DODA BG80 Series Manuel utilisateur
1
USE AND MAINTENANCE MANUAL
MIXER FOR
BIOGAS
FERMENTERS
SERIES BG80
®
COSTRUZIONE MACCHINE AGRICOLE
di
DODA ALDO & C SNC
COSTRUZIONE MACCHINE AGRICOLE di DODA ALDO & C SNC
Via Sante Sal aso 18/20 46010 BUSCOLDO (MN) ITALY
Tel. +39 0376/410043 - Fax. +39 0376/410032
2
INDEX
1 EC Declaration of confor ity
2 Safety instructions
2.1 Allowed employment
2.2 Safety rules
2. Symbols present in the manual
2.4 Stickers
3 Description
4 Functioning
5 Technical features
5.1 Technical data
6 Installation
6.1 Mounting instructions
6.1.1 Mixer with roof mounting
6.1.2 Mixer with wall mounting
6.2 Mixer mounting and installation
6.2.1 General instructions
6.2.2 Mixer with roof mounting
6.2. Mixer with wall mounting
6. Electric connection
6. .1 Setting of the mixer operating interval
7 Setting in otion
7.1 Checks at the first setting in motion
7.2 Checks before each setting in motion / Daily checkings
7. Mixer functioning
8 Maintenance progra
8.1 Maintenance depending on wear level
8.2 Current maintenance
9 Spare part list
1 EC DECLARATION OF CONFORMITY
IN CONFORMITY WITH THE DIRECTIVE 89/ 92 EC
We
DODA di Doda Aldo & c. s.n.c.
Via Contrargine sud, 3/5
46010 Canicossa (Mantova)
hereby declare under our own responsibility that the equip ent, entioned below,
MIXER SERIE BG
confor s to the require ents of the EC Directives 98/37/CE (replacing the previous
one 89/392/CE) and 94/9/CE concerning equip ent intended for use in potentially
Explosive At ospheres (ATEX).
HARMONISED STANDARDS
DIN EN 982 DIN EN 1127-1
DIN EN 12100-1 DIN EN 12100-2
DIN EN 50014 DIN EN 50021
DIN EN 13463-1
The ixer is designed for bio ass ho ogenization, also in the presence of non-
ho ogeneous atter, and as a consequence is suitable for the installation on Biogas
fer enters , available with both wall and roof ounting fra e .
The here enclosed Declaration of confor ity is valid only if all instructions
reco ended with this anual are carefully followed.
The ixer arking includes the following labels:
EX II3GX
CANICOSSA (MANTOVA)
……................................................
(Na e, signature, corresponding)
Notes concerning the declaration of confor ity
The present declaration states that the machines are in conformity with the strict provisions of
the European Directive 98/ 7 CE.
However, please take into account that even though the safety rules are carefully followed,
the employment of each mixer implies certain risks.
Therefore, besides the general safety and accident prevention rules , we recommend that you
should follow the safety instructions indicated in the present manual and the ones suggested
by common sense.
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2 SAFETY INSTRUCTIONS
2.1 Allowed e ploy ent
The BG80 mixer has to be employed only to homogenize biomass present in a digester or in
fermentation tanks , such as slurry, non-homogeneous matter and other co-ferments.
With our mixer it is not allowed to mix the following substances:
Mud obtained by clarification
Solid bulky matters
Bodies with sharp corners which could damage the mixer
Medium mixed with foreign bodies (strings, ropes, plastic tapes, etc..…)
An employment different from that herewith indicated is not allowed.
Therefore the user as well as the mixer owner will be held responsible for any damage caused
by an incorrect use.
For a correct employment:
- Follow the instructions of this manual;
- Respect the check and maintenance intervals indicated.
2.2 Safety rules
Follow the safety rules of the local authorities concerning Biogas plants, as well as the general
safety provisions and the accident prevention regulations.
We recommend that any repair should be carried out either by an authorized mechanic
assistance or by the manufacturer’s technical assistance department.
In case, functioning defects arise due to the non-compliance with the hereby given use and
maintenance instructions, the manufacturer could not be considered responsible.
2.3 Sy bols used in this anual
Warning! Danger!
This sign warns you about a possible danger and suggests the most correct way you
should behave in such situation.
Warning! Danger electricity!
This sign warns you about dangers that can cause damages to the mixers and to
other present equipments as well as environmental degradation.
Warning! Fla able and explosive at osphere!
The employment of the mixer in potentially explosive zones 0 and 1 can cause
damages to things and injuries to persons with danger of death!
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2.4 Stickers
The mixer is provided with the following stickers:
Read the instruction manual!
Warning! Danger!
Warning! Flammable and explosive atmosphere!
PRIMA DELL’USO RIEMPIRE D’OLIO
FINO A LIVELLO
IMPORTANT: Before setting the achine
in otion, fill it up with oil till the
indicated level.
Fill up the achine with oi
l till the
indicated level.
Check periodically the oil level.
This sticker re inds you to check the
rotation direction of the electric otor
before setting the achine in otion.
DATA PLATE INDICATING THE
CONFORMITY WITH
EC REGULATIONS:
1) NAME OF THE COMPANY
2) MONTH/YEAR OF PRODUCTION
) SERIAL NUMBER
4) MACHINE TYPE
1
MARZO 2007 BG
80
2
4
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3 DESCRIPTION
The BG80 mixer is specifically designed for biogas fermentation tanks, characterized by an
high dry matter content.
The mixer employment is aimed at preventing the development of settled and floating layers
in the tank.
To ensure an excellent mixing efficiency, the BG80 mixer is provided with an hydraulic device
for the regulation of the tilt angle of the propeller in the tank.
The medium and gas tightness of the digester is made sure by a strong expansion joint which
is firmly fixed both on the mixer drive line and on the wall /or roof mounting plate, by means
of a flange coupling.
The surfacing and the consequent emission of gas bubbles, which form in the fermented
medium, are made easier by the vigorous and at the same time soft mixing of the bacteria.
That prevents an uncontrolled ferment “swelling”.
The mixer functioning time can change according to needs. It is generally recommended that
the motor rotation speed (r.p.m. ) should be adjusted according to the type of substrate to be
treated, by using an inverter. That can avoid the unnecessary functioning and optimize the
electric power consumption.
During mainly the loading and starting phases, the user has to set the correct functioning
time and the suitable motor rotation speed.
Usually we advise a starting phase with a high rotation speed which has to be gradually
reduced during normal operating.
No white spots have to come up to the surface (sulphur deposition) and no substance has to
deposit at the bottom of the tank.
Furthermore it is necessary to check the tank maximum level, above all in case of high silage
or great manure quantity.
In case of an increase of the tank maximum level or of sulphur deposition, extend the mixer
operating time and, if necessary, speed up the motor revolutions per minute.
The BG80 is standard provided with a 1600mm diameter vane propeller and a strong
vibration-resistant frame, suitable to support the gear box and designed for both roof or wall
mounting.
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4 FUNCTIONING
According to the requested installation, the mixer is provided with a roof or wall mounting
frame.
Usually the mixer arm inclines towards the left with regards to the tank wall, but on request
the mixer can be supplied with arm leaning towards the right.
The machine is equipped with a hydraulic device for the mixing propeller tilt regulation.
The propeller turns clockwise.
With full tank, the rotation direction is recognizable only through the thrust effect
generated by the fluid present in the tank, which should move towards its middle.
The functioning of the mixer in the opposite direction to the recommended one could
cause strong vibrations, as well as serious damages to both the mixer and the tank.
On account of the different composition of the substrate to be mixed, it is necessary to adjust
the mixing propeller of immersion depth and to check that the propeller vanes are completely
covered by fluid during mixing.
During functioning no vortex or splashes have to be noticed in the fermenting medium.
The mixer has to work always in a enough full tank and with the propeller vane covered
at least 0,5m by the fluid; otherwise, a strong side vibration above all around the
Motor-Drive line unit will be noticed, which could damage the mixer.
Even during normal operating the mixer could swing sideways. Anyway, if the vibration does
not exceed 2 cm, that is not dangerous in consideration of the provided vibration-resistant
frame. Besides, this vibration can be prevented by increasing the revolutions per minute by
means of an inverter.
On the contrary, by too low rotation speed, strong side vibrations could occur,
therefore if necessary raise the revolutions per minute in order to avoid possible
damages to the mixer and the tank.
If, in spite of the compliance with the above-mentioned instructions, you do not obtain a
satisfactory mixing performance (e.g. because of a large tank diameter o a high content of dry
matter) , contact promptly the dealer or the manufacturer .
The dealer or the manufacture can not be considered responsible for damages due to incorrect
employment of the mixer.
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If the tank is filled with already fermented substrate coming from other Biogas containers,
there could be material floating on the surface, due to a high dry matter content. That could
also occur in case of a fault in the Biogas plant and the consequent unforeseen mixer
stopping.
In case a great quantity of floating wastes is present, before starting the mixer, take
the necessary steps, which of course have to be previously agreed with the dealer or
the manufacturer of the machine.
Attention! The mixer drive line can be damaged by extreme side thrust caused by
excess floating materials.
The propeller vane can undergo excessive stress which could affect negatively the tank
stability.
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5 TECHNICAL FEATURES
The data indicated refer to a standard supply.
The manufacturer reserves the right to introduce changes without prior notice.
1. All components touching the fluid , as well as all parts situated in the tank, are made of
stainless steel.
2. Mixer drive shaft in oil bath.
. Al Widia mechanical seal on the drive shaft
4. Control of the drive line lubrication oil level through a sight glass, set on the joining point
between the drive line and the gearbox.
5. Strong Bonfiglioli gearbox (Type C 80 2 con P180), 80 propeller rotation speed r.p.m. ,
with 1450 r.p.m. motor, at 50 Hz.
6. Self-cleaning three vane propeller, fixed on the shaft by means of a rotor hub.
7. Hydraulic regulation of the mixing depth through a hand pump and connection pipings,
standard supplied.
8. Roof or wall mounting frame.
5.1 Technical data
The data indicated refer to a standard supply.
The manufacturer reserves the right to introduce changes without prior notice.
Mixer type BG80 22kW BG80 18,5kW
Power /Motor type 22kW/4 poles 18,5kW/4 poles
Rated power 22 kW 18,5 kW
Rated voltage 400 V 400 V
Frequency 50 Hz 50 Hz
Revolutions per minute 1450 r.p.m. 1450 r.p.m.
Electric motor noise level 70dB 70dB
Voltage 4 Amp. 7 Amp.
Starting current cos ϕ 7 6,2
Power factor 0,85 0,84
Temperature probe PTC 160° PTC 160°
Substrate temperature 70° 70°
Gear ratio 18,1:1 18,1: 1
Propeller diameter 1600 mm 1500 mm
Drive line oil quantity 42 kg SAE80 – W90 42 kg SAE80 – W90
Gear box oil quantity 18 litres Shell Tivela
(or equivalent)
18 litres Shell Tivela
(or equivalent)
Hydraulic oil quantity for hand pump litres Nuto 68
(or equivalent)
litres Nuto 68
(or equivalent)
Total weight 960 kg 950 kg
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2
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