Asssembly and Installation Manual Zickert Z2013

Electric Powered Bottom Sludge Scraper
Z-2013
User guide
Project no Delivery date
Project name
Document no. Edition Date
Nordic Water Products AB reserves the right to make improvements and/or

amendments to this installation instruction when needed. Unauthorised
reproduction, modification or communication to unauthorised parties is
prohibited.
Please address all queries, comments or proposals concerning this product to:
Nordic Water Products AB
Business Area Zickert
Sisjö Kullegata 6
SE-421 32 Västra Frölunda
SWEDEN
Tel +46 (0)31-748 54 00
Fax +46 (0)31-748 54 19
zickert@nordicwater.com
The product is compliant with the EC's Machine Directive for elec
Date Product Edition
Contents
01/06/2015 Z2011-2015 1
Contents
1. Introduction
1A Safety
1B Tightening torque and general assembly instructions
1C Product description
1D Before installation
2. Assembly Instructions
2A Placement and welding of steel flat bars on tank bottom

2B Placement and welding of scrapper profiles
2C Placement and welding of steel flat diagonals
2D Welding of push and pull rod
2E Installation of sliders
2F Accuracy of angle
2G Installation of angle arm bracket & angle arm
2H Installation link arm & bracket to push & pull rod
2I Installation pilot pipe
2J Installation of pilots
2K Installation of drive unit
2L Installation of upper link arm and force sensor
3. Monitoring and handling
3A Installation report
3B Initial start
3C Troubleshooting
3D Servicing and maintenance
© Nordic Water Products AB, Sisjö Kullegata 6, 421 32 Västra Frölunda, Sweden. All rights reserved.
Manual_EN 0B Innehållsförteckning - Eldriven

1A Safety
01/06/2015 Z2000 1
1A Safety
The following safety-related instructions must be followed when installing, repairing, servicing and using the
equipment.
General
Read these installation instructions before starting to use the equipment.

Store the instruction in a suitable protected place.
Observe the warning and plant signs.
Apart from the provisions specified in the operating and maintenance instructions, general, local and
other regulations must be observed to prevent accidents.
Pay attention to the risk of slipping in water, sludge and/or oil on the floor.
Spare parts that are used must always be original spares.
It is not permitted to use the equipment for another purpose than the one intended.
Rebuilding and modification of the equipment is prohibited.
The equipment may only be used in a technically faultless condition.
There must be the possibility to stop the scraper on short notice.
In the case of faults, especially where the safety maybe put at risk, the scraper must be stopped
immediately and the fault remedied.
Prior to start, the basin shall be cleaned and evacuated, so there is no risk for crush injuries or similar
while running.
Guards, warning signs and other safety instructions shall be maintained in the same condition as when
the plant is taken over.
Tightening torques shall comply with the instructions to be found in section 1C.
Emergency stop
The emergency stop only breaks the scraper's operating current. The supply to the electrical cabinet is not
interrupted when the emergency stop is pressed. To switch off the power supply completely, the main
switch must be placed in the »0« position.
The person responsible for the plant's commissioning must consider whether just one emergency stop on
the automation cabinet constitutes adequate safety. The plant may need to be supplemented with external
emergency stop. On delivery, the automation cabinet is equipped with a terminal block for connecting an
external emergency stop. If the electrical cabinet is placed at a distance from the scraper, we recommend
that an external emergency stop be placed next to the drive.
An emergency stop must be mounted on the electrical cabinet that is connected to the scrapers.
Emergency stop may only be used in an emergency.
If the equipment is to undergo maintenance or repair, it must be stopped by setting the main switch to
position "0", not by using the emergency stop.
Before the plant is started up, the fault must be analysed and rectified.
During repair or other action, the safety switch for the machine that is to be worked on must be in the
position "Off" (0) and locked with a padlock. Main fuses for any machine concerned must be removed
and a warning sign placed on the relevant fuse box.
Manual_EN 1A Säkerhet
1A Safety
01/06/2015 Z2000 1
To consider when lifting equipment

Lifting gear must be used when lifting any equipment weighing more than 25 kg.
Only approved lifting equipment may be used for lifting and unloading work. The lifting equipment must
be dimensioned for the load in question. Check the weight of each package before lift.
Check the lifting devices are securely fastened.
Use truck or long straps to ensure that the minimum possible angle is formed between the straps.
In the first instance, use the lifting eyes to be found on the equipment.
Avoid short links during lift. Use spreaders if needed.
Do not work under suspended loads.
Never walk under a suspended load.
To consider while running

Work must not be done on any machine while the machine is operational.
Moving parts must not be touched.
Do not start motors and gear from another location without warning.
To consider during work on the equipment
Read all installation instructions. Check to see if there are any project specific installation drawings! This
is essential for installation to be performed correctly and it is a precondition for the guarantee conditions
to apply.
Use hearing and eye protection during installation, where there is a risk for hearing and eye injuries.
Wear work gloves and shoes with steel toecaps during the installation work.
Use gas alarms when working inside tanks or areas below ground level.
Make sure that valves and covers to the inlet in the basin where you are to work are properly interlocked
so water cannot enter the basin.
Installation and heavier service work should be performed by at least two people.
If a ladder is used, it must be approved and equipped with anti-slip device and hanging hooks.
When working at height, where there is a risk for falls, use a harness and fall arrester.
Electrical tools must be connected to sockets via residual current devices.
Protective clothing must be worn.
Where there are any sludge pockets, these are to be covered or cordoned off prior to the start of
installation, if there is a risk of falling in.
Do not weld on wet floors.
Do not perform work, inspection, service or other activity on the equipment during thunderstorms.
The basin must be flushed clean prior to the start of work, to reduce the risk of slipping and infection.
When working on sewage plants, make sure you wash thoroughly in accordance with the plant's routines,
or with equipment you take with you, to prevent infection. This applies both after the end of work and at
every break that involves some form of consumption.
Climbing or walking out on installed equipment is prohibited.
For health measures, see AS 1984:15.
1A Safety
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Functional safety
The occurrence of the following fault automatically results in the skimmer's function being stopped:
The motor protection in the electrical cabinet has tripped.
Electrical connection
The electrical installation and work on sensors, instruments and other cables shall be performed by
certified electricians.
To prevent accidents with electrical currents, it is important that electrical motors, instruments and cables
are correctly connected and maintained.
Electrical cables must be placed to ensure there is no risk for wear or them pinching against mechanical
parts.
All machines and instruments shall be earthed. Moisture and water involve in an increased danger for
fatal accidents with electrical current.
During replacement or repair of an electrical component, its electrical power supply must always be
switched off before starting work.
Work involving hydraulic power unit and hoses
If the equipment is not equipped with an hydraulic power unit, the following section can be ignored.
Prior to starting any work with the hydraulic power unit or hoses, ensure that the electric power to the
hydraulic power unit is disconnected and locked.
Goggles must be worn during all work with the hydraulic power unit and hoses.
If oil is spilled, the floor becomes very slippery and there is a risk of slipping. For this reason, always
make sure you clean thoroughly on and around the power unit. If oil does end up on the floor, wipe up as
much as possible and then pour absorbent on the oil patch to prevent the risk of slipping.
When the hydraulic power unit has been running, in unfavourable conditions the power unit can reach a
temperature of 70°C. Switch off the power unit and leave to cool before restarting work.
If the hoses are replaced, make sure that these are pressure tested in accordance with applicable standards
and that the materials in the hose are suitable for the application, to prevent the hose from wearing from
the inside. Carefully check that the hose does not run over sharp edges or anything else that could
damage the hose.
The hydraulic power unit shall be earthed at the connection point intended for this purpose.
The electrical installation may only be performed by authorised personnel and in accordance with
applicable safety regulations.
Connecting the machine electrically is not permitted for as long as mechanical installation work is
underway.
Date Product Edition 1B Tightening torque and assembly
01/06/2015 Z2000 1 instructions
1B Tightening torque and assembly instructions

The following tightening torques apply for all bolted joints unless otherwise stated on the assembly
drawing.
M6 Expansion bolt 5 Nm
M6 Threaded rod + Hilti 5 Nm

M8 Threaded rod + Hilti 10Nm
M6 Screw nut or lock nut 7 Nm

M8 Screw nut or lock nut 17Nm
All threads must be lubricated with aluminium grease or copper grease!
If the threads are to be locked, we recommend "Loctite red" instead of

grease. In which case, also use "activator" if the threads are stainless.
Manual_EN 1B Åtdragningsmoment och monteringsanvisningar

01/06/2015 Z2011-2015 1
The scrapper is a bottom sludge scrapper designed for continuous or discontinuous sludge transport.
The scraper consists of a drive unit and a number of wedge-shaped profiles welded together to form a single
unit so that they function as a moving floor in the tank.
The drive gives the profiles a forward and return movement, see figure 1.1. During the forward movement,
sediment is moved towards the sludge pit and during the return movement, the profiles move back under the
sludge blanket. The return movement is roughly twice as fast as the forward movement, which provides
continuous sludge transport.
Where the sludge has such a low total solids content that no blanket is formed, the profiles create a flow along
the bottom of the tank. The repeated movements of the scraper have the effect of thickening the sludge, thus
increasing its total solids content At the same time as the sludge is carried towards the sludge pit.
Fig. 1.1. The concave faces of the wedges scrape the blanket of sludge off the bottom. During the return movement, the
profiles move back under the blanket roughly twice as fast as the forward movement.
1 = Slow forward movement 2 = Rapid return movement
Simple to maintain
The demand for maintenance is minimal. With few moving parts and small forces the stress and strain is also
small. The sections run on sliders made from HD polythene. As a result, the friction of the scraper on the tank
bottom is negligible. Furthermore, the power demand is low, which contributes to gentle operation and long
service life.
All material in the water, apart from sliders and bearing bushings, are made of stainless or acid-proof steel
throughout.
Manual_EN 1C Produktbeskrivning - Eldriven

01/06/2015 Z2011-2015 1
Installation alternative
The unit may be assembled either as a pull or push scraper. For pull installation, the drive unit is located on the
short side of the tank by the sludge pit and the scraper "pulls" the sludge towards the pit, see figure 1.2. For the
push function, the power unit is mounted on the opposite short side of the tank and the scraper then "pushes"
the sludge, see figure 1.3.
Fig. 1.2. Pull scrapper
Fig. 1.3. Push scrapper

01/06/2015 Z2011-2015 1
Terminology
To help you understand these instructions, the terms that are use for various objects are presented here. The
numbering follows the assembly order, see figure 1.4 below. The design of the drive varies. For clearer
illustrations - see the figures further on in this manual.
Fig. 1.4. Illustration of the system with numbered components.
1. Slider rail/Steel flat bar 21. Cantilever or foundation

2. Scrapper profile 22. Pressure sensor
3. Steel flat diagonal 23. Electric motor
4. Push and pull rod bracket (25x75x3 mm) 24. Excenter
5. Push and pull rod bracket (25x75x8 mm)
6. Push and pull rod/Pipe
7. Pilot/pipe
8. Pilot pipe
9. Horizontal fixing plate
10. Pilot attachment wall/steel bar
11. Pilot bracket pit 400x125x5mm – can vary in appearance
12. Pilot bracket, pit (200x75x5mm) and (400x150x5mm) (see section 2J)
13. Expansion bolt
14. Slider
15. Nail screw
16. Angle arm bracket
17. Angle arm
18. Link arm
19. Link arm bracket
20. Upper link arm

01/06/2015 Z2000 1
Note
This manual is for a bottom scrapper and contains instructions for installation and operation of the scrapper.
The specifications listed here refer to the ZICKERT standard design. The scraper's parts are delivered in many
cases in a customised design. In these case, the manual is supplemented with project specific documentation
(installation drawing). For this reason, the installation drawing always takes precedence.
When any information is not shown in the customised drawing, the standard instructions in this manual apply.
Before installing and commissioning the equipment, read this guide carefully (including any specific
installation drawing supplied). It provides a good picture of the characteristics of the bottom sludge scraper as
well as the technical requirements for installation.
Check the size of the basin
Check the tank dimensions against the information in the installation drawing. You should contact the seller if
there are any significant deviations.
Measure the centre line of the tank
Check to see if the installation drawing specifies that the scraper's push and pull rod shall run along the exact
centre of the tank. If this is the case, mark the centre line in the tank. In the event of any deviation from the
centre line in the drawing, mark the displacement line. This gives the placement of the push and pull rod.
Also mark the vertical line on the tank wall where the drive unit is to be located. Check that the vertical line
corresponds to the centre line on the tank bottom, see figure 1.5 below.
NOTE! Because of the possibility of slanting tank walls, the vertical must be measured. Use plumb line
or laser to ensure the vertical line is completely vertical.
Fig. 1.5. Vertical line and centre line in the tank.
Apart from the dimensions, the nature of the tank bottom is also important for the function of the scraper. For
this reason, the checks that are described below must always be conducted.
Manual_EN 1D Inför installationen

01/06/2015 Z2000 1
Check of tank bottom
1. Check the gradient in the longitudinal direction of the tank. From wall to sludge pit, there must not be any
upward gradient and the max permitted downward gradient is 1.5 percent (or 0.9°). See figures 1.6 and 1.7
below.
Fig. 1.6. Maximum permitted gradient in the longitudinal direction of the tank.
Fig. 1.7. Forbidden gradient!
Examples:
In a 10 metre long tank, the max difference in level is 0.15 metre
In a 60m long tank, the max difference in level is 0.9 metre
If the gradient is greater, please contact Nordic Water at once to discuss alternative solutions.

01/06/2015 Z2000 1
2. Check the deviation in the width of the tank.. From wall to wall the gradient must not be more than 0.3
percent (or 0.2°), see figure 1.8.
Examples:
If the tank is 1m wide, the max difference in level is 3mm
If the tank is 6m wide, the max difference in level is 18mm
Fig. 1.8. Illustration of the maximum permitted gradient across the width.
If the gradient is greater, please contact Nordic Water at once to discuss alternative solutions.
3. Check local deviations in sections of the tank bottom. Conduct checks using a steel flat bar 50x4 (placed on
end). Place it on the floor and measure the deviation, see figure 1.9 below. The deviation must not be more than
10mm locally. In the case of greater deviations, the crown must be ground down or the pit filled. The pit can be
filled with concrete or, perhaps, with pieces of leftover sliders if the local pit is below a slider track.
Fig. 1.9. Illustration of local deviations in the tank bottom.

Date Product Edition 2A Placement and welding of steel flat
01/06/2015 Z2000 1 bars on tank bottom
2A Placement and welding of steel flat bars on tank bottom
Position, cut and weld the steel flat bars (50x4mm) at a distance of 725 mm from the edge of the sludge pit and
5–10 mm from the end wall as shown in figure 2.1 below.
Make sure the middle row of steel flat bars is exactly aligned with the middle of the tank's centre line.
Always refer first to the assembly drawing, if any!
Fig. 2.1. Illustration of critical dimensions when placing steel flat bars.
When welding several lengths of steel flat bar, ensure the bottoms have been ground level. See figure 2.2
below.
Fig. 2.2 Bottom ground level.
Angle all ends of the welded steel flat bar rows as shown in figure 2.3.
Fig. 2.3. Both ends must be angled.
Manual_EN 2A Placering och svetsning av plattstål på bassängbotten - 3 rader

Date Product Edition 2B Placement and welding of scrapper
01/06/2015 Z2000 1 profiles
2B Placement and welding of scrapper profiles

Start with the first and last scraper profile and place the remainder at the distance »a« specified in the drawing.
The vertical sides of the profiles must lie against the sludge pit.
Place the first profile 750 mm from the sludge pit's edge and 25 mm in on the steel flat bar, as shown in figures
2.4 and 2.5 below. Place the last profile 30 mm from the wall (25 mm in on the steel flat bar)
Fig. 2.4. Placement of scrapper profiles
Number of scrapper profiles: This is determined by the dimension »a« between the front edges of the profiles
which should be no more than 650 mm. Then, place all scraper profiles according the calculated measurement
»a« and 25 mm from the longitudinal walls on both sides, see figure 2.5.
Fig. 2.5. Measurement from scrapper profile to longitudinal walls.
Manual_EN 2B Placering och svetsning av skrapprofiler - 3 rader

Date Product Edition 2B Placement and welding of scrapper
01/06/2015 Z2000 1 profiles
Weld the first and last scraper profiles 20-25 mm on both sides on to the steel flat bars. The rest of the
profiles are welded 10 mm, see figure 2.6 below.
Fig. 2.6. Weld lengths (in mm) for welding scrapper profiles to the steel flat bars.
Manual_EN 2B Placering och svetsning av skrapprofiler - 3 rader

Date Product Edition 2C Placement and welding of steel flat
01/06/2015 Z2000 1 diagonals
2C Placement and welding of steel flat diagonals
In the first instance, follow the instructions on any assembly drawing

when placing the flat steel diagonals
Determine the number of diagonals: The steel flat diagonals together with the steel flat bar rows and the
scraper profiles must form a framed structure as follows:
Requirement 1: D = 35q r 10q

The angle is a recommendation and should be aimed for.
Angles must always be equal for opposing diagonals, see figure 2.7.
Requirement 2: For the first and last scraper profile, the diagonals must meet the steel flat bar row in the
centre of the tank.
Requirement 3: For outer rows of steel flat bars, the diagonals must meet on each side of the scrapper profile,
see figure 2.8a.
Fig. 2.7. Illustration of the flat steel diagonals and necessary angle, Į.
Manufacturing of diagonals
When the number and location of the diagonals has been determined, measure the overall length of the
diagonals.
Weld together the supplied steel flat diagonals, 25x3 mm, to the required lengths. The steel flat diagonals
delivered have a length of 4 m. Cut them to the right length and number. Each leftover bit is welded to the next
4 m length to minimise waste.
Manual_EN 2C Placering och svetsning av diagonalplattstål - 3 rader

Date Product Edition 2C Placement and welding of steel flat
01/06/2015 Z2000 1 diagonals
Welding of diagonals
Pull the steel flat diagonals under the scraper profiles and over the steel flat bar rows.
Weld on the flat steel bar rows as shown in figures 2.8a and 2.8b as well as to the scrapper profiles' front and
back edge as shown in figure 2.8c. W indicates welded joint.
Fig. 2.8a. Inner hub
Fig. 2.8b. Outer hub
The length of all welds is 10 mm.
Fig. 2.8c. Intersection with scrapper profile.
Manual_EN 2C Placering och svetsning av diagonalplattstål - 3 rader

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Attachments
Two types of fixing are used to form the jig that will hold the longitudinal push and pull rod pipes. The first three
or four push and pull rod pipe fixings on one side must be of thicker material, see figure 2.9, because they must
form a spacer with respect to the pilot pipe This applies to both ends of the scraper, see figure 2.11. For the other
fixings, the thinner type is used, see figure 2.10. See drawing for the exact number.
Fig. 2.9. Thick fixing. Total 6-8. See drawing. Fig. 2.10. Thin fixing, see drawing for number.
Start by welding the push and pull rod fixings, to the steel flat bar only, which is on the bottom of the tank. This
forms a jig that you then use when you weld together the longitudinal push and pull rod pipes.
25 x 8 mm
25 x 8 mm
Fig. 2.11. Jig for push and pull rod fixings. The first fixings are thicker.
Manual_EN 2D Svetsning av tryck- och dragstång

01/06/2015 Z2000 1
The first pair of the push and pull rod fixings must be adjusted to the bent-up steel flat bar, see figure 2.12 below.
Fig. 2.12. The first pair of fixings.
Push & pull rod
Place the loose pipes, 54 mm between the fasteners, see figure 2.13, and weld the pipes into one unit. Weld all
round. Take into account that the pipe must protrude 25 mm in front of the first scraper profile and extend 40 mm
over the last scraper profile, see figure 2.14.
Fig. 2.13. Push and pull rod
Fig. 2.14. Protrusion for the pipe on both sides.

01/06/2015 Z2000 1
After this, the push and pull rod pipe is attached to the scraper, ensuring it follows the centre line of the tank.
Weld the push and pull rod fixings securely to the push and pull rod pipe and to the scrapper profiles as shown in
figures 2.15 and 2.16 below. It is of the utmost importance that the thicker pull rod fixings are tight to the push
and pull rod, because the pilot pipe must be fully parallel with the push and pull rod.
Fig. 2.15. Illustration of how the pipe must be welded to the fixings.
Fig. 2.16. Illustration of how the pipe must be welded to the fixings.
When the push and pull rod is in place, wait before assembling the pilot pipe and pilot, so they are not in the way
when welding the link arm bracket to the push and pull rod pipe.

01/06/2015 Z2000 1
OBS! If the basin is wider than 8 meters, four extra pipes must be installed.
These are approximately 6m long and has a diameter of 54 x 2 mm. These are placed according to figure 2.16b
below when the basin is really short. They are assembled in the same way as the pull and push rod i.e. using the
fixing mentioned in the beginning of this chapter.
Fig. 2.16b Way of placing the extra pipes if the basin is very short.
If the basin is longer, the extra pipes should be placed according to figure 2.16c below.
Fig. 2.16c Way of placing the extra pipes if the basin is longer.

01/06/2015 Z2000 1
Location
Raise parts of the scraper construction using wooden blocks that are inserted under the profiles. Place the sliders
under the steel flat bars, making sure the steel flat bars run along the middle of the slider, see figure 2.17.
Note; the plastic material in the sliders expands approx. 10 times more than steel when heated,
therefore the installation temperature must be taken into consideration.
The dimensions of the sliders are: 125 x 3000 x 6 mm.
Fig. 2.17. Placement of sliders
Attachment
When the sliders have been laid, remove the wooden blocks allowing the
weight of the scraper to secure the position of the sliders. Take care that the
sliders do not move during this process. Place the holes as shown in the
figure on the next page.
Use the nail screws supplied to secure the slider to the bottom of the tank.
Manual_EN 2E Montering av glidlister

01/06/2015 Z2000 1
Holes for the nail screw are located in the ends, 35 mm into the slider. The distance between the other holes is 325
from the edge of the slider. Drill 6 mm, bore depth 45 mm and knock in the nail screw (see data sheet) using a
mm alternating on each side of the steel flat bar, see figure 2.18 below. The holes are to be placed 15-20 mm in
hammer. I.e., a slider is attached with a total of 12 nail screws.
Fig. 2.18. Picture showing where the nail screws have to be placed. Pay attention to the alternating placement.
The end of the sliders are secured using two nail screws. Leave a 5 mm gap between the sliders, see figure 2.19
below.
Fig. 2.19. The end of the sliders are attached using two nail screws.
Manual_EN 2E Montering av glidlister

01/06/2015 Z2011-2015 1
To ensure the correct function, vertical and horizontal angle accuracy must be observed during installation, see
figure 2.20a. It is also very important that the drive unit be at a right angle to the push and pull rod as shown in
figure 2.20b.
Defines a vertical centre line.

Specifies that the line by the arrow must be at a right angle (horizontal) to the centre line 'A'
according to the conditions above.
Fig. 2.20a. Accuracy of angle. Fig. 2.20b. Correct angle between motor and
push and pull rod seen from above.
Terms:
For horizontal/vertical measurement,
the air bubble must be within the limit
lines on the spirit level
Acceptable angle deviation tolerance ±
Manual_EN 2F Vinkelnoggrannhet - Eldriven med konsol

2G Installation of angle arm bracket
Z2011-2015,
01/06/2015 1 and angle arm
Z2001-2002EHD
2G Installation of angle arm bracket and angle arm
Mark the tank's vertical line, if this has not yet been done (see section 1D), as shown in figure 2.21 below. Then
dismantle the angle arm bracket and the angle arm by removing the through shaft.
Fig. 2.21. Dismantled angle arm bracket and marked centre line.
Measure the distance from the centre of the oval hole to the centre of the joint, »b«, see figures 2.22a and b below.
The distance differs between the different types of angle arm brackets.
The distance, »a« , from floor level to the joint of the angle arm bracket also differs depending on the type of
angle arm, see figures 2.22a and b. The dimension is on the assembly drawing (standard brackets have the
dimension 910 mm or 1300 mm).
Mark the height, »a«, on the vertical line from floor level and add the distance »b«. Use a Ø10 mm drill bit to
secure a M10 expander in the oval hole in the centre of the angle arm bracket, see figure 2.22c.
Fig. 2.22a and b. Clarification of distance for assembly of angle arm bracket. Fig. 2.22c. Oval fitting hole
Manual_EN 2G Montering av vinkelarmskonsol och vinkelarm

Z2011-2015,
Z2001-2002EHD
Note that, depending on which type of bottom scraper that have been delivered, the angle arm bracket could look
different. This is illustrated in figure 2.22d below. The L-profile for the HD-model is welded at site.
Fig. 2.22d. Different types of angle arm brackets. From left; type 1, type 2, HD och EHD.
Secure the expander bold in the hole and then hang up the angle arm bracket. Assemble washer and nut and
tighten.
Then hang the moveable angle arm on the angle arm bracket. Insert the shaft. Measure using a spirit level to
ensure the angle arm is hanging completely vertically, see figure 2.23. In addition, push the angle arm bracket on
the wall sideways so the centre of the moveable angle arm is at the centre of the vertical line.
Fig. 2.23. Adjustment to ensure that the angle arm will hang vertically and at the centre of the vertical line.

Z2011-2015,
Z2001-2002EHD
Check the angle arm is hanging correctly by connecting the link arm to the angle arm and ensure that the link arm
lines up directly above the push and pull rod pipe as shown in figure 2.24.
Fig. 2.24. The link arm must line up directly above the push and pull rod.
Drill the remaining Ø18 mm holes 125 mm deep. Mount the threaded rods using chemical grout (see Hilti's data
sheet in the packaging). When the grout has hardened, fit the washers and tighten the locking nuts. After this, the
angle arm bracket has to be assembled as shown in figure 2.25.
Fig. 2.25. Completely assembled angle arm bracket.

2H Installation link arm and mount for
Z2011-2015,
01/06/2015 1 the push & pull rod
Z2001-2002EHD
2H Installation link arm and mount for the push & pull rod
Place the angle arm in the horizontal position and check this using a spirit level, see figure 2.26. Do not forget that
the cotter pin must be in the shaft.
Then make a mark on the push and pull rod pipe.
Fig. 2.26. Angle arm in horizontal position.
Then, push forward the link arms 375 mm, as shown in figure 2.27, and make a new mark on the push and pull
rod pipe.
Fig. 2.27. Link arm pushed forwards
Manual_EN 2H Montering länkarm och fäste mot tryck- och dragstången

2H Installation link arm and mount for
Z2011-2015,
01/06/2015 1 the push & pull rod
Z2001-2002EHD
Weld the link arm bracket in place only along the sides using 7x 60mm welds with 30mm between the welds, see
figure 2.28 and welding instruction. Do this on both sides!
Fig. 2.28. Welding instructions for the link arm bracket.
Welding instructions:
All welds are to be pickled.
NOTE! Do not weld the ends to the bracket! There must not be any welds
on the top of the push and pull rod's pipe.
Manual_EN 2H Montering länkarm och fäste mot tryck- och dragstången

Z2011-2015, 2I Installation pilot pipe
01/06/2015 1
Z2001-2002EHD
2I Installation pilot pipe

The pilot pipe (Ø60.3) is rolled on the profiles to the first, thicker, push and pull rod brackets (8 mm) that are
welded to the push and pull rod, see figure 2.29 below. It is important that the pipes are completely parallel.
Therefore make sure there are no welding beads or anything else that might prevent the pipes from being parallel.
Fig. 2.29. The pilot pipe has to be fastened to the first, thicker, brackets.
Weld to the push and pull rod brackets between the pipes.
Push and pull brackets are placed on the outside of the pilot pipe with the dimensions 25x3 mm as shown in figure
2.30.
Fig. 2.30. Placement of outer push and pull rod brackets.
NOTE! The inside of the pilot pipe must remain smooth and unaffected by the welding. For this reason,
weld carefully and prevent burn though.
Manual_EN 2I Montering av styrrör - Topmonterad drivning

01/06/2015 1
Z2001-2002EHD
These brackets are then welded to the profile with two spot welds and to the pilot pipe, see figure 2.31 below.
Fig. 2.31. Welding instruction between brackets, pilot pipes and profiles.
On the top, between the pipes, the fixing plates, size 25x3 mm, have to be welded horizontally, as shown in figure
2.32 below.
Fig. 2.32. Overlying fixing plates.
NOTE! The inside of the pilot pipe must remain smooth and unaffected by the welding. For this reason,
weld carefully and prevent burn though.

01/06/2015 1
Z2001-2002EHD
Carry out the same procedure described above for the other end of the scraper, but on the opposite side of the pull
and push rod, according to assembly drawing and figure 2.33 below.
Fig. 2.33. Placement of overlying fixing plates on the other side of the push and pull pipe.

Z2011-2015, 2J Installation of pilots
01/06/2015 1
Z2001-2002EHD
2J Installation of pilots
Always follow the instructions in the assembly drawing first!
The fastener supplied with the pilot consists of a number of fixing plates depending on the design of the tank, (see
drawing).
x Insert the pilot into the pilot pipe and pull it out to the tank wall.
x Vertically, the centre of the fixing plate must be approx. 80 mm above the tank bottom. Secure the plate in
place with M10 expander bolt.
x Once the fixing plate is attached, weld the pilot pipe to the fixing plate as shown in figure 2.34.
NOTE! It is of utmost importance that the assembly be straight, to ensure that the pilot pipe runs without
much friction in the pilot pipe; therefore, the plate must be properly attached to the wall before the pilot
pipe is welded into place.
Fig. 2.34. Pilot inserted in the pilot pipe and welded to the fixing plate.
Manual_EN 2J Montering av styrtappsrören - Topmonterad drivning

Z2011-2015, 2J Installation of pilots
01/06/2015 1
Z2001-2002EHD
Due to the different designs of sludge pit, the brackets have to be cut to size and adjusted when installing. For this
reason, the placement of the fixing plate depends on the tank's design, see figures 2.35a, and b for examples. An
overall assessment of the fit must to be made. It is essential that the fastener ensures the pilot runs parallel with
the push and pull rod and the tank's centre line.
.
Fig. 2.35a. Alternative design of pilot fastener for the sludge pit that depends on the design of the sludge pit.
Fig. 2.35b. Alternative design of pilot fastener for the sludge pit that depends on the design of the sludge pit.
Manual_EN 2J Montering av styrtappsrören - Topmonterad drivning

Date Product Edition 2K Assembly of cantilever and electric
01/06/2015 Z2011-2015 1 drive
2K Assembly of cantilever and electric drive
Cantilever
The assembly drawing shows the appearance of the cantilever in question. Assembly of a standard cantilever is
described below.
Start by plumbing a line on the wall with its centre above the push and pull rod's pipe, if this has not already been
done.
After this, place the cantilever according to figure 2.36 below. See installation drawing for dimensions.
Fig. 2.36. Distance between cantilever and centre line.
Mark the holes in the cantilever and then drill with Ø10 mm through the oval holes in the crown of the concrete
and put in M10 expander as shown in figure 2.37 below.
Fig. 2.37. The cantilever is secured first using two M10 expanders.
Manual_EN 2K Montering av konsol och eldrift

01/06/2015 Z2011-2015 1 drive
Align the cantilever using a spirit level as shown in figure 2.38 below. If necessary, add pieces of plate between
the wall and cantilever for adjustment.
Fig. 2.38. Alignment of the cantilever using spirit level.
Where the tank wall is uneven, measures may need to be taken to get the side of the cantilever parallel with the
centre line (lines A—B and C—D in figure 2.9, below, must be parallel).
Fig. 2.39. The side of the cantilever must be parallel with the centre line for the scrapper.
Then, use the cantilever as template and drill through the rest holes in the cantilever using a Ø18 mm concrete bit.
The cantilever is secured in place using chemical anchor (see Hilti's datasheet in the pack) and threaded rod
(M16x160).
NOTE! The hardening time for Hilti compound is heavily dependent on the temperature. For temperatures
below 5°C the compound must be heated during the hardening time.

01/06/2015 Z2011-2015 1 drive
Electric drive
When the foundation has been aligned and installed, the motor bridge with motor and gear train are installed. The
assembly kit includes all the screws and nuts.
Lift the assembly with the gear motor and motor bridge on to the cantilever, see figure 2.41a, using a lifting
device.
After this, adjust the motor bridge in relation to the cantilever and screw on all nuts loosely.
Place a spirit level on the gear motor's excenter to trim in the excenter vertically. Adjust with shims where
necessary.
Fig. 2.41a. Motor placed on cantilever.

01/06/2015 Z2011-2015 1 drive
Also trim in the angle between the excenter's direction of travel and the push and pull rod to give an angle of 90°,
see figure 2.42b.
Fig. 2.42b. The angle between the excenter and the push and pull rod must be a right angle.

Date Product Edition 2L Installation of upper link arm and
01/06/2015 Z2011-2015 1 force sensor
2L Installation of upper link arm and force sensor
Make sure that all screwed joints around the motor have been screwed tight prior to
assembling the link arm!
This manual is illustrating a motor placed on a foundation. However, the same process is
applied if a console is used instead.
Force sensor
The assembly drawing shows that the force sensor has to be placed between the excenter and the upper link arm.
Start by assembling the excenter on the shaft of the planetary gear motor by using a fine thread pusher.
NOTE! Must not be knocked on, pusher must be used!

Then, check that the wedge is located in the grove and the lock the excenter using the locking screws, see figure
2.43a and 2. 43b.
Locking
screw
Excenter
Keyway
Fig. 2.43a. Electric motor Fig. 2.43b. Locking screws

After this, assemble the link head by pushing it on to the excenter's shaft and locking it with a circlip, see figure
2.44. Also make sure that the position sensor is mounted on the bracket indicated, which is also shown in figure
2.44.
Circlip
Link head
Fig. 2.44. Placement of circlip, link head and position of sensor.

NOTE! Do not use a hammer or any other hard object to hit with, as this can damage the shaft bearing.
Manual_EN 2L Montering av övre länkarm och kraftgivare

01/06/2015 Z2011-2015 1 force sensor
Then, screw the force sensor on as high up as possible on the link head, loosen a half turn to ensure it is parallel
with the shaft of the planetary gear motor and lock with the counter nut, see figure 2.45.
Counter nut
Force sensor
Fig. 2.45. Counter nut and force sensor
The force sensor's cable must be parallel to the shaft of the motor, see figure 2.46 below.
Parallel
Parallel
Parallel
Force sensor
Fig. 2.46. Parallel shafts.

01/06/2015 Z2011-2015 1 force sensor
Once the force sensor has been installed, it is time to assemble the upper link arm. Screw it clockwise from
underneath, all the way up to the force sensor and loosen a half turn. Then lock it with the counter nut. See figure
2.47.
Counter nut
Upper link
arm
Fig. 2.47. Counter nut and upper link arm.
After this, place the cable chain fastener in the upper link arm by inserting it into the groove on the force sensor
and lock it with the locking plate and locking screw, see figure 2.48a and 2.48b below.
Least possible
distance: 2mm
Locking
Locking
Fig. 2.48a. Locking design Fig. 2.48b. Locking design

01/06/2015 Z2011-2015 1 force sensor
After this, assemble the upper link arm joint in the angle arm, see figure 2.49 below.
NOTE! Do not forget the cotter pin!
Fig. 2.49. Assembly of link arm joint.
Run the drive's excenter round until the upper link arm reaches its lowest position, see figure 2.50.
Fig. 2.50. Link arm in its lowest position

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Then, make a mark for cutting on the upper link arm at the height of the link arm joint's waist, see figure 2.51a,
and cut the pipe at C, see figure 2.51b.
Fig. 2.51a. The mark must be made on the upper link arm. Fig. 2.51b. Cut the pipe at the mark, C.
Before welding the upper link arm to the joint, check that the link head is at 90° to the excenter journal as shown
in figure 2.52. The figure shows the angle as seen from above.
Fig. 2.52. Make sure the link head is at a right angle to the journal on the excenter.

01/06/2015 Z2011-2015 1 force sensor
After this, fully weld the pipe according to the welding instruction in figure 2.53 below. All welds are to
be pickled.
Threaded rod from force
The M8 hole has no

purpose for the electric
Upper link arm
Fig. 2.53. Welding the upper link arm joint on the cut link arm.
The scraper is now assembled and complete. Before starting, please complete the enclosed installation report and
review each item to eliminate any faults.

Date Document no. Edition
01/06/2015 Z2011-2015 1
1. Placement of flat steel bars

a. Are the flat steel bars placed according to the dimensions
set out in section 2A? Ƒ Yes Ƒ No
b. If the flat steel bars are welded, are they ground on the bottom? Ƒ Yes Ƒ No
2. Scraper profiles
a. Are the scraper profiles placed according to the dimensions in section 2B? Ƒ Yes Ƒ No
b. Are the scraper profiles welded correctly in accordance with
the instructions in section 2B? Ƒ Yes Ƒ No
3. Steel flat diagonals

a. Is the requirement for a maximum angle met according
to instruction in section 2C? Ƒ<HV Ƒ No
b. Are the diagonals welded correctly in accordance with the instructions
in section 2C? Ƒ Yes Ƒ No
4. Push and pull rod

a. Are the two different types of fixing welded in the correct place
and according to instruction? Ƒ Yes Ƒ No
b. Is the push and pull rod pipe welded according to instructions
with a correct protuberance on both sides? Ƒ Yes Ƒ No
5. Check of sliders
a. Are all sliders installed with alternating screw nails according to
instructions in section 2E? Ƒ Yes Ƒ No
6. Check of the accuracy of angle

a. Is the angle deviation tolerance within the permitted tolerance ± 0.1 ° Ƒ<HV Ƒ1R
7. Angle arm bracket and angle arm

a. Is the angle arm installed at height a from floor level? See section 2G. Ƒ<HV Ƒ No
b. Does the angle arm hang vertically and at the centre of the vertical line? Ƒ Yes Ƒ No
c. Are the threaded rods securely fixed, washers placed and locking
nuts tightened? Ƒ<es Ƒ No
8. Link arm and attachment to push and pull rod

a. Is the cotter pin placed in the angle arm shaft? Ƒ Yes Ƒ No
b. Is the link arm bracket's short side free from welds? Ƒ Yes Ƒ No
c. Is the link arm bracket welded with correctly performed welds according
to instruction in section 2H? Ƒ Yes Ƒ No
9. Check of pilot pipe and pilot

a. Are the pilot pipe and the push and pull rod totally in parallel? Ƒ Yes Ƒ No
b. Is the pilot pipe correctly fixed according to instructions in section 2I? Ƒ Yes Ƒ No
c. Does the pilot run without much friction in the pilot pipe? Ƒ Yes Ƒ No
Manual_EN 3A Installationsprotokoll - Eldrift

01/06/2015 Z2011-2015 1
10. Check of foundation or cantilever

a. Are the threaded rods securely fixed, washers placed and
locking nuts tightened? Ƒ<HV Ƒ No
b. Is the electric motor placed and adjusted so the excenter is totally
vertical and in line with the centre vertical line? Ƒ Yes Ƒ No
11. Upper link arm and force sensor

a. Is the upper link arm secured, anchored with Loctite
and the locking screw tightened? Ƒ Yes Ƒ No
b. Is the excenter secured with two locking screws according to section 2L? Ƒ Yes Ƒ No
c. Is the distance between sensor and sensor plate 3-5 mm? Ƒ<HV Ƒ No
d. Is the upper link arm joint welded to the link arm according
to the instructions in section 3A? Ƒ<HV Ƒ No
e. Have all bearings been checked (4)? Ƒ<HV Ƒ No
f. Have all shafts been secured with cotter pins? Ƒ<HV Ƒ No
12. Check of the electric drive after 30 min test run

Notes:
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
13. Other
Notes:
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
Verification
Responsible:____________________________________________________
Signature:______________________________________________________
Date and place:__________________________________________________
Manual_EN 3A Installationsprotokoll - Eldrift

3B Initial start
01/06/2015 Z2011-2015 1
3B Initial start
We recommend that you start the unit and check its function before filling the tank.
xStart the electric motor (motors) by putting the control switch in the 'Man' position.
xCheck that the rotational direction of the electric motor (motors) corresponds with the arrow marking, by starting
the electric motor briefly. If it rotates in the wrong direction, switch two of the three phases. Observe the safety
instructions.
xLet the scraper move forwards and backwards for about 30 minutes.
xWhen test running with an empty tank, check that no stresses are built in between the upper link arm – angle arm
– link arm – scraper. Adjust the angle arm bracket or power drive bracket's attachment where necessary.
Sensor for position

1. Mount the sensor in the bracket with the plastic nuts approx. 10 mm from the sensor plate, if not done already,
see figure 3.1 below. See section 2L and figure 2.44 for more information.
2. Screw the sensor closer and closer to the sensor plate until you make contact (the lamp on the sensor lights
up).
3. Unscrew the sensor from the plate by about 1 mm, until the light goes out again. Tighten the plastic screws
carefully.
4. The distance between the sensor and the plate should be about 3-5 mm, see figure 3.2 below.
Sensor
Sensor
Sensor plate
Fig. 3.1. Sensor and sensor plate Fig. 3.2. Distance between sensor and sensor plate
Manual_EN 3B Första start - Eldrift

3B Initial start
01/06/2015 Z2011-2015 1
Force sensor
Check the settings in the electrical cabinet for the force sensor.
The sensor is 4-20 mA and a sensor signal lower than 4mA indicates a faulty cable or sensor.
The force sensor measures the forces of the drive unit in the range -50kN to 50kN, where -50kN corresponds to
4mA, 0kN corresponds to 12mA and 50kN corresponds to 20mA. Table 1 below shows the maximum forces and
corresponding signal strength.
Model Force (kN) Minimum permitted Maximum permitted

signal signal
Z2011 +-7.5 10.8 13.2
Z2012 +-10 10.4 13.6
Z2013 +-15 9.6 14.4
Z2014 +-20 8.8 15.2
Z2015 +-30 7.2 16.8
Table 1. Minimum and maximum signal in the sensor break.
Then adjust the settings for the sensor so it breaks if the signal is outside the permitted minimum/maximum
values.
Manual_EN 3B Första start - Eldrift

3C Troubleshooting
01/05/2016 Z2011-2015 1
3C Troubleshooting
Problem Cause Measure/troubleshooting
Cannot start scraper during first Motor incorrectly connected Check/change electrical
start. connection.
Eccentric arm obstructed Check that the eccentric arm can
rotate freely. Do this by
disconnecting the piston rod
extension.
Wrong voltage Check the voltage to the electrical
cabinet.
Wrong voltage Check the voltage on the
connection to the motor.
Incorrect assembly Check that all joints are free from
welds and that the joints can move
if you disconnect one joint at a
time.
Incorrect assembly Check so the both pilot pipes goes
free from obstructions.
Incorrect assembly Check that the scraper profiles are

free of the walls and floor so they
do not make contact when you lift
the profiles.
The alarm goes off Check the alarm on the electrical
cabinet
Electrical cabinet Check the electrical cabinet's
settings
Scraper has stopped. Tripped quick break switch Check bottom.
Faulty sensor Check the sensor
Power failure Check the voltage across the
motor.
Motor defective Change or repair the motor.
Object in tank Remove whatever fell in and repair
if needed.
Tripped motor protection Check the setting/restore.
Scraper running at wrong speed Incorrectly set frequency converter Check and adjust the settings on
the frequency converter.
Motor incorrectly connected Check/change the connection.
Problem persists? Contact us!
Manual_EN 3C Felsökning - Eldrift

01/06/2015 Z2011-2015 1
Almost maintenance free

Our goal has always been to design machines of high quality that are long lasting and have little need of servicing.
Thanks to our newly developed shafts and bushings, the scraper's need for servicing has been reduced drastically.
Under normal conditions, the scraper needs checking once a year and servicing even less often. All parts that are
not wear parts are made completely from stainless or acid resistant steel. If you have a scraper in water containing
silt, sand or clay, the scraper is subjected to harder wear than normal.
Annual inspection
The scraper should be inspected once a year to ensure everything is alright. During the first year, the inspection
has to be done twice.
1. Drain the tank and carry out a visual inspection and make sure everything
looks normal.
2. Check that all welds between scraper blade and steel flat bars are
undamaged.
3. Check that all attachments in the concrete are rigid. Tighten if necessary.
4. Check the wear of the pilot and pilot pipe. These always wear a bit and
need replacing after being in use some years.
5. Check the wear on sliders and steel flat bars.
6. Check that the sliders are in place under the steel flat bars.
7. Check the joints, shafts and bushings, if there is a gap, it might be time to
replace.
8. Check the link head between upper link arm and excenter.
9. Check the drive unit to make sure that the attachments to the concrete do
not move when the scraper moves.
10. Check that the gears are not leaking oil
11. Check the function of all sensors.
12. Check if there is damp/condensation in the electrical cabinet.
Electric drive
For the service and maintenance of the gear motor, see enclosed service manual.
It is recommended that the following be checked at regular intervals:
x Oil level – the first oil change is to be done after approx. 200 hours operation and, thereafter, after every
10,000 hours or once a year.
x Unusual noise level
x Leakage
x Overload protection
x Bolted joints such as link head
x The function of the sensors.
Manual_EN 3D Service och underhåll - Eldrift

Zickert is a tradename owned by
Nordic Water Products AB.
All images, illustrations, trademarks and text in this

publication are copyrighted material and may not be copied or
reproduced in any way without the express consent of Nordic
Water Products AB.
HEAD OFFICE
Sisjö Kullegata 6
SE-421 32 Västra Frölunda
Sweden
www nordicwater com

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Asssembly and Installation Manual Zickert Z2013

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Electric Powered Bottom Sludge Scraper

Document no. Edition Date

Nordic Water Products AB reserves the right to make improvements and/or

2A Placement and welding of steel flat bars on tank bottom

3. Monitoring and handling

Manual_EN 0B Innehållsförteckning - Eldriven

 Read these installation instructions before starting to use the equipment.

To consider when lifting equipment

To consider while running

To consider during work on the equipment

Work involving hydraulic power unit and hoses

1B Tightening torque and assembly instructions

M6 Threaded rod + Hilti 5 Nm

M6 Screw nut or lock nut 7 Nm

All threads must be lubricated with aluminium grease or copper grease!

If the threads are to be locked, we recommend "Loctite red" instead of

Manual_EN 1B Åtdragningsmoment och monteringsanvisningar

Manual_EN 1C Produktbeskrivning - Eldriven

Fig. 1.2. Pull scrapper

Fig. 1.3. Push scrapper

Manual_EN 1C Produktbeskrivning - Eldriven

Fig. 1.4. Illustration of the system with numbered components.

1. Slider rail/Steel flat bar 21. Cantilever or foundation

Manual_EN 1C Produktbeskrivning - Eldriven

Check the size of the basin

Measure the centre line of the tank

Fig. 1.5. Vertical line and centre line in the tank.

Manual_EN 1D Inför installationen

Check of tank bottom

Fig. 1.7. Forbidden gradient!

Manual_EN 1D Inför installationen

Fig. 1.9. Illustration of local deviations in the tank bottom.

Manual_EN 1D Inför installationen

2A Placement and welding of steel flat bars on tank bottom

Fig. 2.2 Bottom ground level.

Fig. 2.3. Both ends must be angled.

Manual_EN 2A Placering och svetsning av plattstål på bassängbotten - 3 rader

2B Placement and welding of scrapper profiles

Fig. 2.4. Placement of scrapper profiles

Fig. 2.5. Measurement from scrapper profile to longitudinal walls.

Manual_EN 2B Placering och svetsning av skrapprofiler - 3 rader

Manual_EN 2B Placering och svetsning av skrapprofiler - 3 rader

2C Placement and welding of steel flat diagonals

In the first instance, follow the instructions on any assembly drawing

Requirement 1: D = 35q r 10q

Manual_EN 2C Placering och svetsning av diagonalplattstål - 3 rader

Fig. 2.8a. Inner hub

Fig. 2.8b. Outer hub

The length of all welds is 10 mm.

Fig. 2.8c. Intersection with scrapper profile.

Manual_EN 2C Placering och svetsning av diagonalplattstål - 3 rader

2D Welding of push and pull rod

Manual_EN 2D Svetsning av tryck- och dragstång

Fig. 2.12. The first pair of fixings.

Push & pull rod

Fig. 2.13. Push and pull rod

Fig. 2.14. Protrusion for the pipe on both sides.

Manual_EN 2D Svetsning av tryck- och dragstång

Manual_EN 2D Svetsning av tryck- och dragstång

Manual_EN 2D Svetsning av tryck- och dragstång

The dimensions of the sliders are: 125 x 3000 x 6 mm.

Fig. 2.17. Placement of sliders

Manual_EN 2E Montering av glidlister

hammer. I.e., a slider is attached with a total of 12 nail screws.

Read these installation instructions before starting to use the equipment.