Installation, Operation & Maintenance Manual
518 CENTRIFUGE Per Assemblies: 380 VAC 50 Hz 460 VAC 60 Hz 575 VAC 60 Hz
UL Approved Worldwide Headquarters P.O. Box 42842 Houston, Texas 77242-2842 Tel: 281-561-1300 Fax: 281-561-1441 www.miswaco.com E-Mail:
[email protected]
Manual Part #: 90-90-061 Rev. C
DISCLAIMER Recommendations made by M-I SWACO are advisory only. M-I SWACO shall not be liable under any guarantees or warranties, expressed or implied, in any manner or form, AND ALL WARRANTIES, EXPRESSED OR IMPLIED, ARE HEREBY SPECIFICALLY EXCLUDED, and M-I SWACO shall not be liable for the failure to obtain any particular results from the use of any recommendation made by it or from the use of this material. In no event shall M-I SWACO be liable for incidental or consequential damages.
© Copyright 2008 M-I SWACO Publication Date: September 2008 All other products, brand, or trade names used in this publication are the trademarks or registered trademarks of their respective owners. All rights reserved. This publication is the property of, and contains information proprietary to M-I SWACO. No part of this publication may be reproduced in any form or by any means, including electronic, mechanical, or otherwise, without the prior written permission of M-I SWACO. Information contained within this publication is subject to change without notice.
Table of Contents Page 1
Introduction Safety Precautions
2
Section 1
Unit Description
3
Centrifuge Components Specifications Rotating Assembly Components Safety Components Bowl and Conveyor Speeds Step Sheaves
3 7 8 8 9 9
Installation
11
Transportation and Handling Centrifuge Mounting Electrical Installation Feed Pump Liquid Feed and Discharge Solids Discharge Startup and Shutdown
11 12 12 12 13 13 13
Inspection and Maintenance
14
Shop Inspection Lubrication Maintenance of Fluid Couplings Cleaning Belt Tensioning G.S. Coupling Vibration Sensing Switch Fluid Coupling Electrical System
14 15 19 20 20 21 25 25 25
Troubleshooting Chart
26
1.1 1.2 1.3 1.4 1.5 1.6 Section 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Section 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 Section 4
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Page 27
Section 5 Repair and Overhaul 5.1 5.2
5.3
5.4
Rotating Assembly Removal Rotating Assembly 5.2.1 Bearing Alignment 5.2.2 Gearbox Alignment 5.2.3 Disassembly Gearbox 5.2.4 Conveyor Removal 5.2.5 Assembly – Gearbox End 5.2.6 Disassembly – Large Conveyor Bearing 5.2.7 Assembly – Large Conveyor Bearing 5.2.8 Disassembly – Feed End 5.2.9 Assembly – Feed End 5.2.10 Disassembly – Small Conveyor Bearing 5.2.11 Assembly – Small Conveyor Bearing Bowl 5.3.1 Level Regulating Discs 5.3.2 Solids Discharge Bushings Conveyor 5.4.1 Shimming 5.4.2 Installation
Section 6 Diagrams and Parts List 1. 518 Centrifuge 2. Bowl Assembly 3. Gearbox End Assembly 4. Feed End Assembly 5. G.S. Coupling 6. Frame 7. Vessel 8. Conveyor 9. Shim Selection 10. 350 kpm Gearbox 11. Electrical Assembly 12. Electrical Wiring Diagram 13. Electrical Cabling 14. Electrical Schematic Diagram 15. Feed Pump Electrical Diagram 16. Special Tools
27 27 27 30 30 32 33 33 34 37 38 38 39 40 40 41 42 42 42
46 49 51 54 57 59 60 63 65 67 69 71 74 75 76 77
Section 7 Appendix A. Gyrol Fluid Coupling B. Conveyor Wear Recording C. Jolly Couplings Hydromechanical D. Turbostart
ii
Introduction This manual contains directions and information concerning installation, startup, shutdown and service of the Swaco 518 Centrifuge. Appropriate sections of this manual must be read and understood before attempting to install, operate or service this unit. Failure to do so may cause injury to personnel, damage to the equipment or reduced performance. The Swaco 518 Centrifuge is known as a decanting type separator. A decanter is a centrifugal separator having a horizontal axis of rotation. A process liquid or slurry is supplied to the rotating bowl where the solids are separated from the liquid phase. The solids are forced to the inner wall of the bowl while the liquid forms a ring inside the solids. A screw type conveyor transports the solids toward the tapered end of the conical bowl. The liquid flows in a spiral path, established by the conveyor flights, to the discharge ports at the large end of the bowl. The primary application for the 518 Centrifuge is to run in series with the 414 Centrifuge for secondary separation of low gravity solids and recovery of the expensive liquid phase.
3
General Safety Precautions The Swaco 518 Centrifuge is engineered and manufactured to perform safely under conditions described in this manual. This large high speed rotating machine requires care and understanding for maximum safety. Unsafe practices in maintenance and operation will cause conditions which are hazardous to both maintenance and operation and cause conditions which are hazardous to both personnel and property. The following general precautions should be strictly followed to avoid damage to property and/or death to personnel. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Do not allow personnel to maintain, install, or operate the 518 Centrifuge until they have read this manual and understood safety requirements. Do not operate the centrifuge until it is properly mounted. Do not operate the centrifuge if the machine is not completely and correctly assembled. Do not inactivate the centrifuge for any extended period of time without inactivating the electrical circuit to the motors. Be sure wiring is connected according to wiring plate on motors. Do not operate the machine unless the cover is closed and clamps and clamping devices are tightened. Do not use inlet connections as supports for feed hoses. Do not operate the centrifuge if unusual noise or vibration exists. Do not attempt to repair the centrifuge until the switch box is locked in OFF position or has had the breakers locked OPEN. Do not attempt to assemble or disassemble the centrifuge if the bowl is rotating. Do not operate the 518 Centrifuge until startup and shutdown procedures are understood. Do not attempt to manually shutoff the back drive motor. It will automatically shutoff approximately 10 minutes after the bowl drive motor stop button has been released.
4
Section 1
Unit Description
1.1
Centrifuge Components
1.1.1
The centrifuge bowl is the outer member of the rotating assembly and is composed of one cylindrical section and a conical section. The end piece on the cylindrical end has ports through which the liquid flows out. Semidry solids are discharge through ports in the small end of the conical section. The hollow shaft at each end of the bowl is suspended in a pillow block bearing to allow rotation of the bowl. (See Figure 1)
Figure 1 (Bowl) 1.1.2
The conveyor is suspended inside the bowl on bearings and rotates in the same direction as the bowl, only slightly slower. The separated solids are forced to the inside wall of the bowl by centrifugal force and conveyed to the solids discharge ports in the bowl. The pitch (P) of the conveyor flights is the distance in millimeters between the flights measured parallel to the axis of the conveyor.
Figure 2 (Conveyor)
5
1.1.3
The planetary gear box, is fitted on the hollow shaft at the cylindrical end of the bowl. It drives the conveyor by means of a shaft going through the hollow shaft of the bowl. On the end of the gear box opposite the bowl, is a small shaft. This is the small sunwheel shaft of the planetary gear box. The speed and direction of the small sunwheel determines the differential speed, or the relative speed of the bowl and the conveyor.
1.1.4
The frame is the tubular steel member on which the bowl pillow block bearings, feed tube bracket and the vessel are mounted. See Figure 4
Figure 4 (Frame)
6
1.1.5
The vessel is a stainless steel case mounted on the frame that completely encloses the bowl. It is divided into compartments that divert the liquid and solids discharge to their respective outlets. The semi-circular cover is hinged to allow easy access to the bowl for inspection and maintenance.
Figure 5 (Vessel)
1.1.6
A feed tube is shown in Figure 6. Mud is introduced into the centrifuge through the feed tube Item 185, Diagram 1. This is a stainless steel tube approximately 2" O.D. and 36" Lg. It extends into the bowl and conveyor through the hollow shaft on the conical end of the bowl. Mud is pumped into the tube by the feed pump. The mud leaves the feed tube and enters the bowl through a slot in the conveyor (See Figure 2 - Conveyor). This slot in the conveyor extends approximately the length of the conical
section. Figure 6 (Feed Tube)
7
1.1.7
The belt guards on the 518 Centrifuge are made so that access to belts and G.S. Torque limiting coupling is through the split door on the side. The upper half of the door folds down for belt inspection and tightening and resetting the G.S. coupling. The door may be completely removed for other repairs.
Figure 7 (Belt Guards)
8
1.2
Specifications Length Width Height Weight Power Required
119 inches (3023 mm) 70 inches (1778 mm) 34 inches (864 mm) 4660 lbs. (2118 kg.) 380 Vac 50 Hz 3 Ph 460 Vac 60 Hz 3 Ph. 575 Vac 60 Hz 3 Ph. Current limiting fused Bussmann LPS 50 or equivalent (Other voltages and frequency available on special order)
Motors
25 Hp Main Drive 7-1/2 Hp Back Drive
Bowl: Dimensions Material
14" Dia (356 mm). x 56" Lg. (1422 mm) Stainless Steel
Conveyor: Type Pitch Material
4.33 inches (110 mm) Stainless Steel
Gearbox: Type Ration Mx. Torque
Planetary 57:1 350 KPM (Kilopoundal meters)
Bowl Speed: High Speed 3200 rpm Standard 2500 rpm High Volume 1900 rpm Recommended Feed Rate* at: High Speed Standard Speed High Volume
100 gpm (23 m/hr) 150 gpm (34 m/hr) 250 gpm (57 m/hr)
* The maximum feed rates will depend to some extent on the percent and type of solids
9
1.3 The centrifuge rotating assembly consists of the bowl, the conveyor and the planetary gearbox. All these items are described in Paragraph 1.1.1, 1.1.2 and 1.1.3. 1.4
The following safety components are incorporated in the Swaco 518 Centrifuge 1.4.1
Vibration Detection Switch This switch, Item 223, Diagram 1, is mounted on the centrifuge frame. Its function is to automatically shut off power to the bowl drive motor and feed pump when controlled by Centrifuge Control System, should excessive vibration of the unit develop, regardless of cause.
1.4.2
Torque Limiter The torque limiter is a combination of mechanical and electrical controls. The small sunwheel shaft has a spring loaded coupling (G.S. Coupling See Figure 12) which will limit the torque that can be applied to the shaft. If this limit is exceeded the coupling will disengage and will, by axial movement of the coupling, trip a limit switch, Item 224, Diagram 1. This will disconnect power from the bowl drive motor and the feed pump when controlled by Centrifuge Control System.
1.4.3
The mass of the rotating assembly is very high. To bring this assembly up to operational speed takes from 90 to 100 seconds. A fluid coupling is installed between the drive motor and the rotating assembly to allow the motor to attain full operating speed almost immediately and allow the bowl to reach operational speed gradually. Without the fluid coupling, the motor current on startup would be excessively high and could result in damage such as overheating of connectors and cable or motor overload protectors or could overload the power plant if it was operating near full load. Should a high load on the rotating assembly cause excessive slip in the fluid coupling, the heat so generated will melt a fusible plug in the coupling causing the oil to be dumped. This will unload the motor before any damage is done.
10
1.4.4
Overspeed of Back Drive Motor The small sunwheel is driven by a back drive motor (Paragraph 1.1.3). Overspeed of the back drive motor could occur if the back drive motor is turned off before or immediately after the main drive motor. This would allow the conveyor to assume the bowl speed. The rotation would be transferred through the gearbox to the small sunwheel shaft and through the belts to the back drive motor to rotate at higher than designed motor speeds and could cause the motor armature to fly apart resulting in property damage and/or personal injury or death. Back drive over speed is prevented by an electrical interlock. This interlock consists of a relay (Item 250, Diagram 12) which allows automatic shut off of the back drive motor approximately 10 minutes after the main drive motor is shut off. The time needed before back drive shut off is necessary since low friction in the pillow block bearing and the mass of the rotating assembly allow ten (10) to twenty (20) minutes of rotation after main drive motor shut off.
1.5
Bowl and Conveyor Speed The 518 CENTRIFUGE Bowl is operated between 1900 and 3200 rpm’s depending on the application. The conveyor rotates at approximately 10 to 79 rpm’s less than the bowl in the same direction. The 518 CENTRIFUGE operates at all times with the bowl and conveyor turning in the same direction and the conveyor turning slower than the bowl. The main drive motor should be wired so that the bowl always turns clockwise when viewed from the feed tube end. The small sunwheel in the gearbox is used to vary the differential speed between the bowl and conveyor. If the sunwheel is “fixed,” that is, not rotated by the back drive motor, the differential will equal the bowl RPM divided by the gearbox ratio (57:1). If it turns in the same direction as the bowl, the differential will be less than when it is fixed. If it turns in the opposite direction as the bowl, the differential will be greater than when it’s fixed. (See Diagram 10)
1.6
Step sheaves having two pitch diameter sizes each on the main drive motor and bowl sheaves permit operation of the 518 CENTRIFUGE at 1900, 2500 and 3200 rpm’s. The bowl speed is determined by the combination of sheave sizes selected on the bowl and motor. The motor mount is made to allow the motor and sheave to move a full sheave width for proper alignment to obtain the full range of bowl speeds.
Caution: DO NOT ATTEMPT TO OPERATE 518 CENTRIFUGE AT BOWL SPEEDS ABOVE 3200 RPM’S. SPEEDS ABOVE 3200 RPM’S WILL EXCEED THE DESIGN SAFETY LIMITS. THIS COULD CAUSE THE MACHINE TO DESTROY ITSELF POSSIBLY CAUSING INJURY OR DEATH.
11
The figure below provides the combination of sheave sizes to drive the Centrifuge bowl at the speed indicated.
60 Hz 1750 rpm motor: Description Bowl Sheave Bowl Motor Sheave Back Drive Motor Sheave Main Drive Belt Main Drive Belt Back Drive Belt
Part Number 96-10-416 96-10-414 05-79-096 05-06-120 05-06-116 05-06-127
Size 4-3V-5.6/4-3V-7.4 4-3V-10.6/4-3V-8.0 3-3V-10.6 3VX900 3VX850 3VX1000
Part Number 96-10-416 96-10-417 05-79-096 05-06-120 05-06-116 05-06-127
4-3V-5.6/4-3V-7.4 3V-10.6/4-3V-8.0 3V-10.6 3VX900 3VX850 3VX1000
50 Hz 1450 rpm motor: Description Bowl Sheave Bowl Motor Sheave Back Drive Motor Sheave Main Drive Belt Main Drive Belt Back Drive Belt
12
Section 2 2.1
Installation Transportation and Handling 2.1.1
The pillow block bearings are subject to damage from shock and vibration during transportation and handling. To prevent this, the pillow block bearing should be preloaded using wedge blocks shown in Figure 8
Figure 8 (Wooden Wedge Blocks)
13
2.1.2
Care should be used in loading and unloading this unit to prevent unnecessary shock to the components.
2.1.3
Caution: When lifting, always use a four point lift to protect unit from damage and/or turning upside down during lift.
any
2.2
Centrifuge Mounting The 518 Centrifuge must be mounted above the ground to facilitate solids removal. For recovery of weight material the solids discharge outlet should be located over a well stirred area of the mixing pit. A slide attached from the solids outlet may be necessary to route solids to the mixing pit. The slide should be set at a steep angle to prevent a solids buildup. The Centrifuge unit must be set level and on adequate supports. It may be necessary to attach it to the support by tack welding.
2.3
2.4
Electrical Installation 2.3.1
The electrical installation should be made by a qualified electrician. Input power fusing must be current limiting type. See Wiring Schematic, Diagram 12 for sizing.
2.3.2
Feed Pump - Control circuit power is taken from terminals TB1 and TB2 in the main control box (Item 216, Diagram 11) for the feed pump starter. This requires running a 14 gauge 2 conductor approved wire from the main control box to the feed pump starter. For typical hookup see Diagram 15. Pump starter holding coil must be 120 volts. Power for pump may come from any source of sufficient amperage and proper voltage. If feed pump auto shut down feature is not desired, starter may be used as wired and power cable hooked to any source of proper voltage and sufficient amperage.
Feed Pump 2.4.1
Any pump capable of furnishing the feed rate desired at sufficient pressure to overcome line loss may be used to feed the 518 Centrifuge.
2.4.2
A 5 Hp variable speed progressive cavity pump which furnishes 22 gallons per 100 revolutions is available from Swaco and is ideal for feed between 40 and 80 gpm's. (Swaco Type II Pumping Unit)
14
2.5
2.6
2.7
2.4.3
A centrifugal pump assembly capable of furnishing up to 250 gpm at 45 feet of head is adequate for high volume operation. This type of pump is also available from Swaco. (Swaco Type III Pump Unit)
2.2.4
Suction and discharge lines on the feed pump should be sized to minimize head loss due to line friction.
2.4.5
A water line should be connected between the pump and the feed tube for washing the bowl and conveyor prior to shutdown.
Liquid Feed and Discharge 2.5.1
The line feeding mud to the centrifuge should terminate with a male 2" NPT fitting to mate with the 2" elbow on the feed tube. This line should be supported so it's weight will not be on the feed tube.
2.5.2
The liquid outlet is a 8" Victaulic nipple. See Figure 5. The line connecting to this nipple can be steel hard piping, flexible hose or PVC pipe. It should be sized to accommodate the liquid discharge rate. Because the liquid discharge is gravity flow, consideration should be given to the fall and length of this line to avoid plugging from solids settling.
Solids Discharge 2.6.1
The outlet for solids discharge is 11-1/4" (286 mm) x 18-1/2" (470 mm) with a 1-1/4" (32 mm) wide flange. See Figure 5
2.6.2
If the centrifuge cannot be located over the proper area a slide may be attached to the solids outlet to route solids to the mixing pit. Since these solids will be sticky, the slide must be set at a steep angle to prevent a solids buildup.
Startup and Shutdown 2.7.1
Startup Start back drive motor Start main drive motor about 10 seconds after back drive motor. Do not start motors simultaneously. The sudden power drain may overload the power source. Allow at least two (2) minutes for the centrifuge to obtain operating speed. Bring mud feed rate up slowly to desired rate.
15
2.7.2
Before shutdown of the 518 Centrifuge, it is necessary to flush the bowl
with water. 1. 2. 3. 4. 5.
6.
Section 3 3.1
Shut off the feed pump. Close the mud suction valve. After all conveyable solids have cleared the bowl, open the water line which tees into the pump discharge line. Flush the centrifuge until clean water is discharged. Close the water valve. Stop the main drive motor. When the main drive motor is shut off, and electrical interlock activates and will automatically shut the back drive motor off after approximately 10 minutes. If the machine is likely to be subjected to freezing temperatures, the cover should be opened and bowl drained by removing two drain plugs on the liquid discharge end (Item 25, Diagram 2). Drain any hoses and pumps that may have liquid trapped in them.
Inspection and Maintenance Shop Inspection 3.1.1
With the cover closed and bolted down, rotate the bowl by hand and listen for any unusual noise or scrapping. The bowl should turn freely without drag. Any noises should be investigated. Check the G.S. coupling to be sure it is engaged. See Section 3.6
3.1.2
With cover open, rotate bowl assembly by hand and listen for any noise coming from within the bowl or the bearings. Any noisy bearings should be inspected and/or replaced. See Section 5.2
3.1.3
Check gearbox oil level. Remove magnetic plugs and inspect for metallic wear particles - See Figure 10. A large accumulation of metallic wear particles should be investigated and the cause determined. Refer to Section 3.2.2, Lubrication of Gearbox.
3.1.4
Inside J-Boxes, Diagram 12: Check heater packs, Item 249, 237 for proper ratings. Check fuses Item 245,246,244 to see if they are good, properly sized and installed properly. Check limit switch, Item 224, Diagram 1, which is under back drive
16
guard to see if it is closed when set against G.S. coupling, Figure 12, and open when coupling is disengaged, Figure 12. 3.2
Lubrication 3.2.1
Lubrication Bearings The pillow block and conveyor bearings should be lubricated every 100 hours of operation. See Figure 9 for location of grease fittings. Grease vent holes located behind pillow block housing and in gearbox cover nearest the bowl, are shown in Figure 9. Proper greasing is obtained when excess grease comes out the vent holes. The following is a list of factory approved greases which may be used for bearing lubrication. Mystick JT-6 Synthetic Blend Nils Lithoplex NOTE: Use only factory approved lubricants. Use of non-approved lubricants will void warranty.
17
18
3.2.2
Lubrication of Gearbox The 350 KPM gearbox contains two treaded plugs. The two plugs are magnetic and are removed for oil draining and filling. The magnetic plugs attract metallic particles, in the lubricating oil. The oil level in the gearbox should be checked before centrifuge operation. Remove inspection plate on side of gearbox (See Figure 10b). Oil level is checked with the plugs are 64° of vertical (See Figure 10a). Angle is correct when plug is centered on a line between the two inspection palte hold down screw holes. Normal oil level is indicated by oil at bottom edge of hole. After initial centrifuge operation the oil level should be checked weekly or whenever bearings are greased. The magnetic drain plugs should also be checked and metallic particles removed.
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3.2.3
Lubrication of gearbox on units with serial numbers smaller than 1000 Remove gearbox guard exposing entire gearbox. The gearbox contains two threaded plugs. The two plugs are magnetic and are removed for oil draining and filling. The magnetic plugs attract metallic particles, in the lubricating oil. The oil level in the gearbox should be checked before centrifuge operation. Oil level is checked when plugs are 54° off vertical (See Figure A). Normal oil level is at the highest plug. After initial centrifuge operation the oil level should be checked weekly or whenever bearings are greased. The magnetic drain plugs should also be checked and metallic particles removed.
20
The gearbox oil should be changed after the first 150 hours of operation of a new gearbox and at least once a month of normal running. A large accumulation of metallic particles on the magnetic plugs indicates the gearbox oil needs changing. Changing gearbox oil involves flushing of the gearbox with diesel oil or kerosene. The gear box should be filled with diesel or kerosene and rotated a number of revolutions by hand with all plugs screwed in. This flushing should be repeated two to three times or until clean. The gearbox should be filled with one of the gear oils listed below. Gearbox capacity is approximately one-half (1/2) gallon or two (2) liters. Continued accumulation of metallic wear particles in the magnetic plugs indicates abnormal gear wear. Shell Spirax ASX R 75W90 Chevron Tegra Synthetic Gear 75W-90 Citgo Mystik Synguard SX-7000 75W-90 Pennzoil Synthetic SAE 75W-90 GL-5 Texaco Syn-Star GL 75W-90 NOTE: Use only factory approved lubricants. Use of non-approved lubricants will void warranty. 3.3
Maintenance of Fluid Couplings – Item 171, Diagram 1
This coupling must be filled to the recommended oil level to deliver the proper amount of torque and not overheat from slippage. See Appendix D for further details. The oils approved for the use with the fluid coupling are listed below. See the manual in Appendix A for additional information. Mobil DTE 24 Agip OSO 32 BP Energol HLP 32 ESSO NUTO H32 Shell Tellus 32 NOTE: Use only factory approved lubricants. Use of non-approved lubricants will void warranty.
21
3.4
Cleaning Cleaning and inspection should be done every 100 hours when bearings are lubricated. Cleaning may be needed more often when conditions are severe.
3.5
3.4.1
With the cover open, hose down the inside of the vessel and the outside of the bowl. Pay particular attention to removing any solids buildup around the solids discharge bushings (See Item 86, Diagram 2). Also, remove solids buildup inside the cover.
3.4.2
Inspect the solids discharge bushings for wear. Worn bushings should be replaced before any wear has damaged the bowl. See Figure 29 and 30
3.4.3
Inspect wear shield in cover for excessive wear and replace if necessary.
3.4.4
Inspect magnetic plugs in gearbox for metallic particles and check oil level. See Section 3.2.2
Belt Tensioning 3.5.1
Belt tension should be checked routinely when lubricating bearings.
3.5.2
The following procedure for belt tensioning should be used starting when a new 518 Centrifuge is put into service or anytime belts are replaced. It is important that the belts are correctly tensioned. A belt that slips on its pulley is exposed to abnormal wear. If on the other hand the belts are too tight, this will cause wear on the bearings. Proceed as follows to get the correct tension: 1.
2.
3.
4.
Collect the belt slack on the upper side. Adjust the pulley center distance by moving the motor until the belts have a light tension. Rotate the drive parts a few turns by hand. Adjust the center distance so that all belts are lying well. Start the motor and run for approximately 10 minutes so that the belts can adapt themselves to the grooves. Stop the motor and adjust the center distance until all belts are lying evenly and are properly tightened. (A stretch of 1/2 - 1% of the belt length will not damage the belts) New belts should be retensioned every two hours during the first day of running. After this, further tightening may be unnecessary, as the length of the belts remains practically constant. When changing belts,
22
never force them over the side of the pulley. Always loosen the motor to install them. Over tensioning of belts may cause premature failure. 5.
When one or more of the belts is worn out, put on a COMPLETE
set of new belts. 6.
A good way to check belt tension is to strike the belts with a clench fist. A slack belt will feel dead under this test, whereas a properly tensioned belt will vibrate and feel alive. Check the belt tension from time to time. See Figure 11
Warning: Never run unit with belt guard removed and never check belt tension while unit is running. Such unsafe practices can result in injury or death. The working life and proper functioning of the belts depend to a high degree on how they are cared for. Oil and grease will soon ruin them. Oily or greasy belts can be cleaned with a good solvent.
3.6
G.S. Coupling Solids overloading can cause excessive torque between the bowl and conveyor. This torque could damage the gearbox if the overload became too severe.
23
The 518 Centrifuge utilizes a spring loaded coupling to limit this torque. The torque is exerted on this coupling which is mounted next to the gearbox sheave. Should the torque exceed a preset limit, (50-60 ft/lb. (74.4-89.3 km)) the coupling will disengage and trip a limit switch (See Item 224, Diagram 1). This will shut off both the feed pump and main drive motor. The bowl should then be flushed with water to remove any excess solids left in the bowl. The procedure for resetting the G.S. coupling is discussed in the next paragraph. Continued coupling disengagements will require removal of bowl and conveyor for cleaning. Figure 12a illustrates the G.S. coupling in the engaged position. When excessive torque is exerted on the gearbox, the G.S. coupling disengages from the driver (Figure 12b). The three balls of the coupling are forced out of the depressions in the driver an slide down the slopes of the driver. This causes the coupling and the driver to rotate 60° in relation to each other. At the same time, the coupling moves 1/4" toward the driver. This movement trips the limit switch which removes power from the feed pump (when feed pump interlock is used) and the main drive motor. This movement also allows the cams on the V-belt pulley to be released from the slots in the coupling as shown in Figure 12b. The bowl and conveyor now rotate at the same speed.
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3.6.1
Resetting the G.S. Coupling (Refer to Figures 12c and 12d) 1. 2.
3.
3.6.2
Insert a steel bar into a hole in the coupling and a bar in a slot in the driver. Rotate the bars in opposite directions until the steel balls return to original position. Be sure slots in the coupling line up with the cams on the V-belt sheave (See Figure 12c and 12d). If not, the coupling will not reset. Remove bars and reset limit switch. The conveyor and bowl are now again coupled together.
Testing G.S. Coupling for proper release force (Refer to Figure 13) 1.
2. 3.
4.
Place G.S. Coupling torque measuring adapter over coupling assembly. Insert pin in adapter hole through to the hole in the coupling. Place torque wrench socket fitting into socket on adapter. With G.S. Coupling engaged as in Section 3.6.1 turn clockwise and not torque reading at disengagement. Repeat four (4) times. Note smallest reading. This reading should be between 50 and 60 ft.lbs (67.1-81.3 Nm). Repeat step 3 in the counterclockwise direction. Readings should be the same.
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3.6.3
Adjusting G.S. Coupling release force Some adjustment is possible by adding or removing spacer washers (Item 98, Diagram 5). Adding washers increases disengagement force and removing decreases force. If proper functioning and force readings cannot be obtained by washer adjustment, replace spring washer group, eleven (11) pieces, (Item 97, Diagram 5).
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3.7
Vibration Detection Switch The high speed rotating assembly of the 518 Centrifuge requires near perfect balance for minimum vibration. Should an imbalance cause excessive vibration, the main drive motor and fee pump will be shut off by a vibration detection switch, (See Item 223, Diagram 1). Excessive vibration is usually caused by a solids buildup within the bowl or uneven bowl and/or conveyor wear. The vibration detection switch is mounted on the centrifuge frame. Refer to Appendix for manufacturers information on the vibration switch.
3.8
Fluid Coupling Bring the large rotating assembly to operating speed would normally take the main drive motor approximately 100 seconds. This would cause the motor to draw excessive current, overheat conductors, trip thermal protectors or overload the power plant. These problems are eliminated by a fluid coupling installed on the main drive motor shaft. The fluid coupling allows the motor to attain speed almost immediately while the bowl assembly is still accelerating. If excessive drag on the bowl causes greater than normal slip, the heat generated will cause a fusible plug in the coupling to melt. This will dump the hydraulic fluid in the coupling and unload the motor before any damage can be done. See Appendix for manufacturers information on the fluid coupling.
3.9
Electrical System 3.9.1
The electrical system on the 518 Centrifuge conforms to the National Electric Code requirements for Class 1, Division 2, Group D.
3.9.2
The electrical system is shown in Diagram 11, Component Placement and wiring Diagram 12 and Schematic in Diagram 14, Cabling is shown in Diagram 13. These diagrams may be used to trace down individual components or wiring circuits. The use of these diagrams will greatly simplify trouble shooting electrical problems.
27
Section 4
Troubleshooting Chart
Problem Motors do not start
Startup and shutdown vibration Machine vibrates
Fluid coupling plug melts
Noise from gearbox
Continued disengagement of G.S. Coupling
Solids discharge too wet
Cause 1. No power to unit 2. Vibration switch not reset 3. Limit switch on G.S. Coupling tripped 1. Moderate vibration at critical rpm during startup and shutdown 1. Bowl may be out of balance due to poor cleaning, bowl parts interchanged with another bowl or uneven wear on conveyor or bowl. 2. Vibration damping mounts have lost elasticity. 1. Excessive amount of solids causing overloading 2. Fluid volume or type wrong. 1. Oil volume low or type wrong 2. Worn gears 3. Worn bearings 1. Large accumulation of solids in bowl. 2. Excessive amount of solids in feed mud. 1. Feed rate too high 2. Conveyor differential too high
1. 2. 3. 1.
Remedy Restore power Reset vibration switch Section 1.3.1 Reset limit switch Section 1.3.1 None required
1. Determine if vibration is due to the causes described. 2. Replace rubber mounts.
1. 2. 3. 1. 2. 3. 1. 2.
Reduce feed rate Check oil level in coupling Replace oil if in doubt Check oil level and oil type, replace if in doubt Replace gearbox Replace bearings Flush bowl Reduce feed rate
1. Decrease feed rate 2. Change back drive motor sheave to reduce differential See Diagram 1
NOTE THE ABOVE DESCRIBED ITEMS ARE NOT TO BE CONSIDERED CONCLUSIVE. IF YOU HAVE ANY QUESTIONS, CONTACT SWACO ENGINEERING, HOUSTON, TEXAS, 281-988-1868
28
Section 5 5.1
Repair and Overhaul Rotating assembly removal The following procedure is for removal of the rotating assembly. Remember the bearing housings are aligned for each centrifuge frame and should never be interchanged. 1. Open vessel cover. 2. Remove the following parts: a. Bolts from bearing housing cap. b. Belt guards, belts and feed tube. 3. Carefully lift the bowl assembly using a hoist and nylon sling. Set bowl on a wooden pallet to prevent rolling. Parts which are Removed should be placed in a clean area to facilitate cleaning and inspection.
5.2
Rotating assembly 5.2.1
Correct Bearing Alignment The rotating assembly is mounted on two pillow block bearings which are specially aligned. A special alignment shaft is used to align the pillow block housings to the centrifuge frame. This bearing alignment must be performed in Swaco Assembly Shop, in Florence KY. NOTE BOWLS CAN BE SWITCHED FROM ONE FRAME TO ANOTHER ONLY WHEN THE PILLOW BLOCK HOUSINGS REMAIN WITH EACH CENTRIFUGE FRAME. WORN BEARINGS CARTRIDGES MAY BE REPLACED. PILLOW BLOCKS CONTAIN RANDOMLY LOCATED ALIGNMENT PINS THEREFORE A GIVEN SET OF PILLOW BLOCK HOUSINGS WILL ONLY FIT THE ORIGINAL FRAME AS DELIVERED.
29
TAPERED ALIGNMENT PINS ARE USED TO ASSURE PERFECT ALIGNMENT OF BEARING HOUSINGS, IF BEARING HOUSINGS HAVE BEEN REMOVED. ALWAYS INSERT THE ALIGNMENT PINS BEFORE TIGHTENING BEARING HOUSING BOLTS.
30
31
The following sections discuss the dismantling of the rotating assembly. Parts illustrated in the figures are numbered and parenthesized in the instructions.
5.2.2
Removal The procedure for removing the gearbox is as follows: (Refer to Figure 15 and 16 for illustrations) 1. Remove the screws (6) connecting the gearbox to the bowl flange (5). 2. Screw in the two screw plugs (7) and back off gearbox from bowl flange (5). 3. The drive shaft (48) of the gearbox is loose on both ends. Be careful not to
drop shaft when removing the gearbox. 5.2.3
Disassembly gearbox end The procedure for disassembling the gearbox end of the rotating assembly is as follows. (Refer to Figure 16) 1. Remove the 16 screws (29) holding the end piece (27) to the bowl. Remove the 4 screw plugs (28). The end piece is removed from the bowl by screwing 4 screws (29) into the screw plug holes and backing off. Care should be taken to protect the roller bearing inner race (31) and the lip seal ring (30). 2. Remove the round nut (1) with pin spanner. Figure 17a illustrates pin spanner.
32
3. Remove the flange (5) facing the gearbox, using the puller if necessary. Figure 17b illustrates flange removal.
4. The labyrinth ring (10), roller bearing outer race (13), and spacing ring (15) can be removed by hand. The roller bearing inner race can be removed with the special puller tool (P/N: 96-01-036) as shown in Figure 18. The puller tool is needed since the roller and needle bearing inner races are press fitted. The tool consists of a metal clamp ring with four attaching screws. Push the clamping ring on the inner race and clamp tool tight with screws contacting inner edge of bearing race. Using the puller as shown, pull the inner race from the bowl end piece. Refer to Figure 18 for illustration.
33
5. The fat valve disc (17) is removed after removing the bearing inner race. If the fat valve disc has seized to the end piece (27), remove by using the puller as shown in Figure 19. The claws of the tool should seat against the bearing removal tool. (P/N: 96-01-035)
5.2.4
Conveyor Removal It is necessary to remove the conveyor for replacement of bearings and seals. Conveyor removal is also necessary to inspect for unusual conveyor wear or imbalance. The following procedures discuss conveyor removal. 1. 2.
3.
Remove the gearbox and end piece as discussed in Section 5.2.2, 5.2.3 Item 1. After removing the gearbox and end piece, the conveyor can be partly pried out. The conveyor can be completely removed using a hoist as shown in Figure 20. Remove feed end piece to facilitate easier assembly of conveyor. See Section 5.2.8 for feed end piece disassembly.
34
5.2.5
Assembly gearbox end Assemble the parts in sequence as shown in Figure 16. Observe the following when assembling. The lip seal ring (30) of the large conveyor bearing must be mounted on the end piece pivot before mounting the roller bearing inner race (31). Apply ball bearing grease to the lip seal ring. Lubricate the roller bearing with grease listed in Section 3.2.1.
5.2.6
Disassembly large conveyor bearing The procedure for disassembling the large conveyor bearing is as follows: Refer to Figure 21 for identification of parts. 1.
Prior to disassembly, the bearing holder flange (37) and the conveyor edge should be indexed with a center punch to facilitate alignment when reassembling.
35
2.
3.
4.
5.2.7
Remove the screw (38), and set screw plugs (36) from the bearing holder (37). The bearing holder is removed by screwing two jacking screws (P/N: 84-01-460) into the screw plug threads (36) and backing off. The oring (14), roller bearing (31), and snap ring (40) can now be removed. The snap ring (32), o-ring (33), seal lining (34), and lip seal ring (35) may also be removed for inspection. Using the special T-handle screw (P/N: 96-01-006), Figure 21, back out the thrust ring (41), angular contact ball bearings (42), ball bearing holder (43) and ejector disc (46). Inspect parts and replace if necessary. Figure 18 illustrates the large conveyor bearing and part removal procedure. Item (44) shim is used to adjust axial clearance. None, one or more shims may be found upon disassembly. You should reassemble using same number and thickness shims as originally installed. When replacing a conveyor, shims needed should be determined as shown in Diagram 9.
Assembly Large Conveyor Bearings Assemble the parts in sequence as shown in Figure 21. Observe the following when assembling. Fill the ball bearing holder (43) with ball bearing grease before installing the angular contact ball bearing (42) faces the gearbox. If the ball bearing holder (43) cannot be pushed into its seat by hand, use a pipe for a drift and gently tap it in. Be sure the bearing holder bottoms out. The parts should be assembled in the bearing holder (37) in the following order. a. b. c. d. e. f. g.
Roller bearing outer race (31) with rollers. Snap ring (40) facing roller bearing. Lip seal ring (35) in seal lining (34). Be sure lip seal ring is turned outward. O-ring (33) in groove of seal lining (34). Seal lining (34) in bearing holder (37). Snap ring (32) facing seal lining. O-ring (14) in groove of bearing holder (37).
Apply ball bearing grease to the sealing lip of the seal ring. Apply enough grease around the seal lining so the annular space between the lip seal ring of the lining and the end piece (27) will be filled with grease in final assembly.
36
37
38
5.2.8
Disassembly Feed End
The procedure for disassembling the feed end of the rotating assembly is as follows. Refer to Figure 22 1.
Remove the screws (64) holding the end piece (67) to the bowl. The end piece is removed from the bowl by screwing two of the removed screws into the screw plug (65) threads and backing off the end piece. Care should be taken to protect the roller bearing (54) and the lip seal rings (30/35).
2.
Remove the round nut (85) with pin spanner shown in Figure 23. Remove the V-belt pulley (82). The puller, shown in Figure 24, may be needed to remove pulley.
3.
Loosen the labyrinth ring (79) and screws (80). Remove the inner labyrinth ring (10) and labyrinth ring (79) by hand.
39
5.2.9
4.
Remove the fat valve disc (17), spacing ring (75), ball bearing (77) and spacing sleeve (81) with puller as shown in Figure 25. The claws of the puller should rest against the bearing removal tool (P/N: 96-01-035). Difficulty in removing these parts indicates the spacing sleeve (81) has seized. If so, pull spacing sleeve off by inserting the puller claws in the groove of the spacing sleeve.
5.
To remove the needle bearing inner race (54) use the puller tool as discussed in Section 5.2.3. The snap ring (59), and lock ring (60) need removal for needle bearing inner race removal.
Assembly Feed End Assemble the parts in sequence as shown in Figure 22. Observe the following when assembling. 1. 2. 3.
Apply ball bearing grease to the sealing lip of the lip seal ring (30). Install needle bearing inner race by heating as described in Section 5.2.4. Heat pillow block ball bearings (77) in oil before installing on the end piece pivot. Lubricate the ball bearings with grease. See Figure 3.2
5.2.10 Disassembly Small Conveyor Bearing The procedure for dismantling the small conveyor bearing is as follows. Refer to Figure 22.
40
1. 2.
Remove screws (58). Remove the tapered lock ring (57). Using the jack screws (P/N: 96-01-011) ease out the ejector disc
3.
If necessary the protecting tube (50) can be removed. Inspect parts carefully and replace if necessary.
(52).
5.2.11 Assembly Small Conveyor Bearing The procedure for assembling the small conveyor bearing is as follows. Refer to Figure 22. 1. 2. 3. 4. 5. 6. 7.
If the protecting tube (50) was removed, a new o-ring (49) should be installed. Apply grease on the o-ring before installation. Install the ejector disc (52) observing alignment of pin on flange of protected tube (50). Install shims (53) the number and thickness as those removed. Install the bearing outer race (54). Apply grease on o-ring (33). Install o-ring in the groove of the bearing cavity of the conveyor. Install a new lip seal ring (35) in the seal lining (56). Check that sealing lip is turned the correct way. Install the seal lining (56) by pressing it evenly into its seat. The seal lining should be pressed in straight to prevent damage to the oring. Use drift tool (P/N: 96-01-027) to press seal lining into conveyor. See Figure 27.
41
8. 9.
5.3
Install the lock ring (57). Apply grease to the sealing lip of the lip seal ring. Apply enough grease to entirely fill the annular space between the lip seal ring and end piece when assembled.
Bowl 5.3.1
Level Regulating Disc (Overflow dams) The level regulating discs are shown in Figure 28. The discs are mounted to the end piece by three screws. In the 414, discs are used to give a pool radius of 4.52 inch (115 mm) or 4.92 inch (125 mm) and are so marked.
42
5.3.2
Solids Discharge Bushings
The discharge bushings should be replaced before wear is allowed on the bowl. To remove discharge bushings use a soft drift and a hammer to tap out as shown in Figure 29.
Replace bushings in pairs only. Replace the defective bushings and the one opposite it. To install discharge bushings, clean outer surface of new bushings and inner surface seats of the bowl. Apply a thin layer of loctite 270 to the surface of the discharge bushings. Insert bushings into the seat and turn until the loctite is uniformly distributed. Press bushing tightly into place. Handling strength is obtained after 20 minutes and maximum strength after 3 hours. Refer to Figure 30 for installation.
43
5.4
Conveyor 5.4.1
Shimming
When installing a new conveyor in a bowl it is necessary to obtain the correct clearance between the edge of the conveyor flights and the bowl, in the conical end. It is also necessary to obtain the correct axial clearance between the bowl and the conveyor. This is done by the use of shims or adjusting rings inside the bearing cavity in each end of the conveyor. When bearings and/or seals are changed in a conveyor, the existing shims should be reused. If these shims have been damaged in any way, the same size and number of new shims should be used. See Diagram 9 for determining the shims required. 5.4.2
Installation 1. 2. 3.
Bolt the small end piece, Item 67, Figure 22 to the bowl. Insert the conveyor into the bowl, taking care as the protector tube slides through the end piece. Bolt the large end piece, Item 27, Figure 16, to the bowl. If the gearbox flange, Item 5, Figure 16, has been removed, proceed as follows.
44
a.
b. c.
Clean any dirt and grease from the mating surfaces of the large end piece and the flange. Remove any residual Loctite from the splined surfaces of the end piece and the flange. Apply an even coat of Loctite 225/222 on the end piece splines. Install the flange on the end piece. Install lockwasher, Item 2, and the round nut, Item 1, Figure 16.
NOTE: The flange face that bolts to the gearbox must run true to prevent any gearbox runout. Section 6: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Diagrams and Parts Lists
518 Centrifuge Bowl Assembly Gearbox End Assembly Feed End Assembly G.S. Coupling Frame Vessel Conveyor Shim Selection 350 KPM Gearbox Electrical Assembly Electrical Wiring Diagram Electrical Cabling Electrical Schematic Diagram Feed Pump Electrical Diagram (Typical) Special Tools
45
Diagram 1 (518 Centrifuge)
46
Index No. 76 87 124 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200
Swaco Part No. 65-92-328 80-73-868 13-05-393 96-10-030 96-10-034 96-10-035 96-10-379 05-30-117 05-79-096 31-05-265 96-10-414 96-10-394 96-10-395 50-30-089 96-10-104 12-20-061 13-05-015 58-59-347 58-95-175 58-95-176 05-06-114 05-06-126 05-06-119 96-10-429 96-50-350 84-20-207 96-50-345 96-50-363 96-50-361 96-50-344 13-45-092 13-45-088 13-45-090 13-45-087 13-45-086 13-45-389 13-45-212 13-05-571 13-05-391
Description
Qty.
Terminal Wire 1/0 AWG Ring Strap, Braided Scotch Nut, Lock Cad Plt. ½”-13 Skid 414 Centrifuge Guard, Belt, Feed Tube End Guard, Belt, Backdrive End Guard, Gearbox Bushing 1-3/8” Bore Sheave Coupling, Drive, Turbostart Step Sheave, Motor (4-3V-10.6/4-3V.80) Motor Mount Base 25 Hp Motor Mount Base 7-1/2 Hp Ell, Galv., 2” NPT x 1-1/2” NPT Bracket, Limit Switch Stud, ¾” x 10 NC x 5-1/2” GR. 8 Nut, Hex Blk. ¾” x 10 NC 2 H Mount, Shock Washer, Head 4-1/4” O.D. Washer, Tail 3” O.D. Belt, 3V-850 Main Drive Belt, 3V-1000 Backdrive Belt, 3V-900 Main Drive Feed Tube, Standard Decal Warning, Shipping Decal Swaco Decal (Caution), Belt Guards Decal Wiring Hookup 414/518 Decal Sheave Speed Change Decal (Caution), On Cover Washer, Flat Cad. Plt. 5/8” Washer, Flat Cad Plt. 3/8” Washer, Flat Cad Plt. ½” Washer, Flat Cad Plt. 5/16” Washer, Flat Cad Plt. ¼” Washer, Lock Cad Plt. ¼” Washer, Lock Cad Plt. 3/8” Nut, Hex Cad Plt. ¼”-20 Nut, Lock Cad Plt. 3/8”-16
2 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 8 4 4 4 4 2 4 1 2 3 2 1 1 1
Diagram 1 (518 Centrifuge Parts List) 47
56 4 2 2 6 10 2 30
Index No. 202 203 204 205 206 207 208 210 211 212 213 214 215 220
223 224 231 232 235
Swaco Part No. 13-05-395 14-54-003 14-07-054 14-07-086 14-07-066 84-01-447 14-07-140 13-05-039 13-05-037 13-45-342 13-45-345 13-45-344 96-50-367 69-12-050 69-20-023 69-05-126 75-79-569 75-69-011 96-09-252 24-80-050 24-80-063 96-12-018 69-20-010 69-05-029
Description
Qty.
Nut, Lock Cad Plt. 5/8"-16 Screw, Hex Head Cap Cad Plt. 1/4"-20 x 5/8" Screw, Hex Head Cap Cad Plt. 1/4"-20 x 1" Screw, Hex Head Cap Cad Plt. 3/8"-16 x 1-3/4"" Screw, Hex Head Cap Cad Plt. 5/16"-18 x 3/4" Screw, Hex Head Cap Cad Plt. 10 mm x 30 mm Screw, Hex Head Cap Cad Plt. 5/8"-11 x 2-1/4" Nut, Hex Cad Plt. 1/2"-13 Nut, Hex Cad Plt 3/8"-16 Washer, Lock Cad Plt. 1/2" Washer, Lock Cad Plt. 3/4" Washer, Lock Cad Plt. 5/8" Plate, Rotation Indicator Motor, 230/460V 60C 25 Hp 1750 rpm Motor, 575V 60 Hz 25 Hp 1450 rpm Motor, 190/380V 50 Hz 25 Hp 1450 rpm Switch, Vibration, Main Reset Robertshaw 365 D 0 Switch, Limit x Plsn Proff #LSXA3K Box Hr Meter w/ Mounting Posts Meter, Elapsed Time, 60-260V (AC-DC) Meter, Elapsed Time, 120V 50 Hz Motor, 230/460V 60C 7.5 Hp 1750 rpm Motor 575 60 Hz 7.5 Hp 1750 rpm Motor 190/380V 50 Hz 7.5 Hp 1450 rpm
10 10 6 8 2 6 6 4 4 4 8 4 1 1 1 1 1 1 1 1 1 1 1 1
Diagram 1 (518 Centrifuge Parts List)
48
Diagram 2 (518 Centrifuge Bowl Assembly)
49
Index No. 11 25 26 27 28 29 51 58 62 64 65 67 68 83 86 88* 89 90 91 92
Swaco Part No. 28-40-015 96-10-392 84-01-324 96-10-149 84-01-360 84-01-462 84-01-350 84-01-452 84-01-372 84-01-458 84-01-357 96-10-142 96-10-316 84-01-269 96-10-319 96-10-249 96-10-309 84-01-460 96-10-307 14-93-335
Description
Qty.
Grease Fitting Cleaning Plug O-ring Large End Piece Screw SHCS, SS M6 x 12 mm Pin SHCS, SS M6 x 12 mm Pin, Dowel, SS, 6 x 10 mm SHCS, SS, M10 x 25 mm SHSS, SS, M10 x 16 mm Small End Piece Bushing Key Discharge Bushing Overflow Dam 115m Bowl Section, Cylindrical SHCS, SS, M10 x 40 mm Bowl Section, Conical SHCS, SS, M8 x 25 mm
2 2 2 1 4 16 5 12 1 8 2 1 1 1 16 4 3 48 1 1
Diagram 2 (518 Centrifuge Bowl Assembly Parts List)
50
Diagram 3 (518ntrifuge Gearbox End Assembly)
51
Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20 21 23 25 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43
Swaco Part No. 84-01-298 84-01-870 96-10-315 84-01-370 96-10-148 84-01-972 84-01-964 84-01-520 96-10-431 96-10-399 28-40-015 96-10-145 84-01-034 84-01-336 96-10-403 84-01-322 96-10-354 96-10-398 96-10-352 84-01-310 96-10-392 84-01-324 96-10-149 84-01-360 84-01-462 84-01-443 84-01-031 84-01-433 84-01-421 96-10-411 84-01-405 84-01-991 96-10-377 84-01-454 84-01-431 96-10-406 84-01-023 96-10-378
Description
Qty.
Round Nut 80 mm Lock Washer 80 mm Bushing Pin, Grooved 5/16 x 1 inch Flange SHCS, SS, M16 x 30 mm SHSS, SS, M12 x 15 mm SHCS, M12 x 90 mm Washer Spacer Ring Labyrinth Grease Fitting Bearing Housing Cylindrical Roller Bearing SKF NU 1020 M/C3 O-ring Spacer Ring Lip Seal Ring Fat Valve Disc Guard Ring Deflector O-ring Cleansing Plug O-ring End Piece SHSS,, SS, M10 x 25 mm SHCS, SS, M10 x 45 mm Lip Seal Ring Cylindrical Roller Bearing SKF NU 216 Snap Ring O-ring Seal Lining Lip Seal Ring SHSS, SS, M10 x 12 mm Bearing Holder SHSS, SS, M8 x 20 mm Snap Ring Thrust Ring Ball Bearing SK 7316B Ball Bearing Holder
1 1 1 1 1 6* 3 4 4 1* 2 1 1 1 1 2 1 1 1 1 2 2 1 4 16 1 1 1 1 1 1 2 1 6 1 1 1 1
Diagram 3 (518 Centrifuge Gearbox End Assembly Parts List)
52
Index No. 44a 44b 45 46 47 69
Swaco Part No. 96-10-418 96-10-421 84-01-374 96-10-359 84-01-968 84-01-476
Description
Qty.
Shim Shim Pin Ejector Disc SHCS, SS, M6 x 40 mm SHCS , SS, M5 x 8 mm
1 1 4 1 3 1
53
Diagram 4 (518 Centrifuge Feed End Assembly)
54
Index No. 8 9 10 11 14 16 17 20 23 30 33 35 49 50 51 52 53a 53b 54 56 57 58 59 60 62 64 65 66 67 68 69 70 75 77 78 79 81 82
Swaco Part No. 84-01-520 96-10-431 96-10-399 28-40-015 84-01-336 84-01-322 96-10-354 96-10-398 84-01-310 84-01-443 84-01-421 84-01-405 84-01-332 96-10-380 84-01-350 96-10-360 96-10-419 96-10-420 84-01-027 96-10-410 96-10-345 84-01-452 84-01-429 96-10-401 84-01-372 84-01-458 84-01-357 84-01-993 96-10-142 96-10-316 84-01-476 96-10-351 96-10-405 84-01-020 96-10-144 96-10-400 96-10-425 96-10-416
Description
Qty.
SHCS, M12 x 90 mm Washer Spacer Ring Labyrinth Grease Fitting O-ring Lip Seal Ring Fat Valve Disc Guard Ring O-ring Lip Seal Ring O-ring Lip Seal Ring O-ring Protecting Tube Pin Ejector Disc Shim Shim Needle Bearing INA 85/26 Seal Lining Lock Ring SHCS, SS, M6 x 12 mm Snap Ring Lock Ring Pin SHCS, SS, m10 x 25 mm SHSS, SS, M10 x 16 mm Screw, Drive End Piece w/Bushing Bushing SHSS, SS, M5 x 8 mm Deflector Spacing Ring Ball Bearing SKF 6218 M/C4 Bearing Housing Ring Labyrinth Spacing Sleeve Step Sheave (4-3V-5.6/4-3V-7.4)
4 4 1 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 8 1 1 1 8 2 2 1 1 2 1 1 1 1 1 1 1
Diagram 4 (518 Centrifuge Feed End Assembly Parts List)
55
Index No. 83 84 85 87
Swaco Part No. 84-01-269 84-01-860 84-01-300 84-01-371
Description
Qty.
Key Lock Washer 90 mm Round Nut 90 mm Dowel , SS, M5 x 18 mm
1 1 1 1
Diagram 4 (518 Centrifuge Feed End Assembly Parts List)
56
Diagram 5 (518 Centrifuge G.S. Coupling 350 KPM Gearbox)
57
Index No. 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108
Swaco Part No. 84-01-970 96-10-430 96-10-357 96-10-140 84-01-884 84-01-891 96-10-334 96-10-408 84-01-428 84-01-036 96-10-369 96-10-415 96-10-365 84-01-369 96-10-130 84-01-485
Description
Qty.
SHCS, BLK, M8 x 20 mm Washer Driver Coupling Assy. Spring Disc. Washer 7/8 x 1-11/64 Clamp Ring Driver Brass Back Drive Cent. Screw Snap Ring Ball Bearing Ring Spacer Sheave Adapter Sheave Pin Gearbox SHCS, SS, M8 x 30 mm
5 1 1 1 11 1* 1 3 1 2 1 1 1 1 1 4
* Refer to Section 3.6.3 for quantity used. Diagram 5 (518 Centrifuge G.S. Coupling 350 KPM Gearbox Parts List)
58
Diagram 6 (518 Centrifuge Frame)
59
Index No. 8 9 11 12 73 78 110 111 112 113 114 115 163 164
Swaco Part No. 84-01-520 96-10-431 28-40-015 96-10-145 96-10-304 96-10-144 96-10-384 84-01-292 84-01-466 84-01-872 96-10-312 14-07-529 84-01-447 96-10-383
Description
Qty.
SHCS, BLK., M12 x 90 mm Washer Spacer Grease Fitting Bearing Housing Frame Bearing Housing Conical Pin Nut Hex Plt. M12 SHCS, PLT., M16 x 65 mm Clamping Washer Welded Bracket SHCS, SS, 1/2-13 NC x 2-3/4 SHCS, SS, M10 x 30 mm Pin
8 8 1 1 1 1 2 2 4 1 1 4 6 2
Diagram 6 (518 Centrifuge Frame Parts List)
60
Diagram 7 (518 Centrifuge Vessel)
61
Index No. 116 117 118 119a 119b 120 121 122 123 124
Swaco Part No. 96-10-372 84-01-350 84-01-464 96-10-107
Description
Qty.
Gasket Pin SHCS, PLT., M12 x 35 mm Vessel
1 2 4 1
14-07-467 84-01-464 96-10-396 96-10-385 13-05-404
SHCS, SS, 5/8-13 x 2-3/4 SHCS, SS, M12 x 35 mm Protecting Cover Hinge Pin Nut Lock SS 5/8-13 NC
4 4 1 2 4
Diagram 7 (518 Centrifuge Vessel Parts List)
62
Diagram 8 (518 Centrifuge Conveyor)
63
Index No. 125
Swaco Part No. 96-10-338
Description
Qty.
518 Conveyor (110 mm)
1
Diagram 8 (518 Centrifuge Conveyor Parts List)
64
Diagram 9 (518 Centrifuge, Method for determing adjusting shims)
65
Table 1 Difference (a-b) mm 11.0-11.9 12.0-12.9 13.0-13.9 14.0-14.9
In. .43-.47 .47-.51 .51-.55 .55-.59
15.0-15.9
.59-.63
Qty.
Part No.
Tmm
1 1 1 1 2
96-10-418 96-10-421 96-10-418 96-10-421 96-10-422
Qty.
Part No.
Tmm
1 1 2 1 1
96-10-419 96-10-420 96-10-419 96-10-419 96-10-420
1 1.5 2
Part No.
Tmm
96-10-418 96-10-421
1 2
96-10-419 96-10-420
1 1.5
0 1 2 3 4
Table 2 Difference (9.4 + d)-e mm (.370 + d)-e In. Mm In. 0-0.4 0-.016 0.5-0.9 .02-.035 1.0-1.4 .04-.06 1.5-1.9
.06-.075
2.5
Table 3 Shim Thickness Gearbox end of conveyor
Feed End of Conveyor
Adjustment of space between conical part of bowl and conveyor and axial clearance between bowl and conveyor. 1. 2. 3. 4.
5.
In addition to normal procedure when changing conveyor, remove the small end piece. Place the conveyor in the bowl shell so that it touches the cone. Measure the distances a,b,d and e as shown in Diagram 9. Calculate the difference a-b and find in Table 1 the adjusting shim or shims to be placed at position T between the conveyor big end bore and the bearing arrangement to give the right space. Calculate the difference (9.4 + d) - e mm and find in Table 2 the adjusting shim or shims to be placed at position (t) between the conveyor small end bore and the bearing arrangement to give the right axial space between conveyor and bowl.
Diagram 9 (518 Centrifuge Method for determing adjusting shims)
66
Diagram 10 (518 Centrifuge 350 KPM Gearbox)
67
Index No. 108 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 150 151 152 153 154 156 157 160 161 162
Swaco Part No. 96-10-366 84-01-485 84-01-404 84-01-408 84-01-052 96-10-434 96-10-343 84-01-325 84-01-335 96-10-374 96-10-432 96-10-317 96-10-388 96-10-375 84-01-038 96-10-382 96-10-393 90-60-279 84-01-454 84-01-461 84-01-024 84-01-966 84-01-048 96-10-376 96-10-433 96-10-318 96-10-389 84-01-046 96-10-373 84-01-333 96-10-342 84-01-485 84-01-025 96-10-412
Description
Qty.
Grease Nipple (Nave) SHCS, SS, M8 x 33 mm Ring Seal Ring Snap Bearing, Ball SKF 6005 2RS Wheel, Sun Small Cover, Sun Wheel End O-ring O-ring, Cover Holder, Gear Pivot, Gear #1 Wheel, Planetary Bushing, Bronze Gear, Gear #1 Pivot, Planetary Gear #1 Holder, Gear #1 Bearing, Ball SKF 16003 Housing, 350 KPM Gearbox Plug, w/ Magnet Seal, Plug SHCS, M8 x 20 mm SHCS, M6 x 16 mm Bearing, Ball SKF 16012 SHSS, M8 x 10 mm Bearing, Ball Gear #11 Holder, Pivot Gear #11 Wheel, Planetary Gear #11 Bushing, Bronze Gear, Gear #11 Pivot, Gear #11 Bearing, Ball SKF 16004 Holder, Gear #11 O-ring Cover, Drive Shaft End SHCS, M8 x 30 mm Bearing, Ball SKF 16017 Shaft, Drive
1 4 1 2 1 1 1 1 2 1 4 4 4 1 1 1 2 2 10 56 1 4 1 1 3 3 3 1 1 1 1 10 1 1
Diagram 10 (518 Centrifuge 350 KPM Gearbox Parts List)
68
Diagram 11 (518 Centrifuge Electrical Assembly)
69
Index No. 216 217 218
Swaco Part No. 96-10-362 80-16-100 79-06-215
219
79-06-221
220
69-12-050 69-20-023 69-05-126 75-73-324 75-73-290 75-79-569 75-69-011 93-89-007 65-60-161 65-60-059 65-60-275 31493 30221 96-09-252 24-80-050 24-80-063 96-10-361 75-73-320 69-12-018 69-20-010 69-05-029 96-10-391
221 222 223 224 225 226 227 228 229 230 231 232 233 234 235
252
Description
Qty.
Box, Curlee Drain, Breather 1/2" NPT (Reference) Cable, 4/C 10 AWG Itt Surprenant "Exane" Type TC Armoured Cable, 3/C 14 AWG Itt Surprenant "Exane" Type TC Armoured Motor, 230/460V 60C 25 Hp 1750 rpm Motor, 575V 60 Hz 25 Hp 1750 rpm Motor, 190/380V 50 Hz 25 Hp 1450 rpm Switch, Pushbutton Start-stop (Reference) Actuator, Reset (Reference) Switch Switch, Limit Explosion Proof #LAXA3K Arm, Roller Adjustable #LSZ-52KC Terminator Cable 10/4 Arm BICC 3/4 NPT Terminator Cable 14/3 ARM BICC 1/2 NPT Terminator Cable 6/4 ARM BICC 1-1/4 NPT Seal 1" EYS 3C-H Nipple, Electrical 1" X Close Box HR Meter w/mounting Posts Meter, Elapsed Time, 60-260V (AC-DC) Meter, Elapsed Time, 120V 50 Hz Box, Curlee Switch, Push Button Start XPRF (Reference) Motor, 230/460V 60C 7.5 Hp 1750 rpm Motor, 575V 60 Hz 7.5 Hp 1750 rpm Motor, 190/380V 50 Hz 7.5 Hp 1450 rpm Lid (Hour Meter)
1 2 10
Diagram 11 (518 Centrifuge Electrical Assembly Parts List)
70
12 1 1 1 1 2 1 1 1 4 4 1 1 2 1 1 1 1 1 1 1 1 1
Diagram 12 (518 Centrifuge Wiring Diagram)
71
72
Index No. 221 222 236 237 238
250 251 253 254 255
Swaco Part No. 75-73-324 75-73-290 75-84-005 69-45-198 96-10-047-01 96-10-047-04 77-17-083 75-19-600 80-06-063 65-90-003 80-04-016 80-06-123 75-18-540 75-18-456 75-18-458 80-53-636 75-84-004 69-45-194 69-15-193 80-71-379 80-06-207 79-06-011 84-01-077 79-06-012
256
65-92-010
257 258 259
65-92-005 80-06-130 80-06-131 80-06-050 80-06-220 80-87-250 80-87-050
239 240 241 242 243 244 245 246 247 248 249
260
39-95-197 75-119-598
Description
Qty.
Switch, Push Button Start-Stop (Reference) Actuator, Reset (Reference) Starter, Culter Hammer, AE16JNO Heater, Culter Hammer, H2014-3 (Set of 3) Transformer Control Micron Transformer Control Nicron Transformer Control Holer, Fuse 3 ph Buss #2809 Channel, Mntg A-B #1492-N22 (5-5/8" lg.) Block, Terminal A-B #1492-CD211 Barrier, End TB A-B #1492-N16 Clip, Retaining TB A-B # 1492-N16 Fuse, 500V/25A #FNQ-25 Fuse, Bussman KTK-R-1 Fuse, Bussman KTK-3 Jumper, Plug in TB A-B #1492-N3 Starter, Cutler Hammer, AE16ENO Heater, Culter Hammer, H2011-3 (Set of 3) Heater Element Ch H2010 (Set of 3) Relay Timer Agastat #7022 A-H Contact, Aux., Culter Hammer Wire, 14 awg Electric, Cu. THHN, Blk 600V CSA Wire, 10 awg Electric, Cu. THHN, Red 600V CSA Wire, 14 awg Electric, Cu. THHN, Blk 600V Solid, CSA Terminal, #14 awg, HLLGSWTH. Blk-Spade #B241662F Terminal, Ring 10 awg 1/4 Stud, HLLSWTH Coil, Holding 120/60/50 Hz 45 mm Coil, Holding 120/60/50 Hz 65 mm Compound, Sealing C-H # CHICO-A Compound, Sealing Fiber C-H # CHICO-X Tie, Cable, 1/16" x 1-1/8"" T&B #YT-542M Tape, Elec. Vinul 3/4" x 66' x 0.0085" Thick Scotch 88 Waterproofing Tape (Rubber) Holder Fuse .10-30 amp 1 pole
1 2 1 1 1 1 1 1 1 11 1 2 3 2 1 6 1 1 1 1 4 12 10 30
Diagram 12 (414 Centrifuge Wiring Diagram Parts List)
73
14 6 1 1 1 1 20 1 1 1
Diagram 13 (518 Centrifuge Cabling)
74
Diagram 14 (518 Centrifuge Electrical Schematic)
75
Diagram 15 (518 Centrifuge Typical Feed Pump Starter Electrical Schematic)
76
Diagram 16 (518 Centrifuge Special Tools) The following special tools are needed to perform repair and maintenance on the 518 Centrifuge
77
Special Tools Continued
78
Section 7
Appendix Appendix A Appendix B Appendix C Appendix D Appendix E
Gyrol Fluid Coupling (Used on older units) Vibra Switch Conveyor Wear Recording Jolly Couplings Hydromechanical (Used on older units) Turbostart Fluid Coupling
79
APPENDIX A
Gyrol Fluid Coupling
General Information The Fluid drive model NGS Fluid Coupling is designed to be installed as a complete unit on a standard NEMA-B motor shaft with a Worthington Type QD Sheave, furnished by the customer, mounted on the fluid coupling. The input shaft of the fluid coupling is finished bored and keywayed to fit the motor shaft and the stock bores are listed in the table. Oil is not supplied with the coupling. The oil capacity indicated is the nominal amount required to fill the unit. Reference should be made to 3.3 Maintenance of Fluid Couplings in the manual for the correct oil fill angle and oil type for the Centrifuge. Installation Instructions Note: Ensure that all parts are clean and serviceable. Lubricated all screws, mating surfaces, shafts and shaft hub tapers with oil free from Molybdenum Disulfide. 1. 2. 3.
4
Ensure the motor shaft dimensions are correct to NEMA-B Standard. Unscrew the socket set screws and remove the collar from the input shaft. Locate the selected Type QD sheave on the tapered hub of the Fluid drive fluid coupling. Fit and evenly tighten the three hex head set screws and spring washers. Refit the collar on the input shaft and fit the three socket set screws. Ensure that the long screw is located in the input shaft.
80
81
5.
6.
Fit the stepped key supplied into the motor shaft and mount the fluid coupling on the motor shaft, ensuring that the key and shaft key are correctly aligned. Move the coupling along the motor shaft as far as it will go. First tighten the lone set screw opposite the key on to the motor shaft, then tighten the two short set screws alternately to close input shaft evenly on to the motor shaft.
General Dismantling/Assembly Notes 1. 2.
3.
4. 5. 6.
7.
Dismantle and assemble the Fluid Drive Coupling in a clean, dry area. Use lint-free rags for cleaning. Before assembly, ensure that all parts are clean and serviceable. Lubricate all mating surfaces, screws, shafts and shaft hub tapers with oil free from Molybdenum Disulfide. If the fluid coupling is installed, ensure that the motor is correctly disconnected from the power source before removing the coupling for dismantling. Loosen the three set screws in collar and withdraw fluid coupling from motor shaft. Use a suitable container when draining oil from the coupling. For those units not using lockwashers, apply Loctite 242 or equivalent anerobic locking adhesive to the bolt threads or the tappered hole after cleaning with industrial solvent. Tighten all bolts to the torque valves given in the installation instructions or torque table. Always fit new gaskets and oil seals when reassembling the unit.
82
Unit Dismantling Instructions 1. 2. 3. 4.
5.. 6.
7.
8.
Remove the filter plugs. Drain the oil from the coupling. Fully unscrew the three socket set screws and remove the collar from the input shaft. Unscrew the three hex head set screws and spring washers and remove the pulley sheave from the hub. Unscrew and remove the set screws and spring washers from the hub flange. Remove the hub from the coupling, taking care to avoid damage to the needle roller bearings and seal. Discard the gasket. Remove the socket head cap screws and spring washers, and remove the end cover. Discard the gasket. Remove the input shaft. Place a wrench or ring spanner over the shaft washer, "hold" the shaft and unscrew the shaft screw. Remove the shaft washer assembly. Fill the hole in the shaft with good quality grease. Refit the shaft assembly, ensuring that the pins fit in the matching holes in the shaft. Apply teflon sealer on threads of the shaft screw and screw it back into the shaft. Place the wrench or ring spanner over the shaft washer and "hold" the shaft, then tighten the shaft screw so that the hydraulic pressure releases the shaft taper. Remove the shaft screw and washer. Gently tap the end of the shaft thought the ball bearing and remove the shaft. Inspect and replace the ball bearing as necessary, using an extractor to withdraw bearing from casing. A new sealing gasket must be fitted behind the weir ring before re-assembly. The end cover should compress the sealing gasket by a nominal 0.015 inches on final assembly to seal off the weir ring. Extract circle clip from hub and remove the needle roller bearing outer race complete for inspection. Inspect the needle roller bearing inner race on the input shaft and renew the complete bearing as necessary.
Unit Assembly Instructions 1.
2.
3.
Insert a new oil seal into hub. Lightly coat seal lip with oil to ease assembly over input shaft. Press the needle roller bearing into the housing, ensuring that it is square to the bore. Refit circle clip. Ensure that the inner race of the needle roller bearing is correctly seated against the shoulder of the input shaft. Feed the shaft into the coupling until the shaft end just enters the ball bearing. Do not overpress. Fit the shaft washer, taking care to locate the roll pins in the matching holes in the shaft end. Apply loctite 242 to the threads and fit the shaft screw and tighten until the shaft taper engages in the taper of the runner hub. Place a wrench or ring spanner over the shaft washer, "hold" the shaft and tighten the shaft screw to the torque specified in table. Lightly coat oil seal journal of shaft with the oil to ease oil seal assembly.
83
4. 5.
6. 7.
Fit new gasket to the end cover and assemble the cover into casing spigot. Fit and evenly tighten the socket head cap screws and spring washers. Fit a new gasket to the hub and feed the hub over the input shaft taking care to avoid damage to the oil seal and needle roller bearings. To prevent damage to the seal lip, cover input shaft keyway before assembly with masking tape extending beyond the shaft end and fold the free end back onto itself to provide a "grip". Keep the tape lightly tensioned as the oil seal is fed along the shaft until it is located on the seal journal and the hub is correctly located in the casing spigot, then carefully pull the tape from the hub/input shaft assembly. Fit and evenly tighten the set screws and spring washers. Mount the selected type QD sheave on the hub and secure with the three hex. Head set screws and spring washers. Assemble the collar on to the input shaft, ensure that the long socket set screw is located in the hole in the shaft with the two short screws each side of the keyway.
Filling Instructions Fluid drive couplings are shipped without oil and must be filled after assembly and before operation as follows: 1. 2.
3.
Remove one filter plug. Turn the coupling by hand to bring the plug hole to the 12 o'clock position, then turn the coupling back to bring the plug hole to the recommended fill angle from T.D.C (See Section 3.3 Maintenance of Fluid Couplings in this manual), and add oil to bring level up to plug hole. Ensure that the Dowty seal is in good condition and refit the plug. Tighten securely.
DO NOT MIX OILS. CHECK LEVEL WHEN COLD
Maintenance Instructions 1.
2.
Checking tightness of bolts after the fluid coupling has been in service for a few weeks, check that the screws in the collar, pulley sheave, hub and bearing housing are tight. If necessary, tighten the cap screws to the specified torque valves. Checking filling at intervals of about 12 months, check the level of oil in the fluid coupling and, if necessary add oil to make up the level.
Add only the same grade oil as that used for the initial filling of the couplings.
84
85
Index No. 1 2 3 4 5 6 7 8 9 10* 11* 12* 13* 17 18* 29* 30 31* 32* 33 37 38 51 52 53 54 55 56 57 58
Note: 1. 2.
Swaco Part No. 31-70-002 31-70-003 31-70-004 31-70-005 31-70-006 31-70-007 31-70-008 31-70-009 31-70-010 31-70-011 58-67-492 31-70-013 31-70-017 31-70-018 31-70-029 31-70-031 31-70-032 31-70-037 31-70-038 31-70-053 31-70-052 31-70-052
Description
Qty.
Casing Weld Assembly Bearing Ring Ball Bearing Shaft Washer Roll Pin Unbrako Screw Safety Spring Washer Hex Set Screw Spring Washer Filler Plug Dowty Seal Fusible Plug Gasket Shaft Screw Gasket Copper Washer Input Shaft Needle Roller Brg. Oil Seal Hub End Cover Stepped Key Sealing Gasket Weir Ring Collar Socket Set Screw Socket Set Screw Spring Washer Set Screws Hex Head Circlip
1 2 1 1 1 1 1 11 1 2 3 2 1 6 1 1 1 3 12 10 30 14 6 1 1 1 1 20 1 1
Items indicated by and asterisk (*) are recommended spares. In addition to the model and size, the serial no. of the coupling should be quoted when ordering spares.
86
APPENDIX B
Vibraswitch Sensitivity Adjustments; The model 365 VIBRASWITCH is adjusted by a simple three-step procedure as describe below. In making the adjustment, cover bolts should be tight: 1.
2.
3.
With the equipment not running, back off the adjusting screw counter-clockwise (CCW) to the stop and press reset button. Then turn screw slowly clockwise until actuation occurs. Actuation can be heard as an audible "click". In very noisy surroundings, it may be necessary to use a portable ohmmeter or wire the Vibaswitch to the control circuit to tell when actuation occurs. This is the zero vibration point, or actuating point with the machine not running. (The location of this point depends on the mounting position. It will be zero for horizontal mounting. In other positions, loosen set screws on pointer and set pointer at zero and lock set screws at this actuating point with no vibration, or use arbitrary reference point determined above.) With machine running, back off adjusting screw one turn CCW and reset. If it will not reset, back screw off two turns CCW, etc. Again turn screw slowly clockwise until actuation occurs. The difference between the two actuating points is the normal vibration level in divisions. One dial division is 0.1 G's in the standard model or 0.15 G's in the "LS" or special models. Back off screw CCW from the last position in (2) to the desired warning, or shutdown level. The exact amount must be determined from experience. However, if greater than 100% safety factor is required to prevent Vibraswitch actuation from rough startup or transient vibrations a Robertshaw time delay control unit should be used to obtain a reasonable amount of equipment protections. Reset the Vibraswitch and connect into the control circuit.
A typical setting is sketched below:
87
In the above example the normal running vibration is 4 divisions. This would be 0.4 G's in the "LS" (Low Sensitivity) or special units. Here a 50% safety factor or two dial divisions have been added for the shutdown or alarm point.
88
APPENDIX C
89
The scrapping edge of the conveyor is subjected to wear when the conveyor transports the solids towards the narrow drum end. The wear rate depends on the size and type of the solids. The wear will reduce the transporting capacity and thus the separating results. A far advanced wear i.e. radially .250 mm (6.4 mm) or more will also cause high repair costs. It is necessary, therefore, to check the wear regular and observe how rapidly it progresses. Normally the heaviest wear of the scraping edge occurs in the zone where the conical and cylindrical parts of the drum meet. It is possible to measure the wear in this zone without dismantling the drum. In the flange of the conical part of the jacket there is a hole (plugged with a screw) through which the measuring can be done by means of a slide calipers. See below. The measurements should be recorded in a diagram, a number which is enclosed with this description. Effect a first measuring (distance D - see below) before running a new machine or a new conveyor the first time. Insert the numerical value in the square above the diagram. Then measure the wear (i.e. the actual D - value reduced by the first measured D - value) every 100th hour of operation. Plot the value in Diagram 1. As a rule the wear rate can be established after 3-4 times. If the wear is heavy, i.e. .039 in (1 mm) or more after 400 hours of operation, continue the measurings every 100th hours of operation and plot the values in Diagram 1. Otherwise extend the intervals to 500-1000 hours of operation and use Diagram 2. Whenever a new or rebuilt conveyor is installed the above procedure should be followed. (Extra diagrams are included and machine serial numbers should be marked on each diagram.
90
Measure distance D by means of a slide calipers. 1. 2.
After first measuring of a new machine or a new conveyor, insert the numerical value in the square above the diagrams. After subsequent measurings. Calculate the wear and plot it in one of the diagrams.
Note: The slide calipers must always face in the same direction when measuring.
Lubricate the threads of the screw with castor oil or ball bearing grease. Tighten the screw. Tighten torque: 22 Nm (2.2 kpm).
91
92
93
APPENDIX D
94
95
96
97
98
99
100
101
102
103
104
105
106
107
NOTES:
