: 0 /134...

  • Page 28: Name Of Part

    DESCRIPTION AND TECHNICAL DATA JUNIOR | SOOT ABATEMENT SYSTEM NAME OF PART: 1. MACHINE BODY SMOKESTACK CONNECTION (THE SMOKE INLET AND OUTLET CAN BE REVERSED, ACCORDING TO THE CUSTOMER'S CHOICE) 3. MAINTENANCE NOZZLE 4. MACHINE COVER 5. COVER FASTENING KNOBS 6.

  • Page 29: Main Internal Components

    JUNIOR SOOT ABATEMENT SYSTEM 5.1.2 Main internal components Rev: 0 /134...
  • Page 30 DESCRIPTION AND TECHNICAL DATA JUNIOR | SOOT ABATEMENT SYSTEM NAME OF PART: 1. SMOKE EXPULSION "OUT" CYLINDER 2. SMOKE INTAKE "IN" CYLINDER 3. SET OF SPRAY NOZZLES 4. INTERNAL "L" CONNECTION PIPE, BETWEEN PUMP AND SPRAY NOZZLES SET 5. COUPLING TO SOLENOID (RAPID FILLING) 6.

  • Page 31: General Characteristics

    JUNIOR SOOT ABATEMENT SYSTEM 5.1.3 General characteristics GENERAL CHARACTERISTICS POWER SUPPLY .........220V AC 50-60HZ WEIGHT ……………………………………………72Kg (empty) TOTAL INSTALLED POWER ....670w MACHINE DEPTH ......640mm WIDTH ........980 mm....HEIGHT ............705 mm. NOISE LEVEL ......25-30dB WATER TANK CAPACITY....70 litres WATER CONSUMPTION ......

  • Page 32: Dimensions

    DESCRIPTION AND TECHNICAL DATA JUNIOR | SOOT ABATEMENT SYSTEM 5.1.4 Dimensions The overall dimensions of the machine are shown below. NOTE: Measurements are in mm. Rev: 0 /134...
  • Page 33 JUNIOR SOOT ABATEMENT SYSTEM PAGE LEFT INTENTIONALLY BLANK Rev: 0 /134...

  • Page 34: Safety

    SAFETY JUNIOR | SOOT ABATEMENT SYSTEM SAFETY Rev: 0 /134...

  • Page 35: Purpose Of The Chapter

    JUNIOR SOOT ABATEMENT SYSTEM Purpose of the chapter IMPORTANT READ CAREFULLY THE CHAPTER The chapter contains safety information about the machine. Knowledge and understanding of the contents of the chapter is a prerequisite for reading all chapters of the manual, which is why it is mandatory that the personnel in charge of operating the machine are trained and instructed in all the information in this chapter.

  • Page 36: Reasonably Foreseeable Misuse

    SAFETY JUNIOR | SOOT ABATEMENT SYSTEM Reasonably foreseeable misuse Reasonably foreseeable misuse means the use of machinery in a way not intended in the instructions for use, but which may result from readily predictable human behaviour. HAZARD VARIOUS RISKS ARISING FROM IMPROPER USE OF THE MACHINE.
  • Page 37 JUNIOR SOOT ABATEMENT SYSTEM C) TRAINING AND INFORMING PEOPLE It is considered misuse:  Operate on the machine without having read and understood the instructions supplied by the manufacturer.  Carry out operations for which no information has been provided by the manufacturer.

  • Page 38: General Safety Rules

    SAFETY JUNIOR | SOOT ABATEMENT SYSTEM General safety rules Listed below are a series of general rules for the correct use of the machine to be integrated with specific information on the operations that must be undertaken for its use and maintenance.

  • Page 39: Safety Rules For The Operator

    JUNIOR SOOT ABATEMENT SYSTEM 6.4.3 Safety rules for the operator IMPORTANT OBLIGATIONS FOR THE OPERATOR The operator actively participates in maintaining a high level of machine safety over time. Please consider the following aspects regarding your own responsibility for use.

  • Page 40: Protective Measures Adopted

    SAFETY JUNIOR | SOOT ABATEMENT SYSTEM HAZARD VARIOUS RISKS ARISING FROM IMPROPER USE OF THE MACHINE. The work area must never be occupied, so that nothing can interfere with the operator's freedom of movement. • In the event of an emergency, immediate access to the machine by the assigned personnel must be guaranteed.

  • Page 41: Checks Of The Protective Measures

    JUNIOR SOOT ABATEMENT SYSTEM 6.5.2 Checks of the protective measures Ref. MEASURE CHECK PROCEDURE FREQUENCY  Check for loss or damage to any part of the guard, especially if this causes a decrease in the safety functions (e.g. reduction in impact resistance, scratches on glass, etc.)

  • Page 42: Information And Warnings On The Machine

    SAFETY JUNIOR | SOOT ABATEMENT SYSTEM Information and warnings on the machine In compliance with paragraph 1.7.1 of the European Directive 2006/42/EC, the information and warnings described below are supplied on the machine. IMPORTANT OBLIGATIONS FOR THE OPERATOR Failure to comply with any requirement, due to deterioration, loss or failure to consult a safety sticker, can cause serious accidents.

  • Page 43: Layout Of The Information And Warning Signs

    JUNIOR SOOT ABATEMENT SYSTEM 6.6.2 Layout of the information and warning signs Rev: 0 /134...

  • Page 44: Protective Measures To Be Taken By The User

    SAFETY JUNIOR | SOOT ABATEMENT SYSTEM Protective measures to be taken by the user 6.7.1 Type of personal protective equipment (PPE) Symbol Description Technical standard Whole body protection 1) UNI EN ISO13688 Protective clothing general requirements (1, 2, 3, 4, 5 6, 7)
  • Page 45 JUNIOR SOOT ABATEMENT SYSTEM Eye protection UNI EN 166 Personal protection Always wear if operations where there is a Specifications danger of projection of materials or exposure to splashes are necessary. Hearing protection 1) UNI EN 352-1 (1, 2) Ear-muffs...

  • Page 46: Use Of Ppe

    SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 2) UNI EN 354 Always wear safety belt and harnesses if work at height is required. Lanyards 3) UNI EN 355 The column to the side shows the reference Energy absorbers standards based on the required protection 4) UNI EN 360 requirements.
  • Page 47 JUNIOR SOOT ABATEMENT SYSTEM Phase Task Risk Measure (PPE) Person scenario 5. Maintenance Lubrication/greasing Lubrication - Hand protection operations (products/chemical performed on agents) the machine Respiratory protections - Eye protection Cleaning and inspections Using toxic - Hand protection and/or (products/chemical...

  • Page 48: Danger Zones

    SAFETY JUNIOR | SOOT ABATEMENT SYSTEM Warnings regarding residual risks In accordance with paragraph 1.7.2 of the European Directive 2006/42/EC, the residual risks that remain despite having adopted the protection measures integrated in the design and the protections, and the complementary protection measures, are described.

  • Page 49: Zones Layout

    JUNIOR SOOT ABATEMENT SYSTEM 6.7.4 Zones layout Rev: 0 /134...

  • Page 50: Residual Risks

    SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 6.7.5 Residual risks 1. Transport Task Packing/unpacking Exposed person Zone TYPE OF HAZARD Hazardous event Contact with tool parts that can cause cuts Type 9. Environment of use Source Activities and/or processes carried out near the machine...
  • Page 51 JUNIOR SOOT ABATEMENT SYSTEM 1. Transport Task Packing/unpacking Exposed person Zone TYPE OF HAZARD Hazardous event Environmental pollution Type 9. Environment of use Source Pollution Situation Disposal of packaging Consequence Any other consequences caused by sources of risk of the ma-...
  • Page 52 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 1. Transport Task Handling and transportation Exposed person Zone TYPE OF HAZARD Hazardous event Slipping, tripping and falling from parts of machines or areas not prepared for the person to climb Type 1. Mechanical...
  • Page 53 JUNIOR SOOT ABATEMENT SYSTEM 1. Transport Task Handling and transportation Exposed person Zone TYPE OF HAZARD Hazardous event Loss of load stability Type 1. Mechanical Source Instability Situation Cargo handling on the vehicle platform and on the ground Consequence Crushing of the body and head...
  • Page 54 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 1. Transport Task Handling and transportation Exposed person Zone TYPE OF HAZARD Hazardous event Contact with machine sharp elements and edges Type 1. Mechanical Source Sharp parts Situation Work near parts of the machine that have sharp edges or abra-...
  • Page 55 JUNIOR SOOT ABATEMENT SYSTEM 1. Transport Task Handling and transportation Exposed person Zone TYPE OF HAZARD Hazardous event Possible fall of the load during the handling phase also due to the breaking of straps or cables used for lifting Type 1.
  • Page 56 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 1. Transport Task Handling and transportation Exposed person Zone TYPE OF HAZARD Hazardous event Working with poor mental effort Overexertion Type 8. Ergonomics Source - Excessive / poor mental effort - Overexertion Situation Loading and unloading of materials...
  • Page 57 JUNIOR SOOT ABATEMENT SYSTEM 1. Transport Task Passing or standing near danger zones (transport phase) Exposed person Zone TYPE OF HAZARD Hazardous event Possible fall of the load during the handling phase also due to the breaking of straps or cables used for lifting Type 9.
  • Page 58 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 1. Transport Task Passing or standing near danger zones (transport phase) Exposed person Zone TYPE OF HAZARD Hazardous event Impact and collision caused by the presence of the moving vehi- cles Type 9. Environment of use...
  • Page 59 JUNIOR SOOT ABATEMENT SYSTEM 2. Assembly Installation and commissioning Task Commissioning test Exposed person Zone TYPE OF HAZARD Hazardous event Direct and indirect contact with live parts Type 2. Electrical Source - Contact with live elements (direct contact) - Contact with live parts in the event of a fault (indirect contact)
  • Page 60 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 2. Assembly Installation and commissioning Task Connection to energy supply sources Exposed person Zone TYPE OF HAZARD Hazardous event Direct and indirect contact with live parts Type 2. Electrical Source - Contact with live elements (direct contact)
  • Page 61 JUNIOR SOOT ABATEMENT SYSTEM 2. Assembly Installation and commissioning Task Connection to energy supply sources Exposed person Zone TYPE OF HAZARD Hazardous event Fire caused by electrical components and subsequent contact with flammable material Type 3. Thermal Source Fire Situation...
  • Page 62 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 2. Assembly Installation and commissioning Task Assembly Exposed person Zone TYPE OF HAZARD Hazardous event Contact with sharp machine elements or edges Type 1. Mechanical Source Sharp parts Situation Operate in the areas intended for assembly of the machine...
  • Page 63 JUNIOR SOOT ABATEMENT SYSTEM 2. Assembly Installation and commissioning Task Assembly Exposed person Zone TYPE OF HAZARD Hazardous event Possible fall of the load during the assembly phase also due to the breaking of straps or cables used for lifting Type 1.
  • Page 64 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 2. Assembly Installation and commissioning Task Passing or standing near danger zones (assembly, installation and commissioning phase) Exposed person Zone TYPE OF HAZARD Hazardous event Impact and collision caused by the presence of the moving vehi-...
  • Page 65 JUNIOR SOOT ABATEMENT SYSTEM 2. Assembly Installation and commissioning Task Passing or standing near danger zones (assembly, installation and commissioning phase) Exposed person Zone TYPE OF HAZARD Hazardous event Construction site activities that can cause damage to uninformed people Type 9.
  • Page 66 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 4. Use Task Passing or standing near dangerous areas (use phase) Exposed person Zone TYPE OF HAZARD Hazardous event Contact with moving parts of the machine Type 9. Environment of use Source -Various hazards (mechanical, electrical, etc.) arising from activi-...
  • Page 67 JUNIOR SOOT ABATEMENT SYSTEM 4. Use Task Machine operation Exposed person Zone TYPE OF HAZARD Hazardous event Contact with the abrasive surface of the rotating input cylinder Type 1. Mechanical Source Rotating elements Situation Operating near the lamination zone Consequence...
  • Page 68 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 5. Maintenance Task Intervention on the machine systems Exposed person Zone TYPE OF HAZARD Hazardous event Direct and indirect contact with live parts even after the main switch has been disconnected: - Interface signals - Circuits upstream of the switch.
  • Page 69 JUNIOR SOOT ABATEMENT SYSTEM 5. Maintenance Task Intervention on the machine systems Exposed person Zone TYPE OF HAZARD Hazardous event Direct and indirect contact with live parts Type 2. Electrical Source - Contacts with live parts, - Contact with live parts in the event of a fault...
  • Page 70 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 5. Maintenance Task Passing or standing near dangerous areas (maintenance phase) Exposed person Zone TYPE OF HAZARD Hazardous event Contact with moving parts of the machine Type 9. Environment of use Source -Various hazards (mechanical, electrical, etc.) arising from activi-...
  • Page 71 JUNIOR SOOT ABATEMENT SYSTEM 5. Maintenance Task Cleaning and inspections Exposed person Zone TYPE OF HAZARD Hazardous event Direct and indirect contact with live parts Type 2. Electrical Source - Contact with live elements (direct contact) - Contact with live parts in the event of a fault (indirect contact)
  • Page 72 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 5. Maintenance Task Cleaning and inspections Exposed person Zone TYPE OF HAZARD Hazardous event Using toxic and/or harmful substances to clean the machine (ei- ther by contact with the skin or by inhaling hazardous vapours, e.g.
  • Page 73 JUNIOR SOOT ABATEMENT SYSTEM 6. Troubleshooting Task Component failures Exposed person Zone TYPE OF HAZARD Hazardous event Direct and indirect contact with live parts Type 2. Electrical Source Contact with live parts, Contact with live parts in the event of a fault...
  • Page 74 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 6. Troubleshooting Task Passing or standing near danger zones (troubleshooting/defect search phase) Exposed person Zone TYPE OF HAZARD Hazardous event Contact with moving parts of the machine Type 9. Environment of use Source -Various hazards (mechanical, electrical, etc.) arising from activi-...
  • Page 75 JUNIOR SOOT ABATEMENT SYSTEM 7. Dismantling, scrapping, disposal Task Passing or parking near danger zones (dismantling, scrapping, disposal phase) Exposed person Zone TYPE OF HAZARD Hazardous event Construction site activities that can cause damage to uninformed people Type 9. Environment of use...
  • Page 76 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 7. Dismantling, scrapping, disposal Task Passing or parking near danger zones (dismantling, scrapping, disposal phase) Exposed person Zone TYPE OF HAZARD Hazardous event Impact and collision caused by moving transport and loading equipment Type 9.
  • Page 77 JUNIOR SOOT ABATEMENT SYSTEM 7. Dismantling, scrapping, disposal Task Passing or parking near danger zones (dismantling, scrapping, disposal phase) Exposed person Zone TYPE OF HAZARD Hazardous event Possible fall of the load during the handling phase also due to the...
  • Page 78 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 7. Dismantling, scrapping, disposal Task Waste disposal for scrapping Exposed person Zone TYPE OF HAZARD Hazardous event Environmental pollution Type 9. Environment of use Source Pollution Situation Dismantling the machine for end-of-life Consequence Any other consequences caused by sources of risk of the ma-...
  • Page 79 JUNIOR SOOT ABATEMENT SYSTEM 7. Dismantling, scrapping, disposal Task Disassembly Exposed person Zone TYPE OF HAZARD Hazardous event Contact with sharp machine elements or edges Type 1. Mechanical Source Sharp parts Situation Operate in the areas dedicated to the assembly and disassembly...
  • Page 80 SAFETY JUNIOR | SOOT ABATEMENT SYSTEM 7. Dismantling, scrapping, disposal Task Disassembly Exposed person Zone TYPE OF HAZARD Hazardous event Direct and indirect contact with live parts Type 2. Electrical Source Contact with live parts, Contact with live parts in the event of a fault...
  • Page 81 JUNIOR SOOT ABATEMENT SYSTEM 7. Dismantling, scrapping, disposal Task Disassembly Exposed person Zone TYPE OF HAZARD Hazardous event Fire caused by electrical components and subsequent contact with flammable material Type 3. Thermal Source Fire Situation Working near electrical panels or live parts in the presence of...

  • Page 82: Transport And Unloading

    TRANSPORT AND UNLOADING JUNIOR | SOOT ABATEMENT SYSTEM TRANSPORT AND UNLOADING Rev: 0 /134...

  • Page 83: Purpose Of The Chapter

    JUNIOR SOOT ABATEMENT SYSTEM Purpose of the chapter The chapter contains the information required to correctly transport and unload the machin HAZARD VARIOUS HAZARDS ARISING FROM LOAD HANDLING OPERATIONS Load-handling operations may present various risks (crushing, shearing, etc.) to persons present in the areas where the operations take place.

  • Page 84: Equipment Required For Unloading

    TRANSPORT AND UNLOADING JUNIOR | SOOT ABATEMENT SYSTEM Equipment required for unloading The customer receiving the machine must equip himself with the unloading equipment listed below. The dimensioning of the equipment must be made according to the masses of the load units to be lifted and the characteristics of the environment in which the unloading will take place.
  • Page 85 JUNIOR SOOT ABATEMENT SYSTEM Preparation of the unloading area Follow the instructions below in order to set up a dedicated area for unloading. Procedure: Reserve a working area that allows the machine to be unloaded easily. It must be possible to manoeuvre in the area the transport lorry and means provided for unloading.

  • Page 86: Unloading From The Vehicle

    TRANSPORT AND UNLOADING JUNIOR | SOOT ABATEMENT SYSTEM Unloading from the vehicle Follow the instructions below for proper unloading from transport vehicles. Procedure: Use ladders and scaffolding to get on and off the vehicle. Do not climb on either the transport vehicle or the loading units.

  • Page 87: Handling Of Load Groups

    JUNIOR SOOT ABATEMENT SYSTEM Handling of load groups Please follow the instructions below for the correct handling of the load units. Procedure: There may be illustrations on the load unit indicating the type of lifting or other useful information. Pay attention to the presence of these warnings and always follow their instructions.
  • Page 88 TRANSPORT AND UNLOADING JUNIOR | SOOT ABATEMENT SYSTEM General notes for lifting and handling The load groups can be lifted and then moved in two different ways: Lifting from below: Using the forks of a forklift or pallet truck properly inserted into the appropriate slots of the loading unit.

  • Page 89: Unpacking

    Upon receipt of the material, follow the instructions below to unpack it properly. SMOKI systems are delivered in a cardboard carton suitable for the shipment of equipment of this type, on a wood pallet not suitable for stacking, fastened to the pallet with straps.

  • Page 90: Disposal Of Packaging

    TRANSPORT AND UNLOADING JUNIOR | SOOT ABATEMENT SYSTEM IMPORTANT DISPOSAL OF PACKAGING Disposal of the packaging material will be the responsibility of the recipient, which must do so in accordance with the laws in force in the country that the machine will be used in.

  • Page 91: Installation And Commissioning

    JUNIOR SOOT ABATEMENT SYSTEM INSTALLATION AND COMMISSIONING Rev: 0 /134...

  • Page 92: Systems Connections

    INSTALLATION AND COMMISSIONING JUNIOR | SOOT ABATEMENT SYSTEM Systems connections 8.1.1 Electrical system connection IMPORTANT EXECUTION OF ELECTRICAL WORK The installation of electrical equipment must be carried out in accordance with current legislation on safety and electrical installations. • It is the obligation of the final machine manufacturer to assess compliance with the applicable directives and standards.

  • Page 93: Commissioning (First Start-Up)

    JUNIOR SOOT ABATEMENT SYSTEM Commissioning (first start-up) HAZARD VARIOUS MECHANICAL HAZARDS RESULTING FROM THE ABSENCE OR TEMPORARY DISABLING OF MACHINE PROTECTION MEASURES During the initial start-up phase, protection measures may be removed or temporarily disabled for technical reasons. • Only experienced personnel (maintenance technicians and/or the manufacturer's), trained and informed of the risks involved, are authorised to work on the machine with the protective measures removed or temporarily disabled.

  • Page 94: Machine First Start-Up

    INSTALLATION AND COMMISSIONING JUNIOR | SOOT ABATEMENT SYSTEM 8.2.2 Machine first start-up The first start-up of the machine must be performed by our after-sales service or by the maintenance technician, after having been authorised. The first start-up procedure can be carried out without the product, to check the correct operation of the machine assemblies, and then with the product to be processed to check the correct operation of the machine.

  • Page 95: Location Of The System

    SOOT ABATEMENT SYSTEM 8.2.4 Location of the system When installing the Junior system, the client can decide one of the following options, depending on his needs: INDOOR INSTALLATION (OPTION A) As shown in fig. 24, the JUNIOR system is installed inside the building.
  • Page 96 INSTALLATION AND COMMISSIONING JUNIOR | SOOT ABATEMENT SYSTEM INDOOR INSTALLATION (OPTION B) As shown in fig. 25, the JUNIOR system is installed directly over the oven, inside the building. The oven smokestack is connected directly to the entrance marked "IN" of the JUNIOR unit. The exit marked "OUT"...
  • Page 97 WARNING When the JUNIOR system is installed outdoors it must be provided with the special insulated cover for outdoor installation (optional) to protect the system from the weather. A severe temperature drop (below -10 C°) could cause unsafe conditions.

  • Page 98: Commands

    COMMANDS JUNIOR | SOOT ABATEMENT SYSTEM COMMANDS Rev: 0 /134...

  • Page 99: Purpose Of The Chapter

    JUNIOR SOOT ABATEMENT SYSTEM Purpose of the chapter IMPORTANT READ CAREFULLY THE CHAPTER The chapter contains information on the controls provided for the operation and control of the machine. • It is MANDATORY that the personnel in charge of operation be duly trained and instructed in the location of the controls on the machine and their correct use.

  • Page 100: 10 Use

    JUNIOR | SOOT ABATEMENT SYSTEM 10 USE Rev: 0 /134...

  • Page 101: Purpose Of The Chapter

    JUNIOR SOOT ABATEMENT SYSTEM 10.1 Purpose of the chapter IMPORTANT READ CAREFULLY THE CHAPTER This chapter will provide descriptions of the intended use operations. • Correct instructions for future operators, maintenance and service technicians implies a general theoretical knowledge of all described operations.

  • Page 102: System Operation

    If they do not match, do not start the machine, and contact the service department. Connection to the electrical system (to EEC standards), including compulsory grounding, must be made by specialized personnel only. The electrical system to which the JUNIOR machine is connected must be controlled upstream by a differential magneto-thermal switch.

  • Page 103: System Start-Up

    HAZARD For greater operator safety, SMOKI s.r.l. considers it fundamental for the electrical system to which the “JUNIOR” system is connected to comply with the standards as foreseen by Italian law, and therefore to be equipped with a differential magnetothermal switch.

  • Page 104: Maintenance

    MAINTENANCE JUNIOR | SOOT ABATEMENT SYSTEM MAINTENANCE Rev: 0 /134...

  • Page 105: Purpose Of The Chapter

    JUNIOR SOOT ABATEMENT SYSTEM 11.1 Purpose of the chapter The chapter contains information on the maintenance operations that must be carried out to keep the machine in proper working order at all times, in accordance with the purposes for which it was built.

  • Page 106: System Maintenance Frequency

    MAINTENANCE JUNIOR | SOOT ABATEMENT SYSTEM 11.2 System maintenance frequency The maintenance procedures described below cover the entire maintenance process (biweekly, routine and special). The operator should perform them in their proper chronological order. The procedures are divided into "biweekly" every 15 days (fig. marked with letter "A"); "routine"...

  • Page 107: Maintenance Procedures

    IMPORTANT! Maintenance of the JUNIOR must be assigned exclusively to qualified personnel (persons with adequate technical experience in the field). Failure to perform maintenance with the frequency indicated by the manufacturer will cause immediate loss of the benefits of the warranty!
  • Page 108 MAINTENANCE JUNIOR | SOOT ABATEMENT SYSTEM Disconnecting automatic switch Turn off the system by disconnecting the automatic switch of the electric line ("OFF" position) as shown in fig.11 Fig.11 Disconnecting circuit breaker Switch off the circuit breaker on the power panel of the machine, as shown in fig.
  • Page 109 JUNIOR SOOT ABATEMENT SYSTEM Opening water drain gate In the case of an electric water drain valve (see image 15), activate the opening using the control panel supplied with the machine, otherwise unscrew the release screw on the electric valve and manually activate the selector.
  • Page 110 MAINTENANCE JUNIOR | SOOT ABATEMENT SYSTEM Maintenance nozzle cleaning Clean the maintenance nozzle by turning cap "A" shown in Fig. 18 with an Allen key (size 10) Remove nut "A" and clean the nozzle to remove any residues with water or compressed air. To...
  • Page 111 JUNIOR SOOT ABATEMENT SYSTEM Closing the water drain gate In the case of a manual valve: turn the gate lever counter-clockwise to the vertical position as shown in fig. 21. In the case of an electric valve: activate the closure using the control panel...
  • Page 112 MAINTENANCE JUNIOR | SOOT ABATEMENT SYSTEM PAGE LEFT INTENTIONALLY BLANK Rev: 0 /134...

  • Page 113: Dismantling And Scrapping

    JUNIOR SOOT ABATEMENT SYSTEM DISMANTLING AND SCRAPPING Rev: 0 /134...

  • Page 114: Purpose Of The Chapter

    DISMANTLING AND SCRAPPING JUNIOR | SOOT ABATEMENT SYSTEM 12.1 Purpose of the chapter IMPORTANT READ CAREFULLY THE CHAPTER All the operations described in this chapter are reserved exclusively for technical personnel specialized in load handling and waste disposal. • Final decommissioning and scrapping must be carried out by technical personnel working in a specialized waste treatment centre, to which the machine must be delivered or requested to be collected.
  • Page 115 JUNIOR SOOT ABATEMENT SYSTEM Decommissioning and scrapping Procedure: Carefully consult the laws in force in the user's countries regarding environmental protection and safety procedures. In accordance with the provisions of the law, activate the inspection procedure of the competent body and the consequent recording of the demolition.

  • Page 116: Separation, Classification And Disposal Of Waste

    DISMANTLING AND SCRAPPING JUNIOR | SOOT ABATEMENT SYSTEM 12.2.1 Separation, classification and disposal of waste Waste is defined as any substance or object that is the product of human activities or natural cycles, abandoned or destined to be abandoned. The following categories of waste must be considered special waste: ...

  • Page 117: Type Of Waste Produced By Demolishing The Machine

    JUNIOR SOOT ABATEMENT SYSTEM 12.2.2 Type of waste produced by demolishing the machine WASTE MANAGEMENT IMPORTANT The following table summarizes and classifies the type of waste produced by demolishing the machine. • Inquire with the competent authorities regarding the waste storage and disposal methods in force.
  • Page 118 DISMANTLING AND SCRAPPING JUNIOR | SOOT ABATEMENT SYSTEM PAGE LEFT INTENTIONALLY BLANK Rev: 0 /134...

  • Page 119: Troubleshooting

    JUNIOR SOOT ABATEMENT SYSTEM TROUBLESHOOTING Rev: 0 /134...

  • Page 120: Purpose Of The Chapter

    TROUBLESHOOTING JUNIOR | SOOT ABATEMENT SYSTEM 13.1 Purpose of the chapter The information below is intended to assist in the identification and correction of any anomalies and/or malfunctions that may occur when using the machine. IMPORTANT STAFF SAFETY It is MANDATORY to section off power supply sources and lock them with suitable padlocks and jaws •...

  • Page 121: Faults

    SOOT ABATEMENT SYSTEM 13.2 Faults PROBLEM CAUSE REMEDY The JUNIOR system  - Have the system connected as instructed No electric connection does not start in the user manual, by qualified personnel. - Set the automatic “mains” switch to the “ON”...
  • Page 122 TROUBLESHOOTING JUNIOR | SOOT ABATEMENT SYSTEM PROBLEM CAUSE REMEDY cont.'d ./..  The level meter - Clean the float arm inside the tank thor- blocked or faulty oughly (see page 10 item 08). The PUMP does not start Replace the faulty level meter (see page 10 point 12).
  • Page 123 JUNIOR SOOT ABATEMENT SYSTEM PROBLEM CAUSE REMEDY cont.'d ./..  Insufficient cleaning - Perform biweekly, routine and special maintenance with the re- LEVEL METER blocked quired frequency as indicated in the user manual, - Thoroughly clean the float arm in the tank PUMP goes on and off after long ...

  • Page 124: 14 Wiring Diagrams

    WIRING DIAGRAMS JUNIOR | SOOT ABATEMENT SYSTEM 14 WIRING DIAGRAMS Rev: 0 /134...

  • Page 125: Purpose Of The Chapter

    JUNIOR SOOT ABATEMENT SYSTEM 14.1 Purpose of the chapter The wiring diagram of the soot abatement system is shown below. Two wiring diagrams will be inserted:  PQSMK0000B-QE without electric water drain valve  PQSMK0000B2-QE with electric water drain valve...

  • Page 126: Wiring Diagram Pqsmk0000B-Qe

    WIRING DIAGRAMS JUNIOR | SOOT ABATEMENT SYSTEM 14.2 Wiring diagram PQSMK0000B-QE Rev: 0 /134...
  • Page 127 JUNIOR SOOT ABATEMENT SYSTEM Rev: 0 /134...
  • Page 128 WIRING DIAGRAMS JUNIOR | SOOT ABATEMENT SYSTEM Rev: 0 /134...
  • Page 129 JUNIOR SOOT ABATEMENT SYSTEM Rev: 0 /134...

  • Page 130: Wiring Diagram Pqsmk0000B2-Qe

    WIRING DIAGRAMS JUNIOR | SOOT ABATEMENT SYSTEM 14.3 Wiring diagram PQSMK0000B2-QE Rev: 0 /134...
  • Page 131 JUNIOR SOOT ABATEMENT SYSTEM Rev: 0 /134...
  • Page 132 WIRING DIAGRAMS JUNIOR | SOOT ABATEMENT SYSTEM Rev: 0 /134...
  • Page 133 JUNIOR SOOT ABATEMENT SYSTEM Rev: 0 /134...
  • Page 134 WIRING DIAGRAMS JUNIOR | SOOT ABATEMENT SYSTEM Smoki srl: Via Cella Raibano, 16C – 47843 MISANO ADRIATICO (RN) ITALY Tel 0541.833748 www.smoki.it – info@smoki.it – commerciale@smoki.it Rev: 0 /134...

Table of Contents