Download Manual BOSS Kit Pro Farina

Manual
BOSS Kit Pro Farina
380100 • 05/2014
INDEX:
1. Introduction�������������������������������������������������������������������������������� 1
2. Contents������������������������������������������������������������������������������������� 2
3. Important Notice������������������������������������������������������������������������ 3
4. Structure assembly ����������������������������������������������������������������������4
4.1. Elements �����������������������������������������������������������������������������������4
4.2. Assembly����������������������������������������������������������������������������������5
5. Solar panels placement����������������������������������������������������������������9
6. Photovoltaic array wiring sketch������������������������������������������������ 10
7. General wiring sketch����������������������������������������������������������������� 11
8. Stone Mill start operation����������������������������������������������������������� 12
8.1. Placement�������������������������������������������������������������������������������� 12
8.2. Parts��������������������������������������������������������������������������������������� 12
8.3. Mill operation������������������������������������������������������������������������� 13
8.4. Alternative energy source operation���������������������������������������� 15
9. General Maintenance����������������������������������������������������������������� 16
10. FAQ����������������������������������������������������������������������������������������� 16
11. Milling operation trouble chart�������������������������������������������������� 17
1. INTRODUCTION
This solar milling system is a complete equipment. It offers an
affordable system based on solar energy to facilitate an appropriate
cereal/food processing technology for the benefit of smallholder
farms, rural communities, cooperatives or projects in places where
there is not electrical grid. The solar mill guarantees the possibility
to obtain flour from different kinds of most common cereals (maize,
wheat, barley, teff, millet, rice…) directly from the sun energy, so
not electric or fuel bills are involved anymore. The equipment as a
whole can be described as follows: 1. the stone mill; 2. photovoltaic
array; and, 3. control panel. With our electrical stone mill, flour can
be easily obtained from raw cereals. The stone mill is based on pure
granite 500 mm stones and equipped with standard triphase asyn-
chronous motor 230/400 V 50 Hz. This machine, made in the EU,
is CE certified. The photovoltaic array supplies the necessary energy
to run the stone mill. It consists of 7 solar panels (128 W each) with
a total power of 896 W. A hot dip galvanized structure holds the
solar panels. The control panel links the photovoltaic array to the
stone mill. The equipment works without batteries. However during
sunless hours the equipment is capable to work directly through
single phase 230 V source, i.e. a generator (2 KVA minimum, not
included). You will need little time to set up all the elements to start
milling.
Please follow step by step this user’s manual.
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 2
2. Items Supplied / Packing List
2. Items Supplied/Packing List
3
BOX
2 // Measures:
960x 780
x 780
x 1365mm
/ Volume:
/ Weight:
223kgs
BOX 11 of
of 2
Measures: 960
x 1365 mm
/ Volume:
1 m1m3
/ Weight:
223 kgs
Qty
Description
1
Horizontal stone Mill, 1HP 3 x 230/400 VAC, 50 Hz. 50 mm stone diameter
1
Control panel, solar/generator/mains input, Ref. SMCP11
1
User manual
1
Wooden box, measures 960 x 780 x 1365 mm
BOX 2 of 2 / Measures: 1635 x 1072 x 665 mm / Volume: 1,16 m3 / Weight: 252 kgs
Qty
Description
7
Solar panel, Thin-film technology, 128 Wp first quality brand
10
Horizontal rail 41/41 x 1500 mm, for structure
3
Vertical triangle rail, pre-mounted 20º, for structure
1
Vertical triangle rail, pre-mounted 20º, with electrical box fixed, for structure
8
Rail unions, for structure
12
Panel clamps, for structure
4
End panel clamps, for structure
8
Allen screw with nut rail, for structure
1
Electrical cable to Control Panel to photovoltaic array, 25 m, blue plugs
1
Electrical cable to Control Panel to Stone mill, 5 m, red plugs
1
Earth bar with earth cable
1
Pack of fuses 10amps, spare part
2
Wrench key nº17-13 mm
1
Allen key nº8
1
Allen key nº6
1
Metric tape, 5 m
1
Masonry hammer to maintain the granite stones
1
Pack of nylon cable tie, 100 units
1
Wooden box, measures
3
TOTAL WEIGHT: 475 Kgs
TOTAL WEIGHT: 475 Kgs
TOTAL VOLUME: 2,16 m3
TOTAL
VOLUME: 2,16 m3
Total kits
kits per
1010
units
Total
per dry
dry20”
20”container:
container:
units
Total kits
kits per
2020
units
Total
per dry
dry40”
40”container:
container:
units
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
Serial Number: each mill has the serial number noted above the motor.
Structure Holder:
Manufacturer: Solar Milling SL (Spain)
380100 • p. 3
Product description: Hot dip iron structure for 7 solar panels ref. NA-F128GK, Sharp, 20º tilt.
Test Directives by Applus+:
Wind resistance: up to 147 km/h.
3.
Important
Notice:
4. Important
Notice:
1. Heavy equipment. The stone mill is heavy. Take the considerations to its placement.
2. Solar panels are sensible, handle with care.
3. Note that solar panels produces electrical energy.
For your safety:
All the equipment is protected against the following situations:
Short-circuits.
Lightings.
Over/under current.
Over/under voltage.
Empty running mill stone.
It has emergency STOP in the mill.
All the equipment is connected to earth.
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 4
4. Structure assembly
5. Structure assembly
4.15.1.
Elements
Elements
Horizontal rail
41/41x1.500mm
Ref. 444242
Vertical rail, triangle
Pre-mounted, 20º tilt
Ref. 446451
10 units
2 units
Vertical rail, triangle
with electrical box
Ref. 446452
Rail unions
Ref. 444139
5
1 unit
8 units
End Clamps
Ref. 756004
Allen screw
With nut rail
Ref. 756005
Panel Clamps
Ref. 756001
12 units
4 units
8 units
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 5
5.2. Assembly
4.2 Assembly
General View
Tools required:
 Metric tape
 Allen key, nº6 and nº8
 Wrench key, nº13 and nº17
 Compass
STEP 1
Determine the orientation of
the structure (north or south)
Use
compass
6
North hemisphere:
If you are here, face
the structure towards SOUTH
South hemisphere:
If you are here, face
the structure towards NORTH
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 6
STEP 2
Place the triangles
according to the
sketch here below
NOTE: Choose a
flat and levelled place
to install the structure.
2,20 m
NOTE: Place
the triangle with
the electrical box
in the right side.
2,20 m
2,20 m
Use metric
tape
2,20 m
STEP 3
Tight the screws of
the 8 jointed adjustable supports.
2,20 m
2,20 m
7
NOTE: The rear supports must be in vertical position, 90 degrees.
90º
Side view
Use wrench
key nº 17
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 7
STEP 4
x8
Join 2 sets of 5 horizontal rails by unions
(4 unions per set)
Use wrench
key nº13
x5 rail 1,5 m
x5 rail 1,5 m
7,5 m total length
STEP 5
Place 2 horizontal
rails on the vertical
triangle rails
NOTE: Before to go in, pay attention to this sketch with measures and…
0,45m
0,45m
90º
0,9m
90º
Use metric
tape
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 8
… go ahead!
Upper horizontal rail
9
Use allen
key nº8
Bottom horizontal rail
x8
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 9
5. Solar Panels placement
6. Solar Panels placement
Place the solar panels using the clamps.
NOTE: Start the operation placing the first solar panel in one of the sides (vertical position).
Before placing the solar panels be aware to insert the solar panel with the label upside.
1
4
3
2
……
7
Intermediate
panel clamps
End panel
clamps
Use allen
key nº6
Upper Side
Sharp NA-F128GK
Maximum Power: 128Wp
Open-circuit voltage: 59,8V
Short-circuit current: 3,45A
Voltage at point of maximum
power: 45,4V
Current at point of maximum
power: 2,82A
Made In Germany
CE
_
+
Bottom Side
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 10
7. Photovoltaic Array wiring sketch
6. Photovoltaic
Array wiring sketch
11
(Use nylon cable ties to fix the cable in the structure)
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 11
7. General Wiring Sketch
x5m
STONE MILL
STONE MILL
8. General Wiring Sketch
+
PHOTOVOLTAIC ARRAY
x25m
+
PHOTOVOLTAIC ARRAY
CONTROL PANEL
12
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 12
8. Stone Mill start operation
ne Mill start
8.1. operation
Placement:
acement:
Place indoors.
Level the soil surface.
 Place indoors.
 Level the soil surface.
arts:
8.2. Parts:
Security Switch
Electrical Plug
Up / Down
stone positioner
Flour Outlet
13
Auto-stop device
(Hopper empty)
Grain drop
lever
Motor AC 230/400VAC
(Squirrel cage)
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 13
8.3.
Operation
9.3. Milling
Milling Operation
1. Lift the stopper device.
2. Fill the hopper with grain.
3. Down the stopper device above the grain.
4. Press the security switch On.
5. Up the stone using the stone positioner.
Starting up:
6. Select “Solar” mode in Control Panel switch.
7. When the stone rotate, lower the stone by the stone positioner.
8. Regulate the fineness of the flour desired by the dropping cereal ramp and stone position.
2
14
3
GRAIN
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 14
6
0
1
2
GENSET / MAINS
SOLAR
OPERATION SELECTION
8
15
The stone full down and slow grain dropping results in fine flour.
To get coarser flour, lift the stone or increase the amount of grain entering the milling chamber.
When the hopper is almost empty the stopper device will switch off automatically.
This is to avoid stones useless friction without grain.
IMPORTANT NOTICE TO RE START THE SYSTEM:
1)
Switch position to 0 (control panel)
2)
Lift the stone
3)
Press On (mill)
4)
Switch to solar or mains.
5)
Operate the mill.
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 15
9.4. Alternative
energy
source
operation
8.4.
Alternative
energy
source
operation
In some cases you might need to grind after daylight time or very dark clouds can reduce the performance of the system. A single phase 230 VAC/1 KW can be connected to the Control Panel.
 Electrical Grid: Just plug in 230 VAC and turn the Switch to “MAINS/GENERATOR” mode.
The system will start operating.
 Generator: A generator with 230 VAC outlet (Minimum 2 KVA) can be plugged in the Control Panel.
Suggested procedure: Turn the Control Panel Switch to 0 mode. Start the generator and keep running till choke is removed (petrol engines). Then turn the Control Panel Switch to “MAINS/ GENERATOR” mode. The system will start operating.
Switch OFF: Always Switch OFF the switch in Control panel, then stop the generator.
OPERATION SELECTION
SOLAR
0
1
2
16
GENSET or
MAINS
Control
Panel
side
VIEW
MAINS / GENERATOR
SINGLE-PHASE 230 VAC INPUT
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 16
9.10.General
Maintenance
General Maintenance
The installation requires no maintenance except regular array cleaning.
Photovoltaic Array:
10. General Maintenance
 Cleaning the surface of solar panels and visual inspection.
The installation requires no maintenance except regular array cleaning.
 Try to locate the Photovoltaic Array in a place where shadows have the lowest possible.
Photovoltaic Array:
 Recommended fence the Photovoltaic Array for more security.
 Cleaning the surface of solar panels and visual inspection.
Stone Mill:
 Try to locate the Photovoltaic Array in a place where shadows have the lowest possible.
 Locate the Control Panel indoors.
 Recommended fence the Photovoltaic Array for more security.
 Check the stone inside the mill if you detected low flour fineness.
Stone Mill:
 Check the belt below the motor. If it is loose, turn the handle up to tension it.
 Locate the Control Panel indoors.
11. FAQ (Frequently Asked Questions)
 Check the stone inside the mill if you detected low flour fineness.
Q: Can the buyer install himself the system?
 Check the belt below the motor. If it is loose, turn the handle up to tension it.
A: Yes,
the
equipment is supplied
10.
FAQ
(Frequently
Asked pre-mounted
Questions)and can be set up easily within 1H 30m just following
11. FAQ (Frequently Asked Questions)
this user manual provided.
Q: Can the buyer install himself the system?
Q: What is the lifespan of the solar modules?
A: Yes, the equipment is supplied pre-mounted and can be set up easily within 1H 30m just following
A: The solar modules are high quality brand and as per manufacturer specifications, 90% of power
this user manual provided.
peak performance are guaranteed at 25 years.
Q: What is the lifespan of the solar modules?
Q: What is the lifespan of the mill machine?
A: The solar modules are high quality brand and as per manufacturer specifications, 90% of power
A: Due its free maintenance the mill is a very long lasting machine. The mill itself is a very basic mapeak performance are guaranteed at 25 years.
chine equipped with standard tripahse motor can be adapted and found in any market.
Q: What is the lifespan of the mill machine?
Q: What about the stones?
A: Due its free maintenance the mill is a very long lasting machine. The mill itself is a very basic maA: The stones are made from pure granite and most probably you’ll never have to replace it. The machine equipped with standard tripahse motor can be adapted and found in any market.
chine has a stopper device to avoid useless stones friction without grain. Its recommended to
Q: What about the stones?
work with the stopper device operating. In case of need to rough the stone faces, special masonry
A: The stones are made from pure granite and most probably you’ll never have to replace it. The mahammer is provided.
chine has a stopper device to avoid useless stones friction without grain. Its recommended to
Q: Are the spare parts available?
work with the stopper device operating. In case of need to rough the stone faces, special masonry
A: Yes, all spare parts are available from the solar milling company, although some can be locally in
hammer is provided.
any country.
Q: Are the spare parts available?
Q: At night time which kind of electrical source can be used?
A: Yes, all spare parts are available from the solar milling company, although some can be locally in
A: Single phase 230 V - 50 Hz, capable to supply 750 W.
any country.
Q: is there any risk of electrical shock?
Q: At night time which kind of electrical source can be used?
A: No, all the connectors are isolated. You’ll never be in touch with live electrical parts. The earth rod
A: Single phase 230 V - 50 Hz, capable to supply 750 W.
provided is highly recommended to be installed before the operation, to keep the entire equipment
Q: is there any risk of electrical shock?
safe.
A: No, all the connectors are isolated. You’ll never be in touch with live electrical parts. The earth rod
Q: Which kind of cereals can be grinded?
provided is highly recommended to be installed before the operation, to keep the entire equipment
A: All dry cereals can be grinded in this mill. Wet grains can clog the stones and be not effective.
safe.
Q: What happens when there is not enough solar radiation?
Q: Which kind of cereals can be grinded?
A: The machine could not work at full performance or even stop due lack of enough power from the
A: All dry cereals can be grinded in this mill. Wet grains can clog the stones and be not effective.
solar modules. In this case it would be better to wait for better radiation conditions o choose electrical
Q: What happens when there is not enough solar radiation?
Mains.
A: The machine could not work at full performance or even stop due lack of enough power from the
17
17
solar modules. In this case it would be better to wait for better radiation conditions o choose electrical
Mains.
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­
380100 • p. 17
11. Milling operation trouble chart
12. Milling operation trouble chart
DEFECT
Will not turn
MAY BE CAUSED BY
REMEDY
No power supply
Check supply, ensure source of power is
working correctly
Too much fixed load
Disconnect power, check to see if overfeeding has caused a jam
Not enough power
Check if power source is working correctly
Over-feeding
Reduce grain feed rate
Noisy operation
Worn bearing
Check bearing and replace or lubricate as
required
Low output
Caking/blockageing in the mill
Dry grain it too wet
Stones polished
Remove for resurfacing
Stones polished
Remove for resurfacing
Inappropriate feeding
Adjust feeding device (smaller quantity)
Mill will not turn fast
enough
Coarse grinding
18
Phaesun GmbH · Brühlweg 9 · 87700 Memmingen · Germany | Telefon +49 (8331) 990 42 0 · Telefax +49 (8331) 990 42 12 | [email protected] · www.phaesun.com­­­­­­