Manual Turbine
Manual Turbine
SPRAYSTREAM
25i cart, 35i, 50i, 60i, 70i, 80i & 100i
models
25i cart, 35i, 50i, 60i, 70i & 80i HP
models
0. Preface
Dear Customer,
Small dimensions, low weight and high effectiveness have been the
key goals for the SPRAYSTREAM design.
The capacity is set to a very high level for this size of machines and
due to the high effectiveness through the whole capacity, it is possible
to operate it with minimal resources.
Sincerely,
Savic Engineering,
Managing director
Mirko Savic
Belgium
Special attention should be given to the section warning. Of course having the
machine accessible while reading the manual, will help the operator to
understand the machine’s different functions better.
Listed in the section ”TROUBLE SHOOTING” is a diagnostic chart which will help in
answering questions about problems that may arise.
DO have a training seminar before you or your crew ever starts to use the
Spraystream dust controller. Familiarity with the Spraystream and its
procedure could prevent a mishap or injury, and should make dust control
more efficient.
Warranty
The manufacturer declines any warranty and all responsibility for machine failure if
the machine is not operated and maintained according to the regulations described
in this manual or in compliance with the installation requirements.
The manufacturer declines any warranty and all responsibility for the quality and safe
operation of the machine due to any alteration or change to the machine including
not using original spare parts. This includes using parts that are not compatible with
the quality standards for the electrical and mechanical specifications set by
SPRAYSTREAM. Regarding any question concerning the machine, always
indicate the machine number and model type.
Particular attention should be paid to all warnings stated in this manual. The
manufacturer will assume no responsibility for any damage to person(s),
property or the environment due to negligence in compliance with, or from any
deviation of the safety concepts printed in this manual.
NO!
Protective gloves should be worn at all times when in contact with the machine
to help to prevent injuries.
Ear protection that is suitable for working around the machine while the
machine is in operation or is being serviced while in operation.
• Only personnel with proper training and good knowledge of the equipment
is allowed to operate this machine.
• Operators must have a thorough understanding of the safety and operating
procedures.
• They must also be familiar in handling problems that may arise.
• The manual must be available at all times, personnel must have experience
in the structure of the manual and how to use it for references.
• The manual and safety rules must be present and used at all start-ups and
during the operation of the machine.
• All personnel must be trained and educated to operate the machine.
• Always secure the machine before transport.
• Caution must be used when handling a machine not equipped with wheels.
• Always anchor the machine properly before operating.
• The electrical connections must be made by a certified electrician.
• Moving the machine while it is operating or when electricity and/or water is
connected is strictly forbidden.
• Never open the electrical cabinet while the machine is operating.
• Always open and close water hydrants/valves very slowly.
• Use caution when handling hoses and other equipment under pressure.
• Always verify that cables and hoses are in a good state.
• Always set up the cables and hoses with extra moving space for the
oscillation.
• Always check that the machine can oscillate without interference.
• Appropriate warning signs, lights and fencing for the machine and
cables/hoses must be used.
• Never operate the machine without protective clothing/equipment. Care
should be taken that no loose clothing/equipment is used that could be
tangled by the fan or other rotating parts.
• Never stand in the way of the air/mist stream.
• Always use special care when operating in special areas, environments and
weather conditions.
• Always apply your areas additional safety procedures.
The small parts that are supplied upon delivery can be found in the lower section of
the electrical cabinet.
The information that follows concerning the lifting and moving of the machine;
specific symbols are used for this topic and are to be considered as reminders and
are not to be found on the machine.
All operations concerning the lifting and moving of the machine should be carried
out by specialized personnel who, according to the characteristics of the load, will be
responsible for organizing all the operative phases. The most suitable means
respecting the work standards in force should be employed.
When lifting, safety for the personnel and equipment should be a prime
concern. The work should be organized and carried out by trained personnel
to limit the risk of injuries and the amount of time a load must be lifted.
Warning! It is absolutely forbidden to move the vehicle while the load is lifted.
Chains:
Cables:
The safety lock on the hook must always return to its initial
position when the cables are inserted to secure the cables.
Never use cables that are in any way frayed or damaged.
Lifting:
Make sure that there is no one standing in the operation
area of the crane. Lift and lower the load as smoothly as
possible, avoiding any quick-jerky movements. Never drag
the load along the ground. While lifting in difficult
conditions, assign personnel to control the movements to
be made.
Remember to apply the brakes/block the optional wheels before releasing the
machine to the ground.
2.8 Transport
During transport the machine has to be safely secured. The door to the electrical
cabinet must always be shut and locked.
The transport lock needs to be in place before moving.
Put the machine 90° into the wind in order to prevent windmilling, the fan
could exceed the never exceed speed while driving on the highway. This
could result in chattered fan and other damage
To move it with a forklift see the sections above. The machine will take more space
with the addition of the wheels or lifting hook. Therefore you need to be even more
cautious during the maneuvering.
For very short distances and to adjust the position of the machine, it is possible to
tow the machine behind a vehicle using the tow bar (optional wheelset).
During this kind of movement extreme attention must be paid to ensure safety.
The maximum speed is 5km/h with a maximum slope of 5°. The road/ground must
be even and uniform.
It has a dust binding capacity over almost the whole throwing distance (depending
on the version), which is between 5 and 100+ meters and it can oscillate a whole
360° (consideration must be taken to the movement of the power cable).
3.1 Fan
The standard fan for this machine is a multi-blade high performance composite fan
configured for an optimal air velocity and volume. The usage of composite blades is
both for safety reasons and for the overall toughness against abuse.
Composite blades bend or disintegrate when encountering foreign physical contact.
They are also light and have a low rotating weight for the engine to revolve.
Metal blades on the other hand become lethal sharp projectiles that cut through the
barrel (and other things) and which can travel long distances at great speed.
Water is fed into the machine from a water source that has an initial pressure of 2 bar
given at the nominal flow of the machine.
The water is filtrated and distributed to the pump and nozzles through the filter.
The water manifold and filter is located under the barrel of the machine.
3.2.3 Boosterpump
The booster pump boosts the pressure. This pump is not a suction pump.
It is possible to alter the position of the nozzles to achieve special purpose spray
patterns. Ask your service technician for such matters.
With the optional segmented nozzle ring, the water flow can be reduced by 50%.
When the segmented nozzle ring is activated, only the upper half of the ring will
spray water.
3.3.3 Nozzles
Spraystream nozzles are made out of stainless steel, the set consists of 3 pieces:
nozzle tip, cap and last chance filter (for the normal pressure version).
3.5 Chassis
The lightweight chassis is designed to provide a stable and durable platform for the
machine and gives easy access for maintenance. Other important features are the
diverse transport and mobility systems that can be implemented on the chassis.
3.6 Mobility
3.6.1 Standard configuration
Transport and movement on site are essential for a rapid deployment of the system
when dust controlling needs to arise. The machine is standard equipped with forklift
pocket holes.
4.2 Power
The typical electrical requirement is 16A, 32A or a 63A 400V/50Hz
The power supply needs to be fitted with an earth leakage breaker 30 mA and an
according circuit breaker with min. 9kA specs.
Please note that the US versions are not equipped with an earth leakage
disconnector.
Nozzles (Qty.) 15
Fan engine
Effect 2.2 kW
Rpm 2840rpm
Voltage 400V (480 V – US Version)
Frequency 50Hz (60 Hz – US Version)
Rated current 5A
Fan type Composite
Rotation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Rated current 0,43A
Electricity
Voltage 3x400V ( 3 x 480 V – US Version)
Frequency 50Hz (60 Hz – US Version)
Nozzles (Qty.) 20
Fan engine
Effect 3 kW
Rpm 1450rpm
Voltage 400V (480 V – US Version)
Frequency 50Hz (60 Hz – US Version)
Rated current 6.5 A
Fan type Composite
Rotation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Rated current 0,43A
Electricity
Voltage 3x400V ( 3 x 480 V – US Version
Frequency 50Hz (60 Hz – US Version)
Nozzles (Qty.) 20
Fan engine
Effect 2.2 kW
Rpm 1450rpm
Voltage 230V
Frequency 50Hz
Rated current 4.4 A
Fan type Composite
Rotation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Rated current 0,43A
Electricity
Voltage 1 x 230 Volt
Frequency 50Hz
Standard dimensions
Height 225 cm
Width 160 cm
Depth 155 cm
Weight 450 /480 kg
Nozzles (Qty.) 30
Fan motor
Power 7,5 / 11 W
Rpm 1450rpm
Voltage 400V (480V – US Version)
Frequency 50Hz / (60Hz – US Version)
Fan material Composite
Oscillation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Rated current 0,43A
Power
Voltage 3x400 (3 x 480 V – US version)
Frequency 50Hz (60 Hz – US Version)
Standard dimensions
Height 235 cm
Width 160 cm
Depth 155 cm
Weight 480, 540 & 550 kg
Nozzles (Qty.) 30
Fan motor
Effect 11kW / 15 kW / 18.5kW
Rpm 1450rpm
Voltage 400V (480 V – US Version)
Frequency 50Hz (60Hz – US Version)
Fan type Composite
Oscillation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Rated current 0,43A
Electricity
Voltage 3x400V ( 3 X 480V – US Version)
Frequency 50Hz (60 Hz – US Version)
Standard dimensions
Height 235 cm
Width 160 cm
Depth 155 cm
Weight 700 kg
Nozzles (Qty.) 40
Fan engine
Effect 22 kW
Rpm 1450rpm
Voltage 400V (480V – US Version)
Frequency 50Hz (60Hz – US Version)
Fan type Composite
Rotation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Electricity
Voltage 3x400V (3x480V – US Version)
Frequency 50Hz (60 Hz – US Version)
Nozzles (Qty.) 15
Fan engine
Effect 2.2 kW
Rpm 2840rpm
Voltage 400V (480 V – US Version)
Frequency 50Hz (60 Hz – US Version)
Rated current 5A
Fan type Composite
Rotation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Rated current 0,43A
Electricity
Voltage 3x400V ( 3 x 480 V – US Version)
Frequency 50Hz (60 Hz – US Version)
Nozzles (Qty.) 20
Fan engine
Effect 3 kW
Rpm 1450rpm
Voltage 400V
Frequency 50Hz
Rated current 6.5 A
Fan type Composite
Rotation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Rated current 0,43A
Electricity
Voltage 3x400V
Frequency 50Hz
Standard dimensions
Height 225 cm
Width 160 cm
Depth 155 cm
Weight 450 /480 kg
Nozzles (Qty.) 60
Fan motor
Power 7,5 / 11 W
Rpm 1450rpm
Voltage 400V (480V – US Version)
Frequency 50Hz / (60Hz – US Version)
Fan material Composite
Oscillation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Rated current 0,43A
Power
Voltage 3x400V (3 x 480 V – US version)
Frequency 50Hz (60 Hz – US Version)
Standard dimensions
Height 235 cm
Width 160 cm
Depth 155 cm
Weight 480, 540 & 550 kg
Nozzles (Qty.) 60
Fan motor
Effect 11kW / 15 kW / 18.5kW
Rpm 1450rpm
Voltage 400V (480 V – US Version)
Frequency 50Hz (60 Hz – US Version)
Fan type Composite
Oscillation
Power 0.09 kW
Max oscillation capacity 360°
Working area 30°- 360°
Rated current 0,43A
Electricity
Voltage 3x400V ( 3 X 400V – US Version)
Frequency 50Hz (60 Hz – US Version)
Remove the transport lock and any straps and see that all moving parts can
move freely.
Connect the electrical power cable. All electrical connections must follow local
electrical regulations. Check that the emergency button is not pushed in, if so
pull and turn the button to release.
Make sure that the cables and hoses are safely placed so that they don’t
get damaged or crushed when the machine is oscillating automatically.
Check that the fan blades are not coated with ice or dirt. Thin ice that has
formed on the fan blades will blow off by itself.
The use of a hammer or any hard object will void any warranty.
Make sure that the protective screen/grid on the back (air-intake) of the
machine barrel has been safely secured.
Start the fan shortly and verify the direction of the fan rotation. Seen from the back of
the air-intake, it should rotate clockwise. If the fan rotates in the wrong direction, two
of the phase cables inside the cabinet must be switched at the main switch. Consult
an electrician.
Never put your hands through the protective grid which covers the fan.
Connect the water hose to the water supply, open the valve very slowly and
flush the hose clean under low pressure, be cautious of eventual leakages.
Make sure that the water doesn’t exceed 5bar and 22°C.
Make sure that the water doesn’t exceed 3bar and 22°C for the HP machines
Turn off the water supply and connect the hose to the machine. Turn the water valve
for water supply on again very slowly until desired pressure is achieved.
Fill up the suction side hose, additional booster pump and pump with water.
Make sure the suction pump and hoses are filled with water when it is first operated.
To fill the suction pump with water: open the connection indicated below and fill with
water. This only needs to be done once, thereafter the pump is self-priming.
Make sure that the voltages and the frequency correspond with your machine.
Warranty will void by attempts of starting the machine with the wrong voltage.
The machine’s normal water pressure after the booster pump is 20bar for the
normal version and 80 bar for the high pressure version.
The machine can be controlled with the indicated buttons (see red dots).
Emergency Stop
This item can be operated in every working modus, except when the red LED is on,
or when the timer function is activated.
If there is no water pressure at the inlet, it will be not possible to start up the pump
when the optional pressure switch is installed.
With the black 3 position selector you can choose the rotation angle of the machine.
If the remote control option is chosen in combination with the electrical splitting
nozzle ring, the (de-)activation is controlled electrically. You can activate the splitting
ring function by pushing the button “splitting ring” on the electrical cabinet or on the
remote control for more than one second. An activated splitting ring is indicated by a
white led. To deactivate the splitting ring, push the button for more than 1 second.
The led will turn off and all 30 nozzles of the ring will be activated. The splitting
nozzle ring can also be activated without a working pump.
If the optional electrical vertical movement is chosen, you can do this with the
selector in the electrical cabinet. Choose up or down to adjust the throwing angle.
There are several tracing circuits. The first circuit starts at the suction pump and runs
to the filter. The second circuit is placed between the filter (filter included) and the
low pressure pump (low pressure pump included). Another circuit goes from the low
pressure pump to the nozzles.
In case of low temperatures: never turn off the main switch nor the
genset to avoid any frost damage at the machine.
Operating and
function LEDS
STOP BUTTON
UP
Start/Stop FAN
RIGHT
LEFT
LEFT
The remote control transmits discontinuous signals to operate the machine and is
equipped with batteries. To operate the transmitter, pull out the red stop button and
push the different buttons of the transmitter. The correct function of the transmitter is
shown by the middle led which illuminates green when a function is activated.
Every button has 2 positions indicated by 2 clicks. This is important for the splitting
ring and activation of the pump. To activate the splitting ring, push for more than 1
If the remote control is not being used, push in the red stop button on the side of the
remote control. This will increase the batteries’ life. If the batteries are empty, replace
them by 3 x AAA batteries. See pictures below.
6.11.2 Version 2
Operating and
function LEDS
STOP ALL
RIGHT
When the batteries are low, the central operating LED (normally a green LED) will
change its color to red. If so, it is recommended to replace the batteries. To replace
the batteries, unscrew the 5 indicated screws and open the transmitter. After you
have replaced the 3 x AAA batteries. Close the cover.
If the remote control is not being used, switch of the remote control. This will
increase the batteries’ life.
On / off switch
We advise you to inform the personnel about the presence and use of
a remote control.
Establish around the machine a safety perimeter with the indication
that the machine can be operated with a remote control.
The limit switches can be found on the chassis, just above the rotation bearing.
The stops can be mounted in the holes indicated in the red circle below.
In case of a normal shutdown, when the machine is taken out of operation, the
operator should:
1. Turn off the oscillation (the pilot light will go out).
2. Press the button of the pump (the pilot light of that button will go out).
3. The fan will continue to run for approximately another 30 seconds to 1 minute to
dry the barrel. After this drying time, press the button of the fan so that the pilot
light of this button will go out.
4. Switch off the main switch.
7.2 Bearings
It is important that the bearings are lubricated before each operating season, or after
every 250 operating hours (can be less according to the environment).
Check the water hoses from the water manifold to the nozzle ring assembly for
any wear or damage resulting in leakage.
Before starting/using the machine, please check that all water nozzles in the nozzle
ring have the proper spray pattern. From the side or backside of the barrel, it is
possible to observe the spray pattern which should look like the pattern in the
illustration.
If the spray pattern of an individual nozzle deviates at all from the illustration; clean or
replace the nozzle. Be careful with the threads in the nozzle ring assembly. Check
the spray pattern again.
If high pressure nozzles are use, heat the nozzles a little bit before removing,
because the nozzles can be glued.
Check the camlock and other water couplers for damage and make sure that
the gaskets are in place and intact. Check the status from the hoses on
leakages.
The cannon can be turned by hand when the oscillation is not working.
It takes 1 person the rotate the cannon manually in a normal setup to override the
torque limiter.
If the pressure to rotate the cannon is too high, then you need to release the
pressure from the torque limiter by unscrewing the nut.
When there is dust visible, clean the filter. In order to do so, shut down the
pump and stop the water supply. Unscrew the glass bulb and remove the filter
cartridge to clean the inside.
Avoid keeping still water in the system for longer than 24 hours.
Monitor on a regular basis the quality of the water coming out of the machine. Send
a water sample for an analysis to a research center to check for legionella.
The user of the Spraystream machine is responsible for the specification of the
intervals at which tests and maintenance will be executed. This needs to be in
accordance with how often and how long the machine is being used.
• Control panel:
- Check the proper function of all buttons and warning lights.
- Damaged buttons should be replaced before further operating the
machine.
• Simulate an alarm and check the function of the red-alert light.
• Check for loose cables in the electrical cabinet.
• Start the machine to make sure the starting and control sequence is OK.
Check if the valve opens and closes normally when operating the pump. Deposits,
dirt, perished or worn seals may lead to malfunctions. In case the valve does not
covers properly, water will leak out of the nozzle ring even when the pump is not
operating. The membrane of the valve needs to be changed in order to fix this
problem.
The user of the Spraystream machine is responsible to specify the test and service
intervals appropriate to the service conditions of the valve. It’s very important to have
the valve in a good working condition.
If the machine is equipped with a water cutoff valve, it can be opened without
activating the pump. Therefore you need to open the electrical cabinet and switch off
the motor protector. If you press the button of the pump, the valve will open. If so,
you can remove the water by blowing compressed air through the system.
If the drainage kit is used, there is always some water left in the pump. Before
starting the pump again, make sure all the ice inside the pump is melted. Otherwise,
the pump could be damaged!
8.3 Disassembling
To disassemble the machine:
• Lift the machine (see prev. chapter).
• Dismount the wheels or stands.
• Engage the transport locks and straps.
Transfo
Motor protector
fan – pump -
rotation
Contactor
Pump,
Rotation left,
Rotation right
Softstarter fan
Regarding any question concerning the machine, always indicate the machine
number and model type.
9.2 Troubleshoot
The errors, which cannot be detected with this diagram, should not be
attended to by the user. Contact the distributor for trouble shooting and
reparation. This is especially important during the warranty time.
By problems or other interruptions switch OFF the machine and disconnected the
electrical cable. And contact your Spraystream dealer.
As set forth herein, the term “machine” shall refer to SPRAYSTREAM machines as
manufactured by Savic Engineering and sold by authorized distributors. Claims for
warranty shall be submitted by the authorized distributor who performs or authorizes
the repairs.