Qe Gcp-Gce-Gcpc-Gcec-Gcv-Tsf1 - M-A1-0916-En PDF

EN
ELECTRICAL
PANELS
GCP/GCE/
GCPC/GCEC/
GCV/TSF1
2 ASSEMBLY AND
MAIN INSTRUCTIONS
FOR USE AND
MAINTENANCE
Manual No. QE.GCP/GCE/GCPC/GCEC/GCV/TSF1--.M.EN.

Issue: A1 Latest update: September 2016
ORIGINAL INSTRUCTIONS IN ENGLISH
WAMGROUP S.p.A. + 39 / 0535 / 618111

Via Cavour, 338 fax + 39 / 0535 / 618226
41030 Ponte Motta e-mail info@wamgroup.com
Cavezzo (MO) - ITALY internet www.wamgroup.com
All the products described in this catalogue are manufactured according to WAMGROUP S.p.A. Quality System procedures.
The Company’s Quality System, certified in July 1994 according to International Standards UNI EN ISO 9002 and extended to
the latest release of UNI EN ISO 9001, ensures that the entire production process, starting from the processing of the order to the
technical service after delivery, is carried out in a controlled manner that guarantees the quality standard of the product.
This publication cancels and replaces any previous edition and revision.
We reserve the right to implement modifications without notice.
This catalogue cannot be reproduced, even partially, without prior written consent by the Manufacturer.
QE 09.16
INDEX
2
QE.GCP/GCE/GCPC/GCEC/GCV/TSF1--.M.EN. Issue: A1
TABLE OF CONTENTS
1.0 INTRODUCTION.......................................................................................................................................1
1.1 Disclaimers.........................................................................................................................................1
1.2 Symbols: meaning and use................................................................................................................1
1.3 General features................................................................................................................................2
1.4 Lifting and shipment...........................................................................................................................3
1.5 Shipping, storage and dismantling.....................................................................................................3
2.0 INSTALLATION........................................................................................................................................4
2.1 Safety distances.................................................................................................................................7
2.2 Emergency stop ...............................................................................................................................7
2.3 Protection degree...............................................................................................................................9
2.4 Safety switches..................................................................................................................................9
2.5 Technical data..................................................................................................................................10
3.0 COMMISSIONING.................................................................................................................................. 11
4.0 USE AND SETTINGS.............................................................................................................................12
4.1 Use and settings..............................................................................................................................12
4.2 Manual cycle....................................................................................................................................16
4.3 Automatic cycle................................................................................................................................17
4.4 Alerts................................................................................................................................................19
4.5 Led panel indicators.........................................................................................................................22
5.0 MAINTENANCE......................................................................................................................................23
5.1 Qualification of the employees.........................................................................................................24
5.2 Trouble-shooting............................................................................................................................. 25
6.0 MAINTENANCE REGISTER...................................................................................................................32
A ATTACHMENTS......................................................................................................................................33
A1 Electric layout...................................................................................................................................33
A2 Declaration of conformity................................................................................................................ 116
III
QE 09.16
1.0 INTRODUCTION
2
1.1 Disclaimers
WAMGROUP S.p.A.cannot be held responsible in case of:

- Negligent handling of the low the voltage panels and non-compliance to the safety standards and wrong
processing.
- Lack of maintenance, non-compliance to the herein indicated Directives or improper repairs carried out with
improper tools by.
- Any type of damage incurred during shipping.
- Improper use.
- Modifications to the low voltage control panels carried out by unauthorized, non trained personnel.
1.2 Symbols: meaning and use
This manual contains symbols meant to recall the user's attention as regards the safety regulations in force
and maintenance operations. Meaning of he symbols:
Danger - Warning
This symbol is used in the safety warnings or instructions, or in any case when there is a potential
hazard likely to cause injury.
Caution
This symbol is used for safety-related warnings or precautions meant to prevent damage to the control
panel or other important messages to the operator.
Important
This symbol is used in safety-related warnings and compels the user to carefully read this manual.
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1.0 INTRODUCTION
2
1.3 General features
The electrical panel is intended for use by properly trained personnel: the installation must be designed and
carried out only by qualified technicians.
Caution
Inaccurate installation or use can cause serious damage to the electrical panel, to the user and to the
persons involved.
Please be reminded that the regulations in force in the country of installation are compulsory; in case of several
legal indications, always refer to the more binding requirements.
The product has been designed and manufactured in compliance with safety regulations, for use in ordinary,
unclassified environments.
To avoid damage to property and persons, it is recommended to use all the necessary precautions and adhere
to the highest professional standards.
The dimensions of the panel for the estimation of the thermal power loss have been calculated assuming there
are no other heat sources nearby.
If installed in a space where other panels have been installed, ensure a sufficient distance that allows heat
dissipation.
The control panel has to be used only for the intended purpose, all other uses are considered improper and
therefore dangerous.
Caution
The manual shall be kept in a place accessible to operators and it has to be well preserved.
Before operating or carrying out maintenance operations on the machine, the operator shall carefully read
the manual, paying attention to the messages highlighted by the danger warning symbol: these contains the
instructions necessary for a correct use of the machine in maximum safety conditions.
Moreover, this allows verifying the regularity and frequency of the checkings carried out.
Caution
The manufacturer is not liable for the improper functioning of the panel or any damage caused by it,
in case it is tampered with, modified, if operated improperly or inconsistently with other provisions
contained by the present manual.
The Manufacturer shall not be held responsible for possible inaccuracies contained in this instruction manual,
if due to printing or transcription errors. The Manufacturer reserves the right to bring necessary or useful modi-
fications to the product, without affecting its basic features.
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1.0 INTRODUCTION
2
1.4 Lifting and shipment
Avoid shocks and tilting the control panel.

Observe safety distances from the lifting mean.
Prevent the presence of persons under suspended loads or within the operation area of the lifting equipment
used.
Keep the load as low as possible to ensure stability and greater visibility for the operator.
On using the lifting means (hooks, ropes, bands, etc..) ensure they are in good condition and suit the safety
regulations in force.
1.5 Shipping, storage and dismantling
On storing, do not stack other items on top of the device, to avoid damaging it as well as the risk of accidental
falls.
Ensure the integrity of mechanical and electrical engineering parts of the control panel during shipping.
The weight and overall dimensions are indicated on the ID plate of the panel and inside the documentation
enclosed to it.
On receiving the control panel, carry out a visual inspection to ensure no damages have occurred during ship-
ping and that the data on the plate correspond to those present on the acknowledgement of order.
If the panel is not to be immediately installed but it has to be stored, take the necessary some precautions not
to damage the outer casing and the internal electrical components.
Caution
Store the panel packed, indoor, covered and protected from atmospheric agents and animals; the rec-
ommended moisture level should be between 30 and 75% and the temperature between - 25 °C and +
55 °C.
Caution
At the end of it life or in the case of demolition, the device shall be disposed of according to the laws
in force in the country of destination.
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2.0 INSTALLATION
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Danger - Warning
It is forbidden carrying out commissioning, maintenance operations, repairs or modifications unless
entrusted to specialized personnel, under precise instructions.
It is recommended to verify the integrity of the control panel during unpacking; do not use it in case of any
doubts.
Before starting the installation make sure the following piece of information were checked and followed:
a) All installation operations are carried out by qualified personnel and the safety standards of the country of
installation were observed;
b) Make sure that the data contained on the ID plate placed on the panel match to the plant to which it is inte-
grated; check the power, voltage, current and frequency;
c) For the electrical connection follow the wiring diagram;
d) Check and provide the recommended cross section values of the power supply lines;
e) Make sure the earthing is always connected to the distribution system and consistent with the regulations
in force in the country of use;
f) Make sure that the cables are correctly connected the auxiliary circuit; check the proper connection of the
phase conductors and of the neutral;
g) Proper wiring of the buttons /emergency buttons.
The emergency stop push-

buttons, type XALK 188F
Schneider Electric, preassem-
bled, must be wired in series
to the NC contact line, and
they must provide a cable that
passes through all the boxes of
the push-buttons and the mov-
able gates, having two separate
lines to the connections line and
two conductors for the return
from the last device towards
the QE.
Provide therefore two lines of NC contacts. The first line represents the 24Vdc chain that carries the enabling
signal to the PLC. The second line represents the 24Vac chain that carries the enabling signal to the PLC.
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2.0 INSTALLATION
2
SAFETY CHANNEL 24VDC

FOR PLC SIGNALLING.
SAFETY CHANNEL 24VAC

FOR COIL DETACHMENT IN
CASE OF EMERGENCY
Sample wiring of the two channels AC (red) and DC (BLUE)

The two safety channels will therefore be wired in compliance with the two separate streams, paying atten-
tion to the type of line under consideration; only the 24Vac line must connect the NC contacts to the Thermal
protections:
+24 V DC
+24 V AC
SHARED +24 V AC
Push- PLC OUTPUTS
button
Push-
button
Thermal
Gates
Mobile
REMOTE
Thermal
CONTROL
SWITCH
Gates
Mobile
Ref Vac
INPUTS
PLC I4 I6 I7
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2.0 INSTALLATION
2
Wiring example of the first 24VDC channel

at the contact of the emergency stop push-
button.
Wiring example of the second 24VDC

channel at the contact of the emergency
stop push-button.
Caution
A wrong or missing connection of the neutral conductor can cause serious damage to the control
panel and to the distribution installations connected.
Danger - Warning
Prior to use, check the direction of rotation of all equipments and ensure the safety of personnel dur-
ing the examination.
Install the control panel on the basis of the protection degree; it is recommended to use cable having the same
features in order to avoid a downgrading of the protection.
Danger - Warning
The control panels must be perfectly installed; any flow, modification made to the initial project, the
intervention of external agents such as plants, animals, dust, mould or so must be removed; then re-
stored to the default values.
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2.0 INSTALLATION
2
2.1 Safety distances
Danger - Warning
The control panel shall be placed at a safe distance from sources of heat, fuel depots, from flammable
materials, chemicals.
In order to limit potentially dangerous situations, isolate the area surrounding the control panel and
preclude the possibility that unauthorized persons approaches the area.
Although the devices are manufactured in compliance with the regulations on electromagnetic com-
patibility, it is recommended to NOT install the panel near equipments which represent a sources of
emissions.
Particular attention must be paid during assembly phase of the control panel to avoid the falling external ele-
ments, such as metal shavings or other materials that could damage or block the movement of the electric
components.
Danger - Warning
An incorrect installation and electrical connection can cause serious damage to persons, the device,
the electrical installations and to the plant.
Important
The installer must issue a declaration of conformity regarding the installation of the control panel at
the end of the installation operations.
2.2 Emergency stop
Important
The control panel (located to the left) must be equipped with suitable red mushroom-shaped, stay-put
Emergency button to enable the shut-down when completely pushed.
The emergency stop has to be used only in case of danger conditions and therefore the machine must be im-
mediately shut down.
Pushing one of the emergency stop buttons causes the hardware cutting of the controls and the flashing of the
red EMERGENCY led.
In case thee is no safety control unit, in order to start back the plant correctly in the automatic mode, it is suf-
ficient to reset the emergency button and press the button to start the cycle.
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2.0 INSTALLATION
2
Operations to be performed in order to start back the plant in case the emergency stop button has
been pressed or the inspection hatch is open(if provided with safety micro) - if the safety unit option is
available.
In order to restore the plant functionality, it is possible to proceed in two different ways:
1) Option:
- Remove power from the control panel via the appropriate switch;
- Eliminate the causes that led to the actuation of the emergency stop button;
- Reset the emergency push down or close inspection hatch;
- Supply power to the control panel via the appropriate switch.
2) Option:
A) In case of emergency button pressed:
- Open one of the inspection covers, protected by a safety micro;
- Close the inspection hatch mentioned above;
- Reset the pushed emergency stop button;
- Press again start to reactivate the cycle in automatic mode.
B) In the case of inspection hatch (protected by a safety micro) open:
- By pressing one of the emergency buttons;
- Close the inspection hatch which has caused the alarm;
- Reset the pushed emergency stop button;
- Press again start to reactivate the cycle in automatic mode.
Operations to be performed in order to start back the plant in case the emergency stop button has been
pressed or the inspection hatch is open (if provided with safety micro) - if the safety unit option is not available.
The absence of the option safety controller involves the automatic start-up of the machine once restored this'
that has resulted in the state of alarm: the emergency button pressed or opening of the micro contact for the
closing of the inspection hatches).
N.B.: In order to avoid a restart in automatic mode, after having restored the cause of alarms, proceed ad fol-
lows:
- Disconnect the electrical panel using the disconnecter before restoring the fault.
- Place the selector switch to manual operation (selector MAN /AUTO positioned on MAN), before re-
storing the fault.
Caution
Evaluate if further emergency buttons are required near the utilities.
It is recommended to include at least one emergency stop button with safety key to be used during machine
maintenance.
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2.0 INSTALLATION
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2.3 Protection degree
In order to protect the control panel from indirect contact, overload and short circuit, it is the responsibility of
the installer to provide a protection device upstream the line, having the features and values suitable to the
installation point.
In order for the properly sizing of the protection device to check the value expressed in kA found in the docu-
mentation of the framework.
Caution
It is the installer's responsibility to make sure the electrical load connected and the current values do
not exceed the designed value of the control panel
It is recommended to provide the appropriate devices for the protection of circuits fed directly from the line
voltage from overvoltage due to lightning or other particular events.
Important
Never exceed the wires length over 50 m between the control panel and end user.
2.4 Safety switches
Caution
When required by the nature of the equipment connected to the control panel, it is necessary to pro-
vide specific safety switches.
On opening a safety device, all dangerous movements of the equipment need to be stopped and the equip-
ment must be prevented from accidentally getting restarted.
If so, no safety device can be by-passed or tampered with.
Some applications require the movable guards to remain blocked during a hazardous production cycle.
Caution
On choosing the number and features of the switches to be provided (magnetic sensors, mechanical
interlocks, ..) take into account the environment in which the machine operates as the switch have to
ensure an appropriate protection degree (IP).
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2.0 INSTALLATION
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2.5 Technical data
Nominal supply voltage (230/400)V +/- 10%

Phases 3
Frequency: 50/60 Hz
Max. operation nominal output (kW): See ID plate
Max. operation nominal current (A): See ID plate
Protection degree IP65
Danger - Warning
Make sure the micro-switches are correctly positioned and locked.
Check that the electrical drawing regards the components on which the operations are carried out.
Check that the voltage matches the one envisaged for the operation.
Important
Check that the voltage value of the motors stays between ranges +/- 10% of the nominal value.
Check that the movements matches the indications on the related buttons.
Caution
Provide the necessary protection from lightning during operation and the related devices to ground
any electrical discharge.
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3.0 COMMISSIONING
2
Danger - Warning
A wrong or missing connection of the neutral conductor can cause serious damage to the control
panel and to the distribution installations connected.
It is forbidden carrying out commissioning, maintenance operations, repairs or modifications unless
entrusted to specialized personnel, under precise instructions. Always use suitable work clothing for
all operations, that is personal protection devices (shoes, gloves, goggles, etc.) in accordance with
the safety regulations.
Caution
Do not disassemble or force electrical components when the panel is powered.
Danger - Warning
Check the suitability of the supporting plane as well as the support structures on which the control
panel is to be installed.
Check the suitability of manoeuvring space, paths, corridors, passageways and escape routes around
the equipment to avoid situations that could lead to falling hazards.
Important
Checking of the suitability and the proper functioning of the electrical system: supply line, plug, distri-
bution board, safety switches that has to cut off the power short circuit current, section, power, length
of the power supply cable and of the earthing system according to EN 60204 -1.
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4.0 USE AND SETTINGS

2
4.1 Use and settings
Main
Switch
PLC panel
Scada interface
Stop
Start
Auto/Man
4.1.1 START-UP
Start the machine up by means of the main switch, located on the control panel; switch it from position 0 to
position 1 (refer to the safety instructions before performing this operation).
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4.1.2 SETTINGS/ FIRST START-UP

Push SET button on the operator panel to access the menu language setting. In this menu gives access to the
language selection display, to the maintenance menu and also to the machine settings menu. The settings of
the system are responsibility of the installers and they are password protected. To select a language please
push for few seconds the flag of the language you want to select.
On the settings display it is also indicated the version of the software installed.
Only trained personnel authorized by WAM can access the setting menu.
4.1.3 SETTINGS MENU

Push for a few seconds the SETTINGS button to access the settings menu. Insert password (default pass-
word: 9999).
Use the numeric keyboard (push the asterisks up right).
Insert password, push ENT and then OK on the previous display.
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2
The working hours view refers to the electric motors installed on the plant. The maintenance operator can reset
the working hours by pushing on the related digits.
On the same page, the motor maintenance can also be set by setting the remaining working hours countdown
of the related motor on the SET column.
On the next two pages there can be set the delay time of the devices the plant is provided with. The timing
values can be filled in by means of the numeric keyboard. On the first page of the settings menu it is possible
setting the working temperature of the heater.
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Push SAVE button on the last page of the menu to save de modifications.
After saving the panel will restart. Do not unplug the panel during these operations.
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2
4.1.4 INTERNAL PARAMETERS TO BE SET ON ZELIO

On the ZELIO panel, placed inside the control panel, some of the parameters, specifically B 89, B 129, which
are essential to a safe operation of the plant, can be modified upon authorization of the WAM personnel in
charge.
TIMER CODES AVAILABLE ON ZELIO PANEL

B89 - Delay time (during loading) ON screw screen, during measurement of the minimum level (default: 30s).
B129 - Delay time (during loading) during measurement of the maximum level (default: 10s).
B61 - Heater off delay 300S.
4.2 Manual cycle
When the AUTO/MAN switch is positioned to MAN, all components installed can be managed through the
control panel (after the start-up, with no alerts enabled, the panel will show the manual operation view).
4.2.1 ENABLING THE COMPONENTS

Push shortly ON button to enable a component.
The component gets shut down by pushing shortly off.
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4.2.2 CHANGE VIEW

To change the manual commands view of the plant, use the arrows placed on the upper side of the operating
panel (only if there are more pages).
4.2.3 REVERSE MODE

To use the screw screen motor in REVERSE mode, push the REV button for at least 3 seconds while the motor
is shut-down. The REVERSE mode will remain enabled only if the button stays pushed; if the REV button is
released, the motor will shut-down.
4.3 Automatic cycle
For automatic cycle of the equipment position the switch AUTO/MAN on AUTO position. Now, the automatic
mode view is available with cycle stop.
To start-up the plant, if no alerts are enabled, it is necessary for the machine to detect the external consent.
Subsequently, the operator can proceed by pressing the green START CYCLE button. At this point, the RUN-
NING status will be displayed. On each component side there will be displayed the remaining time to the
restart or the running time set.
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When the components are managed in automatic mode, the use can check the maintenance status and select
the language Only trained personnel authorized by WAM can access the maintenance and settings menu.
If the level of the screw screen is lower than the minimum, the plant will go stand by. On reaching a level in be-
tween the minimum and the maximum value (min. lev alert on, during loading or discharging), the entire plant
gets on with the cycle type previously set. To avoid problems in case of abnormalities of the minimum sensor,
there has been provided a delay timer at the start-up and at the shut-down (paragraph 4.1.4).
Once the maximum allowed level has been reached, the machine will work in continuous operation to allow the
emptying of the screen in the shortest possible time.
Refer to paragraph 4.4 in case of alerts enabled.

When the minimum level has been once again reached, the whole plant will start the cycle set. To avoid prob-
lems in case of abnormalities of the minimum sensor, there has been provided a delay timer at the start-up and
at the shut-down (paragraph 4.1.4).
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When the empty tank level has been once again reached, the screw screen and the washings will go into OFF
mode. To avoid problems in case of abnormalities of the minimum sensor, there has been provided a delay
timer at the start-up and at the shut-down (paragraph 4.1.4).
4.4 Alerts
In case of alerts enabled, the control panel view changes from green to red and on the top of the display there
will be given the alert type code. The software allows 7 different alarm views.
The alert banner can be moved on the bottom of the display by means of the arrow placed on the side of the
error message.
4.4.1 EMERGENCY BUTTONS

When this alerts is displayed it means that an emergency button has been pushed. All operators except for
the one in charge with the reactivation of the emergency button are required to keep a safe distance from the
plant If the emergency button remains blocked by means of the special key, refer to the maintenance operator
in charge and ensure no personnel remains in the hazardous area before restoring the normal operation of
the plant.
Only authorized personnel trained for the purpose is allowed to open the control panel, by means of the special
keys. On a visual level on the screen, all functions remain in OFF status.
Only authorized personnel trained for the purpose is allowed to open the control panel, by means of the special
keys.
To restore the functionality of the plant, refer to emergency stop chapter:
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4.4.2 COVERS SENSORS

When this alert is displayed it means that one of the plant guards accompanied by simultaneous sound and
light signals, it means one or more guards are open. Close all guards of the plant and re-start the equipment.
On a visual level on the screen, all functions remain in OFF status.
To restore the functionality of the plant, refer to emergency stop chapter:
4.4.3 MISSING EXTERNAL START-UP ENABLING SIGNAL

When this alerts is displayed it means that plant has not detected the external start-up enabling signal. To start
the plant up the operator is require to provide the external start up enabling signal.
4.4.4 ALERT LEVEL AT THE INLET

When this alert is displayed it means that waste water level is higher the maximum value allowed, and the alert
level has been reached. The cycle must be immediately shut down. Once the normal level has been restored
and no alerts are on, the operation cycle can be restarted.
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4.4.5 UNLOCK SCREW - NUMBER OF RETRIES EXCEEDED

When this alerts is displayed it means that at least 3 unlocking retries have been carried out and none when
good. To avoid damaging the screw or one of the conveying components, it is compulsory to immediately stop
the process. Once the foreign body that blocked the screw has been removed, the normal operation can be
enabled and the material can be discharged.
4.4.6 TEMPERATURE TOO LOW

When this alerts is displayed it means that operating temperature of the heater is lower than the minimum
value allowed (this value can be set by authorized personnel only by means of the settings menu). Proceed
according to the related WAM procedure.
4.4.7 CHECKING THE ELECTRIC MOTORS THERMAL PROTECTION

When this alerts is displayed it means that one or more thermal protection of the plant have tripped. Only
authorized personnel trained for the purpose is allowed to open the control panel, to check the cause of the
problem and re-enable the thermal protection.
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4.4.8 DEFAULT PARAMETERS TABLE
DEFAULT PARAMETERS THAT CAN BE MODIFIED VIA THE PANEL (magelis)

PARAMETER DESCRIPTION STATUS DEFAULT TIME
WASH RUNNING TIME ON 30 s
WASH PAUSE TIME OFF 1800 s
T. ON SCREW SCREEN ON 180 s
T.OFF SCREW SCREEN OFF 1200 s
LEVEL TIME MAX. 180 s
MIN. LEVEL TIME 30 s
DEFAULT PARAMETERS (on zelio)

PARAMETER DESCRIPTION CODE TIMER DEFAULT TIME
Starting time delay of the screw screen on min. level. B89 30 s
Starting time delay of the screw screen on max. level. B129 10 s
Heater off delay B61 300 s
4.5 Led panel indicators
The led panel indicators are placed near the control panel and it indicates the working conditions of the plant
according to the table below.
RED
LIGHT MEAN
GREEN RED FIXED EMERGENCY

GREEN FIXED CYCLE AUTO
GREEN BLINKING POWER ON
BUZZER BLINKING EMERGENCY
BUZZER
XLT
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5.0. MAINTENANCE
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Each control panel require the proper and suitable maintenance to be carried out by specialized personnel
only; this will ensure a constant and proper operation of the plant under due safety conditions .
Danger - Warning
All maintenance operations have to be carried out exclusively by trained, authorized personnel.
All maintenance operations and checkings must be carried out only after the panel has been discon-
nected from the power supply.
Important
For carrying out the operation is necessary to remove the guards; refit the guards in their position
before re-starting the plant.
Disconnect from all power supplies and shut down the plant in case of abnormal working or failure.
Caution
It is forbidden modifying parts of the control panel or changing the position of the mechanical or elec-
trical components.
Failure to follow the given indications could cause a low safety operation conditions of the panel and
the decay of the warranty. The responsibility deriving from any potential intervention will fall on the
executioner as in fact it becomes the manufacturer.
Caution
It is recommended to include at least one emergency stop button with safety key to be used during
machine maintenance.
The objectives the maintenance operators should have are numerous:

● limiting the deterioration of the circuits and equipment;
● preventing work accidents;
● keeping low the costs for accidental failures;
● limiting the number and duration of the interventions;
● perform maintenance by integrating it to the planed maintenance.
To reach all these objectives it is required:
- the presence of the maintenance operation during installation phase;
- scrupulously follow the maintenance-related instructions given by the manufacturers of the various plant
components;
- following the legislation and the safety regulations;
- keeping and organizing an archive containing the maintenance schedules, repairing operations sheets and
keeping constantly updated the maintenance personnel.
A failure is a probabilistic event and, therefore, it cannot be predicted. This statement disagrees with one of the
main purposes of maintenance which represents prevention.
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5.0. MAINTENANCE
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Optimizing prevention is based on having a knowledge of the experimental data measured on plant compo-
nents having similar features.
The prevention is necessary in case components meant to ensure the safety of the operators involved.
It is therefore recommended to register:
1) the specific electrical parameters during normal operation;
2) the electrical parameters measured during abnormal operation;
3) pieces of information provided by the manufacturer and the maintenance rate.
The proper knowledge of the factors previously indicated allow creating a maintenance schedule which re-
duces to minimum the possible hitches, it ensures the necessary plant safety and optimizes the cost/benefits
ratio related to maintenance.
The automatic switches and the main plant devices are supplied by the most qualified manufacturers, which
had their products already tested, to provide the proper operation of the machines during their life time dura-
tion.
5.1 Qualification of the employees
Training the maintenance technicians is fundamental in view of the correct and effective maintenance of the
entire electrical plant and, particularly, of the switches.
The necessary skilfulness and know-how can be reached only by practising along with acquiring the suitable
theoretical knowledge.
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5.0. MAINTENANCE
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5.2 Trouble-shooting
The personnel authorized to intervene in most of failure cases or in those cases not otherwise indicated, is
represented by an expert maintenance operator or authorized and specially trained in regard to mechanical,
electrical and electronic parts.
SCENARIO CAUSES/CONDITION CORRECTIVE ACTIONS

Make sure that the main switch is in the ON position.
The display is off. Verify the presence and condition of the fuses.
Verify the incoming voltage at the electric panel.
The display of the
panel is off, but the light Check the presence of voltage on the display and the
The control panel of the column is green and condition of the fuses.
system is not turned on. blinking.
If there is no voltage, verify the malfunction by con-
sulting the electrical layout.
If electric power is supplied but the display is off,
remove the display and replace it with an already
programmed original spare part.
Verify on the display whether the panel has been set
to manual mode and, if necessary, set it to automatic
mode.
The plant does not start The main start button
Check if the external enabling signal is given
to operate. has been pressed.
When pressed and not operational, it is to be ensured
that emergency stop buttons and safety locks are not
pressed.
Red screen and the
Press the stop button.
message:
MISSING EXTERNAL
No external enabling Start a new discharge cycle, provide the external
START-UP ENABLING
signal and pressed start enabling signal and press the start button.
SIGNAL
button.
The led panel indicators
Ensure that the cycle begins and that the screen
emit a solid red light and
returns to the green background.
the siren sounds.
Ensure that the system is not in a level hysteresis
phase (wait 30 seconds during loading/180 seconds
The sequence of the The start-up - shut-down during discharging).
work phases is uncer- sequence seems to be Check the time set for the hysteresis (refer to the
tain. reversed. manual for the delay time setting).
Check the cycle times (refer to the manual for set-
tings).
25
QE 09.16
5.0. MAINTENANCE
2

Set the electric panel to manual mode and try to op-
erate separately the various motors/solenoid valves
with the manual controls from the display.
Actuate the motors in manual mode: Verify whether
It seems that certain
the devices are actually operated with the correct
The operation of the features of the system
rotational direction.
screw feeders/washes are not active.
is uncertain. If the manually operated device does not activate, it
is necessary to verify the path from the corresponding
output of the PLC to the remote control switch/relay
and to the motor.
If the direction of the rotation is incorrect, simply
reverse the feeding phases.
The minimum, maximum
or alarm thresholds are The system is working properly.
The timers are dis- being exceeded.
played on the panel. Incorrect operation times
The maintenance personnel is to correct the system’s
during loading and dis-
operation times during hysteresis.
charge.
The tank level is below
The system is working properly.
the minimum level.
The system should work in timed mode.
Check on the display whether the system is running a
countdown before reactivation (eventually change the
pause time).
The minimum level is
If it is not performing the reactivation countdown, stop
activated.
the system.
Ensure that there are no obstructions or enabled
alerts.
Restart the system.
The system is running, The system should operate in a continuous cycle.
but none of the screw Stop the system.
The level has exceeded
feeders is operating.
the maximum level or Ensure that there are no obstructions or enabled
the alert level. alerts.
Restart the system.
If the display indicates that the screw screen is ON
but in fact the motor is not running, verify that the cor-
responding remote control switch is active and check
the electrical connections between the control panel
For all tank levels. and the motor.
If the level indicator shows that the level is low (there-
fore the system does not activate the screw screen)
but in fact the level in the tank or channel is higher,
verify the proper operation of the level indicator.
26
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5.0. MAINTENANCE
2

Red screen and the Check the input channel according to the Wam pro-
message: cedures.
The waste water level is ALERT LEVEL AT THE
The system switches to continuous operation.
higher than the maxi- INLET
mum allowed. The led panel indicators
the siren sounds.
The display indicates Verify whether the system is running the turn-off delay
the minimum level or
countdown and, if necessary, reduce the delay time.
the message: TANK
It is set to 30 seconds by default.
EMPTY.
The system continues
to operate, even though Check the display whether the system detected that
the actual level in the the level has dropped. If the level has not dropped,
tank is at a minimum. The system is in an au- check that there are no materials that distort the func-
tomatic RUN mode. tioning of the level indicator.
Check the connections and the functioning of the
level indicator.
Red screen and the There is warning indicating that the heaters operating
message: and the alarm is not of the blocking type.
After a period of about 5 minutes the warning should
The operating tem- disappear; if it does not go out, make sure that the
perature of the heater is
probe is connected.
lower than the minimum TEMPERATURE TOO
value allowed. LOW The maintenance technician that has the password
can disable the rheostats by setting the value of the
ignition temperature to 0, as long as the probe is not
connected.
Ensure that the setting temperature required to start
the heating is higher than the temperature meas-
ured. If necessary, set the parameter correctly (see
manual).
Check on the display of the control panel whether
the measured temperature is consistent. If neces-
sary, check the electrical connections/integrity of the
The tube/screen/dis- thermocouple.
The ambient tempera-
charge heating system Check whether the remote control switches of the
ture is low (T < 5 °C)
does not work. heater power supply can be activated. If neces-
sary, check the connection between the PLC and the
remote control switch (check if the corresponding
output of the PLC is active).
Check the voltage on the corresponding remote con-
trol switch.
Check the connections between the remote control
switch and the resistor.
27
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5.0. MAINTENANCE
2
CAUSES/
SCENARIO CORRECTIVE ACTIONS
CONDITION
Make sure that water is present before the solenoid valves.
Make sure that the system is performing the countdown for the timed
activation of the wash and, if too long, it intervenes on time settings
(see manual).
Ensure that the coil of the solenoid valve is energized.
Ensure that the voltage of the coil matches supply voltage.
The washing The system is
Check the connection between the coil and the control panel.
system is not in an automatic
working. RUN mode. Make sure that the power relay of the coil is energized, check the
proper connection of the relay and the possible malfunction of the
relay contacts.
Make sure that the relevant output of the PLC is energized.
If the coil is energized, the water is present and the washing is not
activated, check the operation of the solenoid valve and replace it, if
necessary.
The display is red
and an error mes- Open the control panel and check which thermal protection intervened.
sage appears.
CHECK THE
If the 60FR10 thermal protection has intervened, make the following
THERMAL MO-
checks to the motor screw screen:
TOR RELAY
Ensure that the setting of the thermal protection absorption is consist-
ent with the absorption of the motor.
Check whether the rotational direction of the motor is correct (if neces-
sary, invert the phases).
Frequent
Ensure that all 3 phases are present on the motor. If necessary, check
interventions
the electrical connections to the remote control switch.
of the mo-
tors’ thermal Ensure that there are no mechanical obstructions that make the motor
protections. The led panel absorb more than expected.
indicators emit a Ensure that there is no actual motor overheating and replace where
solid red light and
appropriate.
the siren sounds.
Reset the thermal protection that intervened.
If the 61FR50 thermal protection has intervened, make the following
checks:
Check the correct connection of heating cables in the appropriate box.
Verify the integrity and proper operation of the heating cables, as de-
scribed by the Wam procedures.
28
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5.0. MAINTENANCE
2
SCE- CAUSES/CONDI-
CORRECTIVE ACTIONS
NARIO TION
Stop the plant.
The Make sure there are no mechanical obstructions, wear or blockages
screw due to which the motor is drawing too much power. If necessary, inter-
screen vene with maintenance according to the manual.
continual-
ly revers- Check whether the “normal” rotational direction of the screw screen is
The system is in correct (if necessary, invert the phases).
es to the
an automatic RUN
rotational Ensure that all three phases reach the motor.
mode.
direction Check the motor absorption with another tool.
and sub-
sequently If the absorption is not greater than the plate absorption, check the set-
goes into ting of the autoreverse parameter in order to release the screw screen
alarm. (may be set too low); increase the value, if necessary.
Restart the system.
Emergency buttons Keep away from the plant all operators who are not in charge with the
pushed. reactivation of the push-button.
An error message
is displayed on the Eliminate all obstacles and solve the problem that prompted an opera-
panel with red back- tor to press the push-button.
ground:
VERIFY THE EMER-
If the emergency stop button remains blocked by means of the special
GENCY STOP BUT-
key, refer to the maintenance operator in charge.
TON.
Ensure no personnel remains in the hazardous area before restoring
the normal operation of the plant.
FOR PLANT WITH NO SAFETY CONTROLLER.
Set to manual the auto/manual selector.
Immedi-
ate inter- Reset the pushed emergency button/s.
ruption of Set to automatic the auto/manual selector.
all system Press start cycle.
functions.
FOR PLANT WITH SAFETY CONTROLLER.
The led panel indica- Open the safety guard (see procedure on Wam manual).
tors emit a solid red
Close the guard.
light and the siren
sounds. Reset the pushed emergency button/s.
Press start cycle.
PLANT WITH SAFETY CONTROLLER IN CASE OF SHUT DOWN
FOR SEVERE REASONS.
Shut down the equipment.
Solve the problem that prompted an operator to press the push-button.
Reset the pushed emergency button/s.
Stop the plant.
Perform the start up procedure.
29
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5.0. MAINTENANCE
2

Emergency covers are
Check the closure of all inspection covers and pro-
open and are not prop-
ceed according to the related WAM procedure.
erly closed.
An error message is
displayed on the panel
with red background:
GUARD EQUIPMENT
OPEN
the siren sounds.
Screw screen propeller At least 3 unlocking retries have been carried out and
jam. none were successful.
An error message is
displayed on the panel
with red background:
UNLOCK SCREW -
In order to unlock the motor, it is necessary to pro-
NUMBER OF RETRIES
ceed according to the related WAM procedure.
EXCEEDED.
the siren sounds.
Intervention of the mo- Open the control panel and check which thermal
Immediate interruption
tors’ thermal protections. protection intervened.
of all system functions.
The display is red and
If the 60FR10 thermal protection has intervened,
an error message ap-
make the following checks to the motor screw screen:
pears.
CHECK THE THERMAL Ensure that the setting of the thermal protection ab-
MOTOR RELAY sorption is consistent with the absorption of the motor.
Check whether the rotational direction of the motor is
correct (if necessary, invert the phases).
Ensure that all 3 phases are present on the motor.
If necessary, check the electrical connections to the
remote control switch.
Ensure that there are no mechanical obstructions that
make the motor absorb more than expected.
The led panel indicators Ensure that there is no actual motor overheating and
emit a solid red light and replace where appropriate.
the siren sounds. Reset the thermal protection that intervened.
If the 61FR50 thermal protection has intervened,
make the following checks:
Check the correct connection of heating cables in the
appropriate box.
Verify the integrity and proper operation of the heat-
ing cables, as described by the Wam procedures.
30
QE 09.16
5.0. MAINTENANCE
2

Provide the start-up enabling signal.
Immediate interruption Missing external start-up Check if the automatic selector is positioned to "auto-
of all system functions. enabling signal. matic".
Press start cycle
Stop the plant and check the fuses.
If the motor dust collector screw has stopped, check
The panel indicates that the 60FU10 fuse.
A motor is not function-
the motor is ON and the
ing. Check the condition of the motors’ connection cables.
panel is green.
Test the motor that did not work in manual mode.
Start the plant in automatic mode.
31
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6.0 MAINTENANCE REGISTER

2
DATE OPERATION TYPE OPERATOR
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A2 Declaration of conformity
The manufacturer:
WAMGROUP S.p.A.
located in
Strada degli Schiocchi, 12 - I-41124 Modena - Italy
under its own responsibility declares that:
the machinery series GCP/GCE/GCPC/GCEC/TSF1 provided with a control panel cod: 044001099
EC DECLARATION OF CONFORMITY OF THE MACHINERY Annex II A 2006/42/CE Directive
EU DECLARATION OF CONFORMITY
complies with the requirements imposed by the following directives:
Directive 2006/42/EC of the European Parliament and the Council of 17 May 2006 on machinery and amending Directive
95/16/EC;
Directive 2014/30/EU of the European Parliament and the Council of 26 February 2014 on the harmonisation of the laws of
the Member States relating to electromagnetic compatibility;
Directive 2014/35/EU of the European Parliament and the Council of 26 February 2014 on the harmonisation of the laws of
the Member States relating to the making available on the market of electrical equipment designed for use within certain voltage
limits.
Harmonized standards, national standards and technical regulations in question:

UNI EN ISO 12100: 2010 ; CEI EN 60204 – 1
The signing company is committed to provide, in response to a reasoned request by national authorities, relevant informa-
tion on products covered by this declaration, without prejudice to the rights of intellectual property of the manufacturer. The
information will be transmitted directly to the national authorities having requested.
Strada degli Schiocchi, 12 - I-41124 Modena - Italy, July 1st 2016
The person authorized to provide The legal representative:

the technical documentation:
Vainer Marchesini Vainer Marchesini
WAMGROUP S.p.A. - Strada degli Schiocchi, 12 - I-41124 Modena - Italy
116

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EN

Manual No. QE.GCP/GCE/GCPC/GCEC/GCV/TSF1--.M.EN.

WAMGROUP S.p.A. + 39 / 0535 / 618111

WAMGROUP S.p.A.cannot be held responsible in case of:

1.2 Symbols: meaning and use

1.3 General features

1.4 Lifting and shipment

Avoid shocks and tilting the control panel.

1.5 Shipping, storage and dismantling

The emergency stop push-

SAFETY CHANNEL 24VDC

SAFETY CHANNEL 24VAC

Sample wiring of the two channels AC (red) and DC (BLUE)

Wiring example of the first 24VDC channel

Wiring example of the second 24VDC

2.1 Safety distances

2.2 Emergency stop

2.3 Protection degree

2.4 Safety switches

2.5 Technical data

Nominal supply voltage (230/400)V +/- 10%

4.0 USE AND SETTINGS

4.1 Use and settings

4.0 USE AND SETTINGS

4.1.2 SETTINGS/ FIRST START-UP

4.1.3 SETTINGS MENU

Use the numeric keyboard (push the asterisks up right).

Insert password, push ENT and then OK on the previous display.

4.0 USE AND SETTINGS

4.0 USE AND SETTINGS

4.0 USE AND SETTINGS

4.1.4 INTERNAL PARAMETERS TO BE SET ON ZELIO

TIMER CODES AVAILABLE ON ZELIO PANEL

4.2 Manual cycle

4.2.1 ENABLING THE COMPONENTS

The component gets shut down by pushing shortly off.

4.0 USE AND SETTINGS

4.2.2 CHANGE VIEW

4.2.3 REVERSE MODE

4.3 Automatic cycle

4.0 USE AND SETTINGS

Refer to paragraph 4.4 in case of alerts enabled.

4.0 USE AND SETTINGS

4.4.1 EMERGENCY BUTTONS

4.0 USE AND SETTINGS

4.4.2 COVERS SENSORS

4.4.3 MISSING EXTERNAL START-UP ENABLING SIGNAL

4.4.4 ALERT LEVEL AT THE INLET

4.0 USE AND SETTINGS

4.4.5 UNLOCK SCREW - NUMBER OF RETRIES EXCEEDED

4.4.6 TEMPERATURE TOO LOW

4.4.7 CHECKING THE ELECTRIC MOTORS THERMAL PROTECTION

4.0 USE AND SETTINGS

4.4.8 DEFAULT PARAMETERS TABLE

DEFAULT PARAMETERS THAT CAN BE MODIFIED VIA THE PANEL (magelis)

DEFAULT PARAMETERS (on zelio)

4.5 Led panel indicators

GREEN RED FIXED EMERGENCY

The objectives the maintenance operators should have are numerous:

5.1 Qualification of the employees

SCENARIO CAUSES/CONDITION CORRECTIVE ACTIONS

SCENARIO CAUSES/CONDITION CORRECTIVE ACTIONS

SCENARIO CAUSES/CONDITION CORRECTIVE ACTIONS