In Vessel Composter Installation & Commissioning Manual

In Vessel Composter Installation & Commissioning Manual

Contents Customer responsibilities Transportation Lifting Delivery Pre-installation requirements Installation Drainage Ventilation Levelling Unpacking Electrical Supply Check list Commissioning Technical data Start up procedures

Customer Responsibilities It is the responsibility of the customer to ensure that the IVC is located in an area where it will not create a hazard to users or passers-by and where it will satisfy any legislative requirements. The customer should also ensure that the food waste can be transported efficiently from its place of origin to the site of the IVC.

Transportation The IVC can only be moved when it is empty. Any food waste or compost contained in the cylinder should first be removed prior to moving. The IVC is delivered with packaging suitable only to protect the IVC from the weather in instances where it is transported uncovered. Particular care should be taken to ensure any connection to the IVC is secure prior to movement. The IVC should be kept as close to the ground as possible during any movement. Lifting The provision of specialist equipment should be made available by the customer to facilitate movement of each IVC as follows:- Model IVC2700 use a pallet truck Model IVC4100 use a forklift truck Model IVC7000 use a forklift truck fitted with forks at least 1.5 metres long The IVC is heavier at the front end ie at the end with the infeed hopper. The centre of gravity point is clearly marked on the frame of the IVC. Delivery The IVC is delivered direct to the site main entrance and will be unloaded by IMC and its representatives. Unless formerly agreed in writing with IMC, the customer is responsible for manoeuvring the IVC into the designated area for installation or to a storage location. Prior to installation, the IVC should be kept in its packaging. IMC can not be held responsible for any damage to the IVC following delivery to site. A Condition Report should be signed by the customer to signify safe receipt of the IVC. The Control Box and any ancillary equipment will be delivered separately by IMC. The customer will be expected to sign a delivery card to confirm safe receipt of goods.

Pre-installation requirements It is the responsibility of the site to ensure that, during storage, the IVC is protected from the weather and to have made suitable preparations for the installation of the IVC; instructions are provided by IMC following the completion of the site survey. These may include any of the following:- Installation of a drain from the IVC (in-feed hopper) to the site s existing foul drain. Installation of any additional IVC venting pipework. Connection of the IVC mains power cable to a 16 amp isolator supplied by the site and installation of any other site electrics. Protection of the IVC from the weather. The flooring on which the IVC is located should be easily washable with easy access to a water supply and efficient dispersal to drain. IMC will provide guidance.

Installation WARNING: The IVC should only be installed by qualified IMC staff members or its approved agents and representatives. Installation of the IVC to mains services brought to within 1 metre will be charged by IMC at the rate published. (Please refer to Installation and Commissioning Service Information Sheet). The price excludes any additional works required to effect installation which will be subject to a site survey and detailed in the Quotation provided. This includes, but is not limited to, the provision of mains services to the place of installation, any additional materials and works required to effect drainage and venting of the IVC. Costs quoted assume that delivery and installation will be effected on the same day, Mon to Fri, 9am to 5pm with ground floor, unrestricted access.. Where installation is to be carried out outside these hours and/or on a separate day this will incur additional charge(s) to be quoted. IMC shall not be held responsible for installations undertaken by the customer or its approved subcontractors or end user. Any installations not carried out by IMC will invalidate the warranty. IMC shall not be held responsible for any injury or damage caused during the delivery and installation of the IVC.

Drainage The drain from the in-feed hopper is supplied with a 50mm diameter pipe which should be connected to the site s main drainage. Ventilation The composting process requires the efficient supply and extraction of air from the drum. Upon extraction the air is vented either to the foul drain or to the open air above. Venting to air Exhaust air is led from the fan by a 110 mm pipe, the total length of which should not exceed 10 metres with a maximum of four 90 degree angles from the fan to the outlet. More angles or a longer pipe may compromise the efficiency of the composting process. The outlet should be fitted with a tapered vented cap on top of the pipe and should be set at a level above the roof, or at least 900mm above a window, of the building in which the IVC is housed to ensure that any smells are dispersed by the wind. Venting to drain A push fit 110 mm soil pipe should be connected to the exit on the fan at the top of the IVC and terminated at the chosen drain. Compost outlet chute The plastic sock attached to the outlet chute should be secured at all times in order to ensure the correct air pressure and, by preventing the ingress of cold air, maintain temperatures in the IVC.

Levelling Please note the lifting requirements specified:- Any movement of the IVC should be made only when there is a minimum of 2 people present. Before placing the IVC on the ground ensure that the black plastic feet covers have been fitted. Use a tape measure to check that these are set at the same level. Use a spirit level to check that the IVC frame is true and not out of alignment and that it does not tilt from one end to the other. Unpacking Please note the unpacking requirements specified:- Remove the packaging one side at a time, ensuring sufficient clearance space at each side. Dispose of the packaging responsibly. Remove and retain the parts that are stored in the hopper for transportation purposes.

Electrical supply Prior to connection for the first time, the details shown on the rating plate fitted to the IVC should be examined to ensure that the specification shown is correct for the supply available. Any changes to the supply or new mains runs should be carried out by a qualified electrician and in accordance with the IEE Codes of Practice. The IVC should be connected to a 30A isolator providing at least 3 mm separation in all poles and fused at 6A. The supply to the IVC must also be protected by a 30A RCD (Residual Current Device). The 5-wire mains lead that is fitted to the IVC is the minimum required for individual connection to the mains supply. All wires should be connected as wire No.5 is used to power the single phase functions of the control system. The table below shows the wire colours in the mains lead. Colour Description Wire identification Green & Yellow Earth 106 Brown Phase 1 (Live 1) 102 Black Phase 2 (Live 2) 104 Grey Phase 3 (Live 3) 105 Blue Neutral 103

Check list Check that the following items are present:- Control Box Key x 1 Drum Inspection Door Key x 1 per door

Commissioning Following installation and prior to staff training and initial operation of the IVC, IMC will commission the equipment and make the following checks:- Electrical supply Correct (30 amp) isolator supply is installed. Motor gearbox (main cylinder) The drum rotates correctly in both clockwise and anti-clockwise directions and the motor gearbox runs with no faults. Motor gearbox (in-feed hopper) The auger rotates in both clockwise and anticlockwise directions and the motor gearbox runs with no faults. Inspection door and in-feed hopper interlocks All interlocks are present and operate correctly. Warning lights The Traffic Light Warning System beacon is fitted and all lights operate correctly. Fan The fan speed control operates correctly - by increasing and decreasing the speed setting. Temperature sensors The sensors are all present and operate correctly. Air heater The heater is in the correct position and operates correctly.

Heat blanket (standard on IVC7000, optional on other models) The blanket operates correctly. Emergency Stop Is present and operates correctly. External connections Vent pipe work is correctly fitted and has no leaks. The air filter is correctly fitted and in working order. External wiring is correctly connected to the mains supply and is in good condition. Control box cables are fitted to the correct sockets. Compost outlet chute and sock are present and free from any obstructions. Overloads All overloads are set to auto and are at the correct amp settings. Control Display Panel The panel is easily visible and functions correctly. Controls & programming All controls have been tested and operate correctly. Data logging The temperature and operational recording software functions correctly. Password protection The Control Panel operates only after keying in the correct Service Code.

Staff training Upon commissioning of the IVC, IMC will conduct free of charge training of any staff members that are expected to operate the equipment. A follow-up visit will be made free of charge one month after commissioning to check that staff members are operating the equipment correctly and to ensure that the IVC s biological process is operating effectively. Any subsequent training requested by the customer or identified by IMC as essential for the correct operation of the equipment will be charged at IMC s published rate. (Please refer to Quarterly Site Support Programme Information Sheet & Order Form). Staff successfully completing their training will receive a Certificate from IMC to confirm their understanding of how to operate and manage the equipment.

IVC Start-up Procedures Once your IVC has been commissioned and you have received full training from IMC on how to operate the IVC, it is important to feed the machine gradually over a period of approx 12 weeks in order to build up the biological process in the drum. During this period, IMC will provide guidance over the phone or by email and will visit you around 4 weeks after the start-up process has commenced to ensure it is progressing correctly. Temperature Logging The temperature recording data should be emailed to IMC every week in order that any potential issues can be identified more readily and advice of remedial action given quickly. Operating Guidelines The enclosed Start-up Procedure Form provides you with the necessary instructions on how to establish and maintain the biological process in the drum over the initial 12 weeks of operation.

These instructions enable you to take control of the following key settings:- Amount of dewatered food waste that should be emptied into the IVC every day expressed as weight in kgs. Amount of wood pellets, ie carbon, that should be emptied into the IVC every day expressed as weight in kgs. Frequency of drum rotation expressed as dwell time in hours. Duration of drum rotation expressed as drum churn time in minutes. Speed of fan rotation expressed as a % of its maximum capacity. Frequency of drum unload* expressed as a ratio to the frequency of filling. Duration of auger rotation expressed as auger run time in minutes. *Please note that until the drum is approx 60% full, which would usually be achieved half way into the biological set-up schedule, the IVC is unlikely to discharge its contents on the unload cycle.

It is recommended that you also use the Form on which to manually record the weight of dewatered food waste and wood pellets that is emptied into the IVC every day. House-keeping Good house-keeping plays an important role in maximising the efficiency of the IVC. Every day, the hopper and auger screw should be cleaned using warm, soapy water and the hopper drainage filter removed and cleaned. Full instructions on these two procedures can be found in the Training Guide.

IMC 2700 IN VESSEL COMPOSTER START UP PROCEDURE Start up period Daily Checks ( ) Setup Week No Start date 1 20 4 1 min 20 1:5 8 2 20 4 1 min 20 1:5 8 2 20 4 1 min 20 1:5 4 2 20 4 1 min 20 1:5 4 2 20 4 1 min 20 1:5 2 2 20 4 1 min 20 1:5 2 2 20 4 1 min 20 1:5 2 2 2 3 4 5 6 Target Dewatered Food Waste (kg) Target Carbon Pellets (kg) Weight of food added Clean both auger & hopper Remove fan filter & clean Drum churn Fan speed (%) Unload ratio Dwell time (hrs) Continued Auger run

Start up period Daily Checks ( ) Setup Week No Start date Target Dewatered Food Waste (kg) Target Carbon Pellets (kg) Weight of food added Clean both auger & hopper Remove fan filter & clean Drum churn Fan speed (%) Unload ratio Dwell time (hrs) Auger run 7 8 9 10 11 12 First Quarterly Site Support Visit by IMC (if Support Programme has been purchased)

IMC 4100 IN VESSEL COMPOSTER START UP PROCEDURE Start up period Daily Checks ( ) Setup Week No Start date 1 20 4 1 min 20 1:5 8 2 20 4 1 min 20 1:5 8 2 20 4 1 min 20 1:5 4 2 20 4 1 min 20 1:5 4 2 20 4 1 min 20 1:5 2 2 20 4 1 min 20 1:5 2 2 20 4 1 min 20 1:5 2 2 2 3 4 5 6 35 7 1 min 20 1:4 2 2 35 7 1 min 20 1:4 2 2 35 7 1 min 20 1:4 2 2 35 7 1 min 20 1:4 2 2 35 7 1 min 20 1:4 2 2 35 7 1 min 20 1:4 2 2 35 7 1 min 20 1:4 2 2 Target Dewatered Food Waste (kg) Target Carbon Pellets (kg) Weight of food added Clean both auger & hopper Remove fan filter & clean Drum churn Fan speed (%) Unload ratio Dwell time (hrs) Continued Auger run

Start up period Daily Checks ( ) Setup Week No Start date Target Dewatered Food Waste (kg) Target Carbon Pellets (kg) Weight of food added Clean both auger & hopper Remove fan filter & clean Drum churn Fan speed (%) Unload ratio Dwell time (hrs) Auger run 7 40 8 1 min 20 1:4 2 2 40 8 1 min 20 1:4 2 2 40 8 1 min 20 1:4 2 2 40 8 1 min 20 1:4 2 2 40 8 1 min 20 1:4 2 2 40 8 1 min 20 1:4 2 2 40 8 1 min 20 1:4 2 2 8 45 9 1 min 20 1:4 2 2 45 9 1 min 20 1:4 2 2 45 9 1 min 20 1:4 2 2 45 9 1 min 20 1:4 2 2 45 9 1 min 20 1:4 2 2 45 9 1 min 20 1:4 2 2 45 9 1 min 20 1:4 2 2 9 50 10 1 min 20 1:4 2 2 50 10 1 min 20 1:4 2 2 50 10 1 min 20 1:4 2 2 50 10 1 min 20 1:4 2 2 50 10 1 min 20 1:4 2 2 50 10 1 min 20 1:4 2 2 50 10 1 min 20 1:4 2 2 10 55 11 1 min 20 1:4 2 2 55 11 1 min 20 1:4 2 2 55 11 1 min 20 1:4 2 2 55 11 1 min 20 1:4 2 2 55 11 1 min 20 1:4 2 2 55 11 1 min 20 1:4 2 2 55 11 1 min 20 1:4 2 2 11 12 First Quarterly Site Support Visit by IMC (if Support Programme has been purchased)

IMC 7000 IN VESSEL COMPOSTER START UP PROCEDURE Start up period Daily Checks ( ) Setup Week No Start date 1 50 10 1 min 20 1:5 8 2 50 10 1 min 20 1:5 8 2 50 10 1 min 20 1:5 4 2 50 10 1 min 20 1:5 4 2 50 10 1 min 20 1:5 2 2 50 10 1 min 20 1:5 2 2 50 10 1 min 20 1:5 2 2 2 60 12 1 min 20 1:5 2.5 2 60 12 1 min 20 1:5 2.5 2 60 12 1 min 20 1:5 2.5 2 60 12 1 min 20 1:5 2.5 2 60 12 1 min 20 1:5 2.5 2 60 12 1 min 20 1:5 2.5 2 60 12 1 min 20 1:5 2.5 2 3 4 5 6 80 16 1 min 20 1:5 2 2 80 16 1 min 20 1:5 2 2 80 16 1 min 20 1:5 2 2 80 16 1 min 20 1:5 2 2 80 16 1 min 20 1:5 2 2 80 16 1 min 20 1:5 2 2 80 16 1 min 20 1:5 2 2 Target Dewatered Food Waste (kg) Target Carbon Pellets (kg) Weight of food added Clean both auger & hopper Remove fan filter & clean Drum churn Fan speed (%) Unload ratio Dwell time (hrs) Continued Auger run

Start up period Daily Checks ( ) Setup Week No Start date Target Dewatered Food Waste (kg) Target Carbon Pellets (kg) Weight of food added Clean both auger & hopper Remove fan filter & clean Drum churn Fan speed (%) Unload ratio Dwell time (hrs) Auger run 7 85 17 1 min 20 1:5 2 2 85 17 1 min 20 1:5 2 2 85 17 1 min 20 1:5 2 2 85 17 1 min 20 1:5 2 2 85 17 1 min 20 1:5 2 2 85 17 1 min 20 1:5 2 2 85 17 1 min 20 1:5 2 2 8 90 31 1 min 20 1:5 2 2 90 31 1 min 20 1:5 2 2 90 31 1 min 20 1:5 2 2 90 31 1 min 20 1:5 2 2 90 31 1 min 20 1:5 2 2 90 31 1 min 20 1:5 2 2 90 31 1 min 20 1:5 2 2 9 95 31 1 min 20 1:5 2 2 95 31 1 min 20 1:5 2 2 95 31 1 min 20 1:5 2 2 95 31 1 min 20 1:5 2 2 95 31 1 min 20 1:5 2 2 95 31 1 min 20 1:5 2 2 95 31 1 min 20 1:5 2 2 10 100 31 1 min 20 1:5 2 2 100 31 1 min 20 1:5 2 2 100 31 1 min 20 1:5 2 2 100 31 1 min 20 1:5 2 2 100 31 1 min 20 1:5 2 2 100 31 1 min 20 1:5 2 2 100 31 1 min 20 1:5 2 2 11 110 31 1 min 20 1:5 2 2 110 31 1 min 20 1:5 2 2 110 31 1 min 20 1:5 2 2 110 31 1 min 20 1:5 2 2 110 31 1 min 20 1:5 2 2 110 31 1 min 20 1:5 2 2 110 31 1 min 20 1:5 2 2 12 125 31 1 min 20 1:5 2 2 125 31 1 min 20 1:5 2 2 125 31 1 min 20 1:5 2 2 125 31 1 min 20 1:5 2 2 125 31 1 min 20 1:5 2 2 125 31 1 min 20 1:5 2 2 125 31 1 min 20 1:5 2 2 First Quarterly Site Support Visit by IMC (if Support Programme has been purchased)

Imperial Machine Company Limited Unit 1 Abbey Road, Wrexham Industrial Estate Wrexham LL13 9RF United Kingdom Tel: +44 (0)1978 661155 Fax: +44 (0)1978 729990 Email: sales@imco.co.uk Web: www.imco.co.uk