Installation Instructions

INST/WS/13735

IBC WASHING SYSTEM

Contents
page
Preface .............................................................................................................. 2
Health & Safety ................................................................................................ 2
1.0 Equipment Configuration.............................................................................. 3
2.0 Services & Consumption ............................................................................... 4
3.0 Installation Procedure.................................................................................... 4
4.0 Contract Drawings ......................................................................................... 4

ISSUE A – June 2015

MATCON Limited, Bramley Drive, Vale Park, Evesham, Worcs. WR11 1JH UK
Tel: 01386 (Int +44 1386) 769000 Fax: 0870 (Int +44 870) 1911116
E Mail: [email protected] Web Site: www.matconibc.com
Registered in England as MATCON Limited, No: 315837
MJH
IBC WASHING SYSTEM

Preface
This document provides information on the installation of the IBC Washing System, supplied
by Matcon Ltd. under contract number UK13735.

Copyright Notice
© Copyright Matcon Ltd. All rights reserved.
Information in this document is subject to change without notice and does not represent a
commitment on the part of Matcon. No part of this document may be copied or distributed,
transmitted, transcribed, stored in a retrieval system or translated into any human or computer
language, in any form or by any means, electronic, mechanical, magnetic, manual or
otherwise, or disclosed to third parties without the express written permission of Matcon.

Health & Safety

Notices
This manual contains advice notices, which should be observed to ensure personal safety, as
well as to protect the product and connected equipment. These notices are highlighted in the
manual by a warning triangle and appropriate text according to the level of danger, as
follows:

WARNING
Indicates that death, severe personal injury, or substantial property damage
can result if proper precautions are not taken.

CAUTION
Indicates that minor personal injury or property damage can result if proper
precautions are not taken.

NOTE: Draws attention to particularly important information about equipment

handling, equipment operation, or to emphasise a particular part of the text.

Potential Hazards
All equipment supplied by Matcon is fully tested for safety before being despatched.
However, as with all items of machinery, certain hazards exist for which precautions must be
taken. Attention is drawn to the following potential hazards when installing/operating the
IBC Wash System.
• Electricity - 415V, 3 phase, 50 Hz.
• Compressed Air - 4 - 7 bar(g).
• Water/Cleaning Agent - 0.5 - 4.5 bar(g)
- Up to 80OC
• Hot Air (drying) - Up to 80OC

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2 INST/WS/13735 - ISSUE A
 IBC WASHING SYSTEM
General Safety Precautions
The Matcon IBC Wash System is operated by pressurised air, in the range of 4 - 7 bar(g),
with a 415V, 3 phase, 50 Hz. electrical supply to the control panel. Compressed air represents
a source of considerable potential energy and as with electricity, precautions must be taken to
prevent personal injury.
• Compressed air should never impinge upon the body. Ports, pipes etc. must never be
blocked by hand.
• Before connecting any pneumatic equipment to a compressed air supply, mountings,
fittings, pipework and electrical connections should be checked for security and all
plastic protection plugs removed.
• No pipework alterations or removal of fittings should be attempted with air supplies
connected.
• Air and electrical supplies must be disconnected before any adjustment, maintenance or
dismantling of machinery is started.
• The maximum allowable operating pressures, temperatures etc. must be strictly
observed.
• Only suitably trained and authorised persons should be allowed to install and operate the
Wash System.
• During washing and drying cycles, avoid contact with the IBC, wash cowl and
surrounding surfaces, which can reach temperatures in the region of 80OC.

1.0 Equipment Configuration

The IBC Wash System is comprised of the following main sub-assemblies:

Wash Station Base A floor-mounted IBC location frame, supporting a central wash cowl
which introduces wash water and cleaning agent around the outlet and
the underside of the cone valve of an IBC loaded onto it.

Wash Lid A fabricated IBC lid incorporating a wash lance with a rotary jet head,
to introduce wash water, cleaning agent and drying air to the internal
surfaces of an IBC. The lid is attached to a raise and lower pneumatic
cylinder, mounted onto a support column adjacent to the wash station
base.

Service Skid A steel frame onto which are mounted appropriate pumps, valves, air
heater, fan and instrumentation to deliver hot/cold water, cleaning agent
and drying air to the wash cowl and wash lid.

Controls Pneumatic Panel: a steel cabinet mounted on the support column,

housing the various pneumatic valves and regulators required to control
the airflow to the pneumatic cylinders and wash lid inflatable seal.
3 phase panel (EP03): a steel cabinet mounted onto the service skid
frame, housing the main power distribution circuit and programmable
logic controller (PLC) circuits.
Operator panel (EP02): a steel cabinet mounted onto the service skid
frame, housing a programmable logic controller (PLC), operator
interface unit (HMI) and associated control circuitry.

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INST/WS/13735 - ISSUE A
IBC WASHING SYSTEM

2.0 Services & Consumption

Refer to P & I Diagram M3000, Electrical Drawings and Controls drawings 13735-9070.

3.0 Installation Procedure

The Wash Station, Wash Lid, Service Skid and Control Panels are delivered as fully
assembled units, merely requiring bolting into position, interconnecting and connecting to the
air, water and electrical supplies.

CAUTION
The weight of the wash station base is approximately 115kg. The weight of the
support column and wash lid assembly is approximately 670kg. The weight of
the wash skid is approximately 550kg. Care must be taken during installation to
avoid personal injury and damage to the equipment.
All lifting operations must be carried out in accordance with current Health &
Safety Regulations.

1. The wash station base, wash lid support column and service skid frame are mounted on
support legs, which have pre-drilled mounting plates for bolting directly to the floor.
2. Position the units as required, taking into consideration correct orientation of inlet
hoses, drainage and fork lift access etc.
3. Mark the position of the mounting holes onto the floor, drill to suit proposed method of
anchorage and bolt in place.
+
NOTE: The base frames should be level to within 2mm and shimmed, as required,
to within 1mm at each mounting point before final bolt down.
4. The pneumatic panel is pre-mounted and piped onto the support column. The control
cabinets (EP01 and EP03) are pre-mounting and wired onto the frame of the service
skid.
5. Refer to the appropriate contract drawings, listed below, and interconnect the units and
services.
NOTE: Pneumatic pipe runs should not exceed 5 metres in length.

4.0 Contract Drawings

The following is a list of associated drawings for this installation.

DRAWING NO. DESCRIPTION ISSUE

13735-008 SYSTEM ARRANGEMENT DRAWING A
13753-9070 CONTROLS DRAWINGS - PNEUMATIC PANEL B
CIP SKID DRAWINGS – SEE SECTION 3.0
M3000 P & I DIAGRAM A
M3001 GENERAL ARRANGEMENT CIP SKID A
39256 ELECTRICAL CONTROL CIRCUITS (7 PAGES) B

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4 INST/WS/13735 - ISSUE A