INSTALLATION INSTRUCTIONS

SP-60S PULPER, D5 DISPOSER & W/HE-9 HYDRA-EXTRACTORS

165 Independence Court, Lancaster, PA 17601

Telephone 717-397-5100 Fax 717-291-0877 1-800-23 SOMAT (1-800-237-6628)

SAFETY

INSTRUCTIONS READ THE MANUAL COMPLETELY BEFORE ATTEMPTING TO OPERATE THE UNIT. HIGH VOLTAGE! DO NOT PERFORM ANY REPAIRS TO MOTORS OR CONTROL

SYSTEMS WITHOUT TURNING OFF THE MAIN POWER. ALWAYS TURN THE MAIN POWER OFF AND LET ALL MOTORS COME TO A

STANDSTILL BEFORE DOING ANY MAINTENANCE ADJUSTMENTS OR CLEANING OF THE UNIT.

BEFORE STARTING, BE SURE ALL PERSONNEL ARE CLEAR OF MOVING PARTS. KNOW LOCATION AND FUNCTIONS OF ALL START/STOP BUTTONS AND SAFETY

SWITCHES. DURING PERIODIC MAINTENANCE, CHECK ALL SAFETY SWITCHES TO BE SURE

THEY ARE OPERATING PROPERLY. DO NOT REMOVE OR ALTER GUARDS. DO NOT REMOVE SAFETY LABELS. IF LABELS ARE MISSING OR DESTROYED,

CONTACT FACTORY FOR REPLACEMENT. DO NOT OBSTRUCT ELECTRICAL PANELS OR PUSH BUTTONS. GOOD HOUSEKEEPING IS THE MOST IMPORTANT SAFETY PROCEDURE. REV.01/99

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INSTALLATION INSTRUCTIONS

INDEX

SP-60S PULPER, D5 DISPOSER & W/HE-9 HYDRA-EXTRACTOR WASTE HANDLING SYSTEMS

GENERAL DESCRIPTION

UNPACKING

PULPER INSTALLATION

HYDRA-EXTRACTOR INSTALLATION

PIPING INSTALLATION

ELECTRICAL INSTALLATION

GENERAL DESCRIPTION

The SOMAT® System prepares solid waste materials for disposal by transforming the materials, mixed with water, into a pulp. This transformation takes place in a unit called a pulper which is designed to reduce all forms of paper, plastic, foil, and food waste to small sizes. The waste material is manually fed to the pulper. The continual flow of water and the rotation of the cutting mechanism create a strong vortex action which pulls the waste against the cutting blades of the impeller. A portion of the resultant slurry passes through a perforated stainless steel ring surrounding the pumping impeller. This ring allows sufficiently small particles to pass through the sizing holes. These particles are carried in the slurry to the extractor where the water is separated and returned to the pulper. Refer to the pulper section for detail views of the cutting mechanism. Items such as tin cans, silverware, nails, bolts and other non-pulpable objects which may be inadvertently fed into the pulper are separated out by centrifugal force and gravity. These items settle to the bottom of the tank. These items should be emptied manually while wearing gloves during cleanup.

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The SOMAT® System is designed to pump the mixture of macerated solids and water, called slurry, to the extractor where the slurry is reduced to a semi-dry pulp. Within the extractor, the slurry is carried upward by a helical screw within a perforated tubular screen. The water passes through the screen and is pumped back to the pulping unit. The solids continue up the screw to a compression chamber, where additional water is removed. The solids in this area are called the plug. This plug is broken up at the discharge opening by a cutter. The pulp then falls out of the discharge chute in to a waste container. This system is capable of reducing the volume of average non-compacted waste by approximately 80 percent. During the process some water is absorbed by the pulp. Fresh make-up water is supplied to the pulper automatically through a solenoid valve which responds to a PLC. The system is powered by electric motors with the associated controls housed in the Som-A-Trol enclosure (electric control panel). In addition to the basic system as discussed to this point, numerous additional items of equipment may or may not be required to comprise a specific system.

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GENERAL DESCRIPTION

The SOMAT® system prepares solid waste materials for disposal by transforming the materials, with water, into a pulp. This transformation takes place in a unit called a disposer which is designed to pulp

all forms of food waste. The waste material is fed manually or automatically to the disposer. The continual down flow of water and the rotation of the disposer impeller create a strong vortex action which pulls the waste down against the cutting blades of the impeller. The resultant slurry is then fed to a slurry pump which continues the slurry mixture to the extractor.

TYPICAL DISPOSER

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The SOMAT® System is designed to pump the mixture of macerated solids and water, called slurry, to the Hydra-Extractor where the slurry is reduced to a semi-dry pulp. Within the Hydra-Extractor, the slurry is carried by a Helicoid screw within a perforated tubular screen. The water passes through the screen and is pumped back to the pulping unit. The solids continue up the Helicoid screw to a compression chamber or plug area where additional water is removed by extrusion. The solids in this area are called the plug. This plug is broken up at the Hydra-Extractor discharge opening by a cutter and the pulp then falls out of the discharge chute. This system is capable of reducing the volume of average non-compacted waste by approximately 80 percent.

TYPICAL HYDRA-EXTRACTOR The system is powered by electric motors with the associated controls housed in Som-A-Trols (electric control panels). Since, in the course of operation, some water is absorbed by the pulp, fresh make-up water is supplied to the Pulper automatically through a solenoid valve which responds to a PLC. In addition to the basic system as discussed to this point, numerous additional items of equipment may or may not be required to comprise a specific system. You are provided with Installation Drawings contained within your Installation Package. These drawings show the equipment comprising your system.

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UNPACKING

The crate containing your SOMAT equipment will contain the following items: Pulper W/Slurry Pump Hydra-Extractor w/return pump Tray, if so equipped Discharge chute w/hardware Pulper Som-A-Trol Panel Hydra-Extractor Som-A-Trol panel Pulper return line piping assembly Hydra-Extractor return pump piping assembly Pulper slurry pump piping assembly Misc. parts box containing: ALL UNITS: Mounting Pads Installation Drawings UDT UNITS ONLY: Stainless Steel Lid Stainless Steel Cone Adaptor Rubber Gasket TRAY ONLY: Gasket & Hardware TROUGH ONLY: Gasket & Hardware Trough Nozzles & Throttling Valves (See Installation Drawing for quantity) OPTIONAL EQUIPMENT: Remote Push Button Station Trough Magnet & Hardware Feed hood Stainless steel angular stand w/hardware Weather seals Through-wall extractor chute

The crate containing your SOMAT equipment will contain the following items:

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Disposer W/Slurry Pump Hydra-Extractor Disposer Som-A-Trol Panel Tubular aluminum stand w/return pump Disposer return line piping assembly Discharge chute w/hardware Disposer slurry pump piping assembly Hydra-Extractor Som-A-Trol panel Hydra-Extractor return pump piping assembly Misc. parts box containing: ALL UNITS: Anti-Vibration Pads Installation Drawings 18” Disposer bowl Connector Sleeve Stainless Steel Clamps OPTIONAL EQUIPMENT: Remote Push Button Station

PULPER INSTALLATION

NOTE: BE SURE TO MATCH SERIAL NUMBERS AS LISTED ON PRINTS TO PROPER LOCATION.

HIGH TANK MODELS: 1) Put the Pulper into position as shown on the Installation Drawings.

2) Place the Mounting Pads under each leg of the Pulper.

3) TROUGH FEED UNITS ONLY - Install the provided gasket between the Pulper's inlet and the trough outlet and secure with the provided hardware.

4) TRAY FEED UNITS ONLY - Install the tray to the Pulper (if it was not already installed at the

factory) using the provided gasket material and hardware.

UDT MODELS: 1) Cut a hole in the top of the table as shown in the Installation Drawing using the following

diameter: SP-60S Pulper – 18.5" Diameter hole

2) Center the provided UDT Cone beneath the opening and weld it into place as shown per drawings.

3) Put the Pulper into position.

4) Place the mounting pads under each leg of the Pulper.

5) Install the rubber gasket onto the Pulper tank and around the outside of the adaptor cone as shown per drawings.

6) Adjust the Pulper legs so that the rubber gasket provides a water tight seal.

7) Install the provided gasket between the Pulper's inlet and the trough outlet and secure with the provided hardware.

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DISPOSER INSTALLATION

NOTE: BE SURE TO MATCH SERIAL NUMBERS AS LISTED ON PRINTS TO PROPER

LOCATION. DISPOSER MODELS: 1) Put the Disposer into position as shown on the Installation Drawings. 2) Place the Anti-Vibration Pads under each leg of the pump stand.

HYDRA-EXTRACTOR INSTALLATION

1) If so equipped, attach stainless steel angular stand to assembled Hydra-Extractor using provided

9/16" bolts. 2) Move the assembled Hydra-Extractor into position as shown on the Installation drawings. 3) Install vibration pads under foot pads. 4) Install discharge chute and optional weather seal. 5) Secure Hydra-Extractor to finished floor. MOUNTING OF THE GRABBER MAGNETS:

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Preferred: Locate per detail below and weld into place. Optional: Drill four 7/32” diameter holes into the trough as shown below. Seal the heads of

the provided screws with silicone and attach the magnet.

RECOMMENDED POSITION OF THE GRABBER MAGNETS

EXAMPLE PULPER FLANGE DETAIL

PIPING INSTALLATION

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*NOTE: In Massachusetts, the Public Water Supplier shall be contaced regarding the proper backflow prevention device to be installed. *

1) ALL INTERCONNECTING PIPING, FRESH WATER LINES AND DRAIN LINES NOT SUPPLIED BY SOMAT. 2) PIPE SIZES TO BE IN ACCORDANCE WITH SOMAT RECOMMENDATIONS. 3) SLURRY AND RETURN WATER PIPING TO BE TYPE L COPPER. SCHEDULE 40 GALVANIZED OR EQUAL (PVC PIPING NOT ACCEPTABLE). 4) SLURRY LINES MUST NOT INCLUDE ANY VALVING EXCEPT THOSE AUTHORIZED BY

SOMAT. 5) ALL FITTINGS MUST BE PRESSURE RATED DRAINAGE TYPE (SEE BELOW) AND KEPT

TO A MINIMUM. MAXIMUM TURNS ALLOWED 10 PER 100 FEET. RECOMMEND USE OF TWO 45°ELBOWS. USE ELBOWS ONLY TO CHANGE DIRECTION. DO NOT OFFSET AROUND BEAMS, COLUMNS, OR OTHER OBSTRUCTIONS.

6) USE 45 DEGREE Y-BRANCHES OR 90 DEGREE LONG TURN T-Y WHERE TWO LINES INTERCONNECT. CONNECTIONS SHOULD NOT BE MADE FROM THE BOTTOM.

7) INSTALL ALL VALVES AND CHECK VALVES HORIZONTALLY. 8) CLEANOUTS REQUIRED IN SLURRY LINES ONLY AND MUST BE INSTALLED AT EVERY

90 DEGREE BEND AND EVERY 60 FEET MAXIMUM IN STRAIGHT PIPE RUNS. USE 45 DEGREE Y-BRANCH AND 90 DEGREE LONG TURN T-Y FOR CLEANOUTS. (ALL CLEANOUTS MUST BE ACCESSIBLE).

9) SOMAT DISPOSERS REQUIRE FLEXIBLE CONNECTORS IN SLURRY AND RETURN LINES ONLY.

10) COMPANION FLANGE, GASKETS, AND HARDWARE NOT SUPPLIED AT PIPE LINE TERMINATIONS.

11) KEEP DRAINS ACCESSIBLE TO UNIT. DO NOT INSTALL DRAINS UNDER SOMAT EQUIPMENT.

12) PIPING MUST BE SUPPORTED AND BRACED INDEPENDENTLY OF SOMAT EQUIPMENT. ALL INTERCONNECTING PIPING MUST BE SUPPORTED SO THAT NO MOVEMENT OCCURS DURING OPERATION. USE UNIONS OR FLANGES FOR FINAL CONNECTIONS.

13) NO EXTERNAL STRAIN TO BE EXERTED ON SOMAT EQUIPMENT. 14) PROTECT ALL SOMAT EQUIPMENT AND PIPING FROM FREEZING AND

CONDENSATION. 15) ALL PIPING TO BE IN ACCORDANCE WITH STATE AND LOCAL PLUMBING CODES. 16) "F" = FURNISHED BY SOMAT/"NF" = NOT FURNISHED BY SOMAT. The following are some suggested forms of pipe bracing for a SOMAT waste handling system. There are many factors involved which require the additional bracing. This system in normal operation is subject to surges from air, water and solids. If the piping is not properly supported and “works” during operation it will only be a matter of time before a failure occurs. If you have any questions or concerns please call Somat Company and speak with the service or engineering departments to get clarification.

1. Support horizontal piping and fittings at sufficiently close intervals to maintain alignment and prevent sagging or grade reversal. Support each length of pipe by an approved hanger located not more than 18 inches from the joint.

2. Support terminal ends of all horizontal runs or branches and each change of direction or alignment with an approved hanger to prevent movement. (see below for examples)

See figure # 1 and # 2 below for fastening to prevent movement when using hanger type supports. These should be installed within 18” inches of each change of direction and every 10’ feet of straight run.

Figure 1 - Horizontal Pipe with Sway Brace (Longitudinal)

Figure 2 - Sway Brace (Traverse) 1Reprinted with permission of the Plumbing & Piping Industry Council, Inc. See figure #3 and #4 for examples of horizontal suspension.

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Figure 3 - Horizontal Pipe Supports

Figure 4 - Horizontal Pipe Supports (continued) FRESH WATER:

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*NOTE: In Massachusetts, the Public Water Supplier shall be contaced regarding the proper backflow prevention device to be installed. * 1) Bring a 1/2" cold water line for the SP-60S, to the pre-piped fresh water assembly. (See

enclosed diagram and Installation Drawings) 2) Bring a 1/2" cold water line for the D5 disposer to the pre-piped fresh water assembly. (See

enclosed diagram and Installation Drawings) 3) Bring a 1/2" hot water line for the Hydra-Extractor to the pre-piped fresh water assembly. (See enclosed Diagram and Installation drawings)

SLURRY AND RETURN PIPING: 1) Install the Pulper slurry pump piping assembly on to the slurry pump. (See Installation

drawing.) 2) Install the Pulper return line piping assembly on to the Pulper tank. (See Installation drawing.)

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RETURN PIPING FOR UNITS WITH A TROUGH:

1) Pipe the trough spreader plate and optional side nozzles and silver saver to the tee in the return line piping assembly as shown in the trough detail on the Installation drawing using the provided throttling valves and trough nozzles.

NOTE: All Pre-Piped Assemblies are hand tightened for shipping purposes only. SILVER SAVER (TROUGH UNITS ONLY, IF EQUIPPED):

1) Connect hose (provided by Somat) with hose clamp to ½” x 1” lg. pipe nipple on silver saver.

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ELECTRICAL INSTALLATION

NOTE: BE SURE TO MATCH SERIAL NUMBERS AS LISTED ON PRINTS TO PROPER LOCATION.

1) PRE-WIRED CONTROL PANELS, OPERATOR DEVICES & ELECTRIC VALVES BY SOMAT. 2) INSTALL A PIECE OF CONDUIT FROM PANEL TO PREWIRED JUNCTION BOX, PULL

MOTOR WIRES AND CONTROL WIRES THRU THIS CONDUIT AND DO THE FINAL HOOKUPS.

2) GROUND ALL ELECTRICAL EQUIPMENT. 3) CONTROL CIRCUIT TO BE 115 VAC AND/OR 24VDC NOMINAL. 4) ALL SOM-A-TROL PANELS ARE TO BE WIRED IN ACCORDANCE TO LOCAL, STATE

AND/OR NATIONAL ELECTRIC CODE (NEC 1993) SPECIFICATIONS. 5) REMOTE PUSH BUTTON STATION TO BE MOUNTED & WIRED AT WORK STATION BY

CUSTOMER. (BRACKET REQUIRED BY CUSTOMER) OPTIONAL INTEGRAL PUSH BUTTONS ARE LOCATED IN PANEL DOOR AND PRE-WIRED AT FACTORY.

6) THE PUSH BUTTON STATION HOUSES TWO (2) ILLUMINATED PUSH BUTTONS, INDICATED WITH THE LETTERS "A" AND "B".

PANEL & OPTIONAL REMOTE PBS MOUNTING: 1) Mount both the Pulper and Hydra-Extractor Som-A-Trol in a suitable location (see Diagram and

Installation drawings) so that the bottom of the panel is at least 48" above the finished floor. 2) Install the Optional Remote Push Button Station onto the Dish Table or at another convenient location. (See Diagram and Installation Drawings.)

MOUNTING PATTERN FOR SOM-A-TROL PANELS AND THREE PUSH BUTTON STATION

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SUPPLYING THE SOM-A-TROL WITH POWER

Bring the (4 wire) customer power supply to the top right side of the Som-A-Trol and connect to the panel disconnect and ground lug. (See Diagram and Installation Drawings.)

All remote systems are prewired, there is a prewired junction box mounted to the side of the

extractor shell. Inside this prewired junction box there will be terminals that are the same as in the panel. Install conduits from the panel to the pre-wire junction box, pull the motor wires and control wires thru these conduits separately and do your final wire terminations matching numbers from panel to pre-wire junction box.

PUSH BUTTON STATION Mount the push button station, run the conduit from push button station to prewired junction

box, then pull the wires from push button station to prewired junction box and do your final hookups in the prewired junction box.

INTERCONNECTING WIRES On the remote system there are interconnecting wires that go from the extractor panel to the

pulper panel. To install run a piece of conduit between the extractor panel and pulper panel. Pull control wires thru from extractor panel to pulper panel and install the wires to the terminals which have the same numbers in both panels.

WARNING: Improper connection of the equipment grounding conductor can result in a risk of electrical

shock. An equipment grounding conductor must be run with the circuit conductors and connected to the pulper/extractor grounding terminal.

TYPICAL FOR REFERENCE ONLY

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TYPICAL FOR REFERENCE ONLY

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