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DE-7200 离心机 变频驱动 2009 年 10 月 30 日发布 2010 年 7 月 30 日修改 操作维护手册 Derrick 设备公司 德克萨斯州休斯敦市,77032 15630ExportPlazaDrive 电话:281.590.3003 免费电话:1.866.DERRICK 传真:281.442.6948 www.derrickequipment.com 装置编号对于提供DERRICK专业服务十分关键 对 Derrick 所有产品的询问均需提供设备编号。安装在每台 Derrick 设备上的 不锈钢编号牌是确保得到有效服务和支持的关键。 典型的 Derrick 装置编号 独一无二的装置编号可以向服务人员提供重要信息,帮助在填写订单时识别正 确的部件、对售后服务的问题提供精准的回复、追查资料、追查设备历史记录 或配置等。简单地讲,装置编号提供能够确保 Derrick 用户得到最佳服务所需 的关键信息。 装置编号包括一个用来表示设备类型的双字符字母前缀和一个表示设备制造顺 序的序列号。例如:装置编号为 MA000001 表示第一台 Derrick 制造的筛分 机。目前仍在使用的字母前缀如下: MA – 筛分机 AD – 集尘器与分砂器 DG – 除气装置 AG – 泥浆搅拌机 CF – 离心机 SF – 筛分系统 为确保经过多年在严酷环境下使用后装置编号牌仍能保持完整无损,要用铆钉 将重型荷载工况下的设备编号牌铆固到包括振打装置支撑结构等的结构件上。 不要与设备上包括振动电机序列号等在内的任何其它标识符混淆。 为便于了解,随设备一道提供的操作维护手册中也记录有装置编号。与 Derrick 公司就任何设备问题或有任何需要进行联系时,请将装置编号准备 好。这是从我方专业服务和设计人员得到最有效服务的最佳办法。 关于本手册 本手册有印刷板和电子版。在电子版手册中,目录所列所有章节和段落均对应于相应的 文本。 按以下方式浏览电子手册: 1. 查阅所需信息时,请点阅 CONTENT(目录)页,并将光标移动到所需段落或章节的 标题上。 2. 如果要显示所需的信息,可在文本上出现小指头书签时点击清单。 3. 文本查阅完毕后,按 Alt + 左箭头键返回目录页。 4. 如果要返回前个信息,请按下 Alt + 右箭头。查找其它内容时,请重复第 1 步和第 2 步。 本资料的内容可能随时发生变动。本手册所包含信息既不包括 Derrick 设备的全部细节或可能发生的全部修改,也不包括与设备安 装、操作、维护或故障处理有关的所有偶然事件。如需更多资料,或者出现本手册未包括的其它情况,请将问题交由 Derrick 公司当 地的代表处或 Derrick 公司位于纽约州布法罗市的售后服务部处理。 Copyright 2008 归 Derrick 公司所有。 目 录 章节 页数 1 - 前言.............................................................................................................................. 1-1 概述 ............................................................................................................................ 1-1 安全 ............................................................................................................................ 1-1 设备使用 ..................................................................................................................... 1-1 描述 ............................................................................................................................ 1-2 机械操作 ..................................................................................................................... 1-5 控制系统 ..................................................................................................................... 1-7 联系信息 ..................................................................................................................... 1-7 产品支持 ..................................................................................................................... 1-8 2 - 安全.............................................................................................................................. 2-1 概述 ............................................................................................................................ 2-1 警示 ............................................................................................................................ 2-1 材料安全数据表(MSDS)......................................................................................... 2-3 3 -安装............................................................................................................................... 3-1 概述 ............................................................................................................................ 3-1 安全 ............................................................................................................................ 3-1 储存 ............................................................................................................................ 3-1 安装顺序 ..................................................................................................................... 3-2 要求的净空与定位....................................................................................................... 3-3 设备的定位与固定....................................................................................................... 3-3 液体和固体排放溜槽 ................................................................................................... 3-5 设备的找平 ................................................................................................................. 3-5 放低并固定旋转总成 ................................................................................................... 3-6 进料和排料管的连接 ................................................................................................... 3-8 新水水源 ..................................................................................................................... 3-8 压缩空气 ..................................................................................................................... 3-9 进料泵 ........................................................................................................................ 3-9 电源连接 ..................................................................................................................... 3-9 转鼓、传输装置和进料泵的连接 ................................................................................. 3-11 10 年 3 月 15 日 目录-1 DE-7200VFDCentrifuge 目录 章节 页数 极性的测试 ................................................................................................................. 3-12 传感器的连接 ............................................................................................................. 3-12 吹扫系统压缩空气的连接 ........................................................................................... 3-13 设备起动 .................................................................................................................... 3-13 4 - 操作指导 ...................................................................................................................... 4-1 概述............................................................................................................................ 4-1 操作的安全 ................................................................................................................. 4-1 吹扫系统(仅针对危险环境) .................................................................................... 4-2 初次起动 .................................................................................................................... 4-2 正常起动 .................................................................................................................... 4-3 运行............................................................................................................................ 4-5 进料速率的调整.......................................................................................................... 4-6 转鼓的速度 ................................................................................................................. 4-7 传输装置的差动速度................................................................................................... 4-7 液池的深度 ................................................................................................................. 4-7 差动速度/传输装置的扭矩.......................................................................................... 4-8 报警与故障信息.......................................................................................................... 4-9 轴承的温度 ................................................................................................................. 4-9 电机扭矩的趋势.......................................................................................................... 4-9 系统诊断 .................................................................................................................... 4-10 性能状态 .................................................................................................................... 4-11 报警............................................................................................................................ 4-11 VFD 的状态 ................................................................................................................ 4-12 VFD 的故障复位 ......................................................................................................... 4-14 设置屏 ........................................................................................................................ 4-15 泵的设置屏 ................................................................................................................. 4-15 登录............................................................................................................................ 4-16 清理............................................................................................................................ 4-16 正常停车 .................................................................................................................... 4-17 自动停车 .................................................................................................................... 4-18 紧急停车 .................................................................................................................... 4-19 5 - 维护 ............................................................................................................................. 5-1 概述............................................................................................................................ 5-1 目录-2 10 年 3 月 15 日 目录 章节 页数 预防性维护 ................................................................................................................. 5-1 润滑轴承 ..................................................................................................................... 5-2 检查齿轮箱里的油位 ................................................................................................... 5-3 齿轮箱机油的更换....................................................................................................... 5-4 构件的维护 ................................................................................................................. 5-5 传动皮带 ..................................................................................................................... 5-5 旋转总成的维护 .......................................................................................................... 5-7 主轴承的更换.............................................................................................................. 5-9 传输装置轴承的更换 ................................................................................................... 5-16 齿轮箱的拆除与安装 ................................................................................................... 5-19 扭矩紧固件的技术规格 ............................................................................................... 5-28 推荐的备品备件 .......................................................................................................... 5-29 故障排除 ..................................................................................................................... 5-32 报警与故障信息 .......................................................................................................... 5-35 控制元件指示器 .......................................................................................................... 5-42 6-7 - 未使用 8 - 参考图纸....................................................................................................................... 8-1 9 - 安装与维护记录............................................................................................................ 9-1 10 - 供货商资料 ................................................................................................................... 10-1 10 年 3 月 15 日 目录-3 DE-7200VFDCentrifuge 第 1 章:前言 概述 本手册提供 DE-7200 变频驱动(VFD)离心机(见图 1-1)的安装和操作指导。为方便用户使用, 手册分为许多章节。指导包括描述、操作理论、安全、安装与维护。提供的参考图纸可以便于对部 件进行定位和定购,并且有利于理解设备操作和故障排除。本手册还包括许多由外部供货商提供的 技术资料。这些资料包括离心机所使用的但不是由 Derrick 制造的部件。 图 1-1:DE-7200 变频驱动(VFD)离心机 安全 本手册第 2 章包含与本设备操作维护有关的安全信息。所有人员必须阅读并领会这些信息。 如果查明设备的任何机械或电气元件出现缺陷或者故障,不得对设备进行操作。 设备使用 DE-7200 VFD 离心机专为从泥浆中将低比重固体料分离出来而设计。要么是将固体分离出来并将 液体返回流程循环。 要么就是将固体返回工作系统而将液体废弃。 Derrick 公司未授权对本设备做其它使用。设备的设计用途包括要满足本手册所述操作、维护和安 全规程。 09 年 10 月 30 日 1-1 DE-7200VFD 离心机 前言 描述 离心机主要构件(见图 1-2)包括旋转总成、控制柜、转鼓和传输装置驱动电机、控制系统、吹扫 系统、振动开关,以及机箱、底座总成和滑架。 以下段落将分别对这些构件进行了描述。 图 1-2:DE-7200 VFD 离心机主要构件 旋转总成 旋转总成包括圆柱形高强度碳钢转鼓、传输装置总成、齿轮箱和相关构件。转鼓包括一个不锈钢圆 柱筒:固体排料端是一个锥形头,对面是平的液体转鼓头。两端都有开口,方便液体和固体排出。 转鼓两端用带有润滑接头的滚柱轴承支撑,润滑接头可以方便定期进行润滑。 转鼓总成 液体转鼓头位于液体排放端,带有活动的堰板,方便旋转时对转鼓内的液位人工进行调整。堰板旁 边的切口定位板方便进行精确调整。液位或液池深度连同其它因素一道,有助于确定所排固体中的 含液量。固体端锥形转鼓延伸部分形成向上斜坡,固体集中于此并通过固体排料口连续排出。可更 换的插件衬于固体排料口内,可以降低磨损率。 传输装置 传输装置总成是一个中空的圆柱形螺旋输送机,可以将料浆进料送入其内部,然后通过喷嘴再分配 到转鼓总成,并且将固料输送到固料排出口。传输装置由电机驱动并通过一个三级行星齿轮箱作用 而旋转,旋转方向与转鼓旋转方向相同,但旋转速率更高。齿轮箱的外壳与转鼓固定在一起,轴则 直接与传输装置连接。 差动速度可以在控制盘上设定,该设定值可以确定相对于转鼓速度的传输装置的速度。这种速度差 动关系保持不变,即随着转鼓速度的改变,传输装置的速度也相应发生改变,但保持与前者之间的 差动关系。例如:转鼓速度为 2000 RPM 且传输装置的差动速度为 10 就表示传输装置的旋转速率 为 2010RPM。 1-2 09 年 10 月 30 日 前言 液体排放端的进料部件将料浆直接导入传输装置内部,并通过进料喷嘴迅速将物料分配到转鼓内。 可更换的插件衬于八个进料喷嘴内,可以降低其磨损率。传输装置在液体转鼓头一端由滚柱轴承支 撑,而在固体端则由传输装置驱动齿轮箱支撑。 传输装置驱动齿轮箱 传输装置驱动齿轮箱是一个三级行星齿轮箱,它驱使传输装置旋转速度快于转鼓总成的旋转速度。 齿轮箱安装在转鼓总成上,并由转鼓总成驱动。齿轮箱的输入输出轴均于内部轴承支撑。传输装置 驱动电机通过一个挠性联轴节与齿轮箱输入轴联接,允许略微有一点对正偏差。齿轮箱包括一个齿 轮系统,可以将旋转动作从电机和转鼓传送到传输装置的输出轴。 齿轮箱的输入轴一端由固体端的主轴承支撑,而输出端则与转鼓固定在一起。齿轮传动比为 49:1 让传输装置以按比例高于转鼓总成转动的速度旋转。控制系统确保传输装置旋转速度的变化与转鼓 速度变化呈正比,保持恒定的固体物料输送差动关系。 出现过载时,传输装置上固体物料过多使电机超负荷,造成电机扭矩增大,并出现过载报警。如果 达到传输装置预设的扭矩极限,控制系统会自动降低进料速率,使传输装置能够清除过多的固体物 料。如果离心机在进料速率已经降低的情况下运行,Operation (操作)屏会显示出一条信息,告 知操作人员状态已修改。除非消除过扭矩状况,否则离心机将自动停车。 如果突然出现过扭矩情况,传输装置驱动离合器会机械式将传输装置的驱动电机分开,保护齿轮箱 (见图 1-3)不受损坏。驱动电机分开后,离心机必须停车,并按以下方式手动复位离合器: 将离合器的两半与导环砂型体上的任一标记对齐。 将螺丝刀插入导环和调整螺母之间彼此间隔 180°的两处,将导环压入啮合位置。 分开 重新啮合 图 1-3:传输装置驱动离合器的工作原理 09 年 10 月 30 日 1-3 DE-7200VFD 离心机 前言 驱动电机 离心机采用两台三相防爆型变频器专用电机驱动。150 HP 转鼓驱动电机通过一个皮带轮和一系列 传动皮带与转鼓总成连接,而 60HP 电机则直接通过离合器联轴节与齿轮箱输入轴耦合。保护罩盖 住皮带轮、传动皮带和传输驱动离合器的联轴节,保护人身安全。 吹扫系统(仅针对危险环境) 针对在危险环境下操作,离心机控制柜配备有吹扫系统。吹扫系统连续吹出的气流可以防止控制柜 内部蓄积爆炸性蒸气。离心机接通电源时,控制柜的吹扫系统以 16 立方英尺分(稢 FM)的速度 开始进行 14 分钟的快速吹扫作业。此吹扫作业包括五个完整的空气交换器。快速吹扫作业完成 后,吹扫系统将自动关闭到控制柜的电源控制开关。 离心机运行时,吹扫系统保持连续气流,在控制柜内提供正压,防止易燃气体进入。如果吹扫系统 不能使控制柜内保持令人满意的气压,最小压力和吹扫空气流量传感器将向 PLC 提供输出信号。有 关吹扫系统工作的详细情况,请参见第 10 章 Expo 技术公司技术资料—供货商资料。. 振动开关 振动开关(见图 1-4)是一种安全装置,专为出现过度振动时为保护人员和设备而停止离心机运行 而设计。正常情况下,开关触点通过一个机械式压紧闩的作用保持闭合。但是,当出现达到 2G 的 强烈振动或冲击时,磁性压紧闩将会脱开,使开关磁舌脱离常闭位置,从而向 PLC 提供输入信 号。必须手动按下开关侧面的复位开关,使触点闭合并重新接合磁性压紧闩。振动脱扣级别可以通 过设定值调节开关进行调节,该调节开关可以调节磁部件与闩臂片之间的间隙。逆时针方向旋转可 以降低磁舌脱扣所需的以“G”力表示的振动设定值。将调节开关按顺时针方向完全拧到头时,开 关将在达到额定的最大振动级别时脱扣。 振动开关安装在离心机底座上最易受到转鼓总成失衡振动力影响的方位。传输装置堵塞或轴承磨损 时都会产生足以使该开关脱扣的振动。 图 1-4:振动开关 1-4 09 年 10 月 30 日 前言 机箱与底座 顶盖关闭时,机箱将转鼓总成整个围住,密封并保护转鼓总成。液体排放斜槽和固料排放斜槽安装 在下半部分机箱的底部。上下两半机箱内部安装的配套隔板将固体和液体分开。螺栓有效地将上下 两半机箱连接起来,下机箱的垫圈有效密封上下两半机箱。 机箱与焊接的钢制底座总成栓接,该底座有轴承轴台的安装预留口。机箱总成支撑离心机构件,包 含有空心的橡胶振动隔离器,该隔离器与安装平台内嵌入的定心销啮合。 机械操作 离心机在设备皮带轮端部(固体排料端)进料。为达到最佳性能,料浆进入离心机之前应当用振动 筛分机过滤到 74 微米。料浆通过进料管流入旋转的转鼓中,转鼓中的离心力将液体与固体分离 开。液体从离心机齿轮箱一端的液体排放口流出,固体则输送到固体排料端并排入设备底部的斜 槽。 离心机的工厂设置为采用规定的 AC 电压等级、三相、50Hz 或 60Hz 电源。电气控制元件安装在位 于设备液体排放端一侧的电气控制箱内。出现传输装置压力过大、电机温度过高、振动过度或其它 误动作时,离心机内置的安全保护装置通过停止驱动电机工作有效地保护人员和设备的安全。 转筒高速旋转所产生的 G 力将固体从进料泥浆中分离出来。离心机的性能取决于以下三个变量: 作用到液体上的力 G — 重力将液体从离心机外壁抽走。 离心机里的停留时间 — 泥浆在离心机里停留时间越长,能够分离的固体颗粒越小。 传输机的差动速度 — 传输机旋转速度越快,固料含湿量越高,排出的固体量越多。 可以通过对上述三个因素进行控制来达到修改液体和固体排料情况的目的。修改电机皮带轮的直径 可以改变转鼓的转速。调整液体转鼓头上的液体排放口可以控制料浆停留时间,从而改变液池深度 (即液位高度),改变齿轮传动比可以改变传输装置的差动速度。传输装置运行的速度低于转鼓的 运行速度;其速度从齿轮传动比推导而来。 转鼓和传输装置的传输速度不同。 任何参数进行调节时都要求设备停车,包括液池深度、转鼓速度、传输装置的差动速度等调节。改 变排料结果的另外一种方法是改变进料速率。 离心机工作时,料浆通过进料管泵送到旋转的传输装置的中心(见图 1-4),并在此迎着进料加速 器飞溅转动。接着,高速料浆通过安装在传输装置缸体周围的四个进料喷嘴流出。由于转鼓转速高 于传输装置的转速,因而会额外产生一种剪力效应,从而进一步增加料浆的加速度。 09 年 10 月 30 日 1-5 DE-7200VFD 离心机 前言 机械操作(续) 当料浆流入传输机刮板之间的通道时,较重的固体颗粒由于转鼓所产生的力 G 而加速沉积。砂状颗 粒几乎瞬间就沉淀下来;然后沉淀的是较轻较细的颗粒。在目前设定的离心力条件下不能沉降的颗 粒将随着液体通过液体转鼓头上的可调式溢流堰排出。流出液体转鼓头的液体经过液体排料口。 沉积下来的固体在转鼓内部形成一层饼状物,并通过传输装置送到转鼓的狭长端,或曰砂滩端。由 于固体输送时要经过砂滩,它们的自由液膜会由于离心式挤水和脱水作用而脱除。当固料通过转鼓 的固体排料口高速排出时就只剩下吸附水份。 图 1-4:离心机的操作 控制系统 离心机的操作由可编程逻辑控制器(PLC)监控,该 PLC 与向转鼓、传输装置和进料泵驱动电机供 电的变频驱动装置(VFD)接合。离心机既可以就地监控,也可以相隔数千公司以外进行监控。坚 固的 PLC 还可提供短期数据存储和高度的操作灵活性。控制柜上安装的图形界面方便与 VFD 进行 通讯并实时访问系统的操作特征。通过控制盘,操作人员可以起动离心机、输入并调整转鼓和传输 装置的速度、设定进料速率,并关停设备。 包括主轴承温度、转鼓速度、转鼓和传输装置的扭矩、控制柜内部温度、以及振动等在内的各种输 入信号传送到 PLC 后,PLC 会做出反应,通过相应的输出对离心机的工作进行操控。关键状态信息 会显示在控制盘上,提示操作人员有任何潜在的或迫近的误操作的报警和故障信息也会显示在控制 盘上。如果振动超过预设极限,PLC 会自动关停离心机并显示停车原因的解释性信息。另外,操作 人员还可以随时在面板执行紧急停车。 进料泵无论手动操作还是自动操作,都完全由 PLC 控制。自动操作能够保证物料最大的通过率,因 为 PLC 针对不同工作条件都能够确保对进料速率进行优化。进料速率会自动提高,直到转鼓或传输 装置的驱动电机达到预设的扭矩极限为止。如果进料泥浆的性质发生变化,进料速率会自动进行调 整,确保不超过预设的扭矩极限。 1-6 09 年 10 月 30 日 前言 联系信息 联系信息 地点 电话 传真 美国纽约州布法罗市 Duck 路 590 号,14225 Derrick 公司 716.683.9010 716.683.4991 281.590.3003 美国德克萨斯州休斯敦市 Export Plaza Drive15630 号, 77032 Derrick 设备公司 281.442.6948 德国法灵博斯特尔 Bockhorner +49 5162 98580 +49 5162 985821 Weg 6 29683 Derrick 公司 电子邮件 / 网址 服务部总经理 [email protected] 总经理 [email protected] [email protected] www.derrickinternational.com 产品支持 Derrick 公司提供每天 24 小时,每周 7 天的产品支持。产品支持范畴包括滤网更换/订购信息和整个 生产线的修理/更换部件和服务。参见下表查找距离你方最近的部件/服务中心。 部件销售与服务地点 科罗拉多 - 970.241.2417 路易斯安那 布鲁萨尔德 - 877.635.3354 密西西比 劳里 - 877.635.3354 纽约 – 公司总部 布法罗 - 716.683.9010 俄克拉何马 奥克拉荷马市 - 405.208.4070 德克萨斯 休斯敦 (Oilfield Headquarters) - 866.DERRICK (337.7425) 布里奇波特 - 940.210.9975 库普斯·库瑞斯蒂 - 361.664.2410 朗维龙 - 337.298.9411 米德兰 - 432.230.3720 怀俄明 - 307.265.0445 德国 - 011.49.5162.98580 09 年 10 月 30 日 1-7 DE-7200VFD 离心机 第 2 章:安全 概述 本章概述了手册中所使用的所有警示牌以及设备适用的材料安全数据表(MSDS)。离心机设计为 要能够安全实现所述的各项功能。 警示 负责对本设备进行操作和维护的人员在操作和/或维护之前,都必须阅读并领会本手册中的所有安全 信息。以下所列安全警示牌包含在手册适用的章节中。 声音 警示!为避免丧失听力,在 Derrick 设备上或附近工作的任何时候都应当佩戴好保护 耳罩。 电气危险 警示!为避免人员受重伤,设备维护和/或调整之前必须将设备切断、挂牌上锁、断 开电源,并且停止转动。 警示!驱动电机必须在指定的电压等级条件下工作。 警示!可能有高压。确保设备的熔断电源是断开的。进行设备维护和/或调整时,一 定要切断电源并挂牌上锁,以防意外送电。 警示!电气连接必须符合国家电气法规(NEC)和所有适用的地方性法规。违反这 些法规规定会造成可能导致人员受伤和设备损坏的不安全条件。要确保所有电气和 导线管连接均牢固可靠。 09 年 10 月 30 2-1 DE-7200VFD 离心机 安全 设备搬运 警示!设备提升时要使用舒展杆,以防设备提升时受损。 警示!提升时要确保设备正确地平衡和定位,以防损坏设备部件,只能在指定的起 吊点固定吊绳。起吊时不能将吊绳固定在电机或其它任何位置。 警示!确保起吊装置的起吊能力足以安全处理待吊设备的重量。 警示!备定位到最终安装现场之前不得拆除运输托架。 运行 警示!开始对设备进行操作之前,所有操作和维护人员必须阅读并领会本手册中的 所有安全信息。 警示!设备起动之前,首先要确保所有防护装置均已安装到位且牢固可靠,并且所 有人员均已远离设备。 警示!离心机起动之前,首先要确保所有运输托架均已拆除,所有轴承轴台均已正 确紧固。 警示!打开顶盖或拆除防护板之前,必须让机器惯性滑行直至完全停止转动。 警示!如果出现异常噪音或振动时,不得对离心机进行操作。必须随时确认振动开 关和其它安全装置工作正常。 维护 警示!可能有高压。必须断开设备的熔断电源,进行任何设备维护和/或调整时必须切 断电源并挂牌上锁。 储存 警示!在湿度高的环境里(相对湿度大于 50%)存放离心机会使其损坏。设备必须存 放在湿度低的环境中。 2-2 09 年 10 月 30 安全 材料安全数据表(MSDS) 外表打磨抛光产品的材料安全数据表 (MSDS)罗列在以下部分,目的是告知相关人员这些材料的特 性和可能存在的危害。这些资料由产品制造商制备并对资料的精准度负完全责任。 所含材料安全数据表是手册发布之日现行有效的,仅做参考之用。最新资料应由用户负责与产品制 造商联系索取。 除最终产品的资料外,设备所用的其它产品也列有材料安全数据表。为确保获取目前的资料,产品 采购时可以得到每种产品的材料安全数据表。请注意:与所列材料同等的产品经由 Derrick 公司批 准,可以用于相应的领域。 材料描述 –凡是出现(在本文件内) 材料安全数据表编号 / 日期 涂料 迪威耳高光油霸面漆 359 – 面漆 359 / 05-06-08 迪威耳环氧树脂底漆 – 底漆 313K/08-02-04 润滑剂 主轴承和传输装置轴承–壳牌 AlbidaEP2 * 传输装置驱动齿轮箱–美孚 SHC629 * 转鼓和传输装置驱动电机–雪佛龙 SR1#2 * 密封剂 乐泰 243 防粘着润滑剂 – 紧固剂 76764 / 09-27-04* 没有材料安全数据表的;可与制造商联系索要最新修订版。 09 年 10 月 30 2-3 DE-7200VFD 离心机 (ANSI Section 4) FIRE-FIGHTING MEASURES (ANSI Section 5) Fire extinguishing media : Dry chemical or foam water fog. Carbon dioxide. Closed containers may explode when exposed to extreme heat or fire. Vapors may ignite explosively at ambient temperatures. Vapors are heavier than air and may travel long distances to a source of ignition and flash back. Vapors can form explosive mixtures in air at elevated temperatures. Closed containers may burst if exposed to extreme heat or fire. Dust explosion hazard. May decompose under fire conditions emitting irritant and/or toxic gases. Fire fighting procedures : Water may be used to cool and protect exposed containers. Firefighters should use full protective clothing, eye protection, and self-contained breathing apparatus. Selfcontained breathing apparatus recommended. (ANSI Section 6) Steps to be taken in case material is released or spilled : Comply with all applicable health and environmental regulations. Eliminate all sources of ignition. Ventilate area. Ventilate area with explosion-proof equipment. Spills may be collected with absorbent materials. Use non-sparking tools. Evacuate all unnecessary personnel. Place collected material in proper container. Complete personal protective equipment must be used during cleanup. Large spills - shut off leak if safe to do so. Dike and contain spill. Pump to storage or salvage vessels. Use absorbent to pick up excess residue. Keep salvageable material and rinse water out of sewers and water courses. Small spills use absorbent to pick up residue and dispose of properly. HANDLING AND STORAGE (ANSI Section 7) Handling and storage : Store below 80f. Store below 100f (38c). Keep away from heat, sparks and open flame. Store in original container. Keep away from direct sunlight, heat and all sources of ignition. Keep container tightly closed in a well-ventilated area. Other precautions : Use only with adequate ventilation. Do not take internally. Keep out of reach of children. Avoid contact with skin and eyes, and breathing of vapors. Wash hands thoroughly after handling, especially before eating or smoking. Keep containers tightly closed and upright when not in use. Empty containers may contain hazardous residues. Ground equipment when transferring to prevent accumulation of static charge. EXPOSURE CONTROLS/PERSONAL PROTECTION (ANSI Section 8) Respiratory protection : Respiratory protection is required for use in isocyanate containing environments. Consider type of application and environmental concentrations when selecting respiratory protection. Observe governmental regulations for respirator use. (29 CFR 1910.134(OSHA))(Canadian z94.4) The use of positive pressure supplied air respirator is mandatory when the airborne isocyanate concentrations are not known. Note: isocyanate based materials have been determined to cause allergic sensitization in humans. Avoid inhalation and dermal (skin) contact with the uncured material. Ventilation : Provide dilution ventilation or local exhaust to prevent build-up of vapors. Use explosionproof equipment. Use non-sparking equipment. Personal protective equipment : Eye wash, safety shower, safety glasses or goggles. Impervious gloves, impervious clothing, face shield, apron, boots. STABILITY AND REACTIVITY (ANSI Section 10) Under normal conditions : Stable see section 5 fire fighting measures Materials to avoid : Oxidizers, acids, reducing agents, bases, aldehydes, halogens, amines, alkalis, water, peroxides, nitric acid, alcohols, combustible materials, caustics, mineral acids. Nitrates. Conditions to avoid : Sunlight, elevated temperatures, moisture, contact with oxidizing agent, storage near acids, sparks, open flame, ignition sources. Hazardous polymerization : Will not occur 359D The information contained herein is based on data available at the time of preparation of this data sheet which ICI Paints believes to be reliable. However, no warranty is expressed or implied regarding the accuracy of this data. ICI Paints shall not be responsible for the use of this information, or of any product, method or apparatus mentioned and you must make your own determination of its suitability and completeness for your own use, for the protection of the environment, and the health and safety of your employees and the users of this material. Complies with OSHA hazard communication standard 29CFR1910.1200. EMERGENCY TELEPHONE NO. (800) 545-2643 Inhalation : Remove to fresh air. Restore and support continued breathing. Get emergency medical attention. Have trained person give oxygen if necessary. Get medical help for any breathing difficulty. Remove to fresh air if inhalation causes eye watering, headaches, dizziness, or other discomfort. Skin contact : Wash thoroughly with soap and water. If any product remains, gently rub petroleum jelly, vegetable or mineral/baby oil onto skin. Repeated applications may be needed. Remove contaminated clothing. Wash contaminated clothing before re-use. Dispose of contaminated leather items, such as shoes and belts. If irritation occurs, consult a physician. Eye contact : Flush immediately with large amounts of water, especially under lids for at least 15 minutes. If irritation or other effects persist, obtain medical treatment. Ingestion : If swallowed, obtain medical treatment immediately. ACCIDENTAL RELEASE MEASURES 15885 Sprague Road Strongsville, Ohio 44136 FIRST-AID MEASURES Hazardous decomposition or combustion products : Carbon monoxide, carbon dioxide, oxides of nitrogen, oxides of sulfur, ammonia, hydrogen chloride, toxic gases, barium compounds. Cyanides. DEVTHANE 359 DERRICK GREEN HAZARDS IDENTIFICATION (ANSI Section 3) Primary route(s) of exposure : Inhalation, skin contact, eye contact, ingestion. Effects of overexposure : Inhalation : Irritation of respiratory tract. Prolonged inhalation may lead to. Inhalation of spray mist may cause irritation of respiratory tract. Mucous membrane irritation, fatigue, drowsiness, dizziness and/or lightheadedness, headache, uncoordination, nausea, vomiting, abdominal pain, chest pain, coughing, apathy, central nervous system depression, intoxication, anesthetic effect or narcosis, difficulty of breathing, allergic response, tremors, severe lung irritation or damage, pulmonary edema, pneumoconiosis, loss of consciousness, respiratory failure, death. Possible sensitization to respiratory tract. Skin contact : Irritation of skin. Prolonged or repeated contact can cause dermatitis, defatting, severe skin irritation. Possible sensitization to skin. Eye contact : Irritation of eyes. Prolonged or repeated contact can cause conjunctivitis, blurred vision, tearing of eyes, redness of eyes, severe eye irritation, corneal injury. Ingestion : Ingestion may cause lung inflammation and damage due to aspiration of material into lungs, mouth and throat irritation, drowsiness, dizziness and/or lightheadedness, headache, uncoordination, nausea, vomiting, diarrhea, gastro-intestinal disturbances, abdominal pain, visual disturbances, apathy, central nervous system depression, intoxication, anesthetic effect or narcosis, burns of the mouth, throat, stomach, pulmonary edema, loss of consciousness, respiratory failure, death. Medical conditions aggravated by exposure : Eye, skin, respiratory disorders, kidney disorders, liver disorders, nervous system disorders, respiratory disorders. prepared 05/06/08 ICI Paints North America MATERIAL SAFETY DATA SHEET TOXICOLOGICAL INFORMATION (ANSI Section 11) Supplemental health information : Contains a chemical that is moderately toxic by ingestion. Contains a chemical that is toxic by inhalation. Contains a chemical that may be absorbed through skin. Free diisocyanate may cause allergic reaction in susceptible persons. Notice - reports have associated repeated and prolonged occupational overexposure to solvents with permanent brain and nervous system damage. Intentional misuse by deliberately concentrating and inhaling the contents may be harmful or fatal. Contains iron oxide, repeated or prolonged exposure to iron oxide dust may cause siderosis, a benign pneumoconiosis. Other effects of overexposure may include toxicity to liver, kidney, central nervous system, blood. Carcinogenicity : Contains formaldehyde, a potential cancer hazard. Rats exposed to formaldehyde via inhalation developed cancer of the nasal cavity. Evidence in humans is limited (nasal and nasopharyngeal cancer). Formaldehyde is listed as a carcinogen by OSHA, probable human carcinogen (group 2a) by IARC, and anticipated human carcinogen by NTP. Overexposure can cause eye, skin, and respiratory tract irritation, and skin and respiratory sensitization. In a lifetime inhalation study, exposure to 250 mg/m3 titanium dioxide resulted in the development of lung tumors in rats. These tumors occurred only at dust levels that overwhelmed the animals' lung clearance mechanisms and were different from common human lung tumors in both type and location. The relevance of these findings to humans is unknown but questionable. The international agency for research on cancer (IARC) has classified titanium dioxide as possibly carcinogenic to humans (group 2b) based on inadequate evidence of carcinogenicity in humans and sufficient evidence of carcinogenicity in experimental animals. Physical Data Product Code 359F65DGF 379C0910 ECOLOGICAL INFORMATION (ANSI Section 12) No ecological testing has been done by ICI paints on this product as a whole. DISPOSAL CONSIDERATIONS (ANSI Section 13) Waste disposal : Dispose in accordance with all applicable regulations. Avoid discharge to natural waters. REGULATORY INFORMATION (ANSI Section 15) As of the date of this MSDS, all of the components in this product are listed (or are otherwise exempt from listing) on the TSCA inventory. This product has been classified in accordance with the hazard criteria of the CPR (controlled products regulations) and the MSDS contains all the information required by the CPR. (ANSI Sections 1, 9, and 14) Description Wt. / Gal. devthane 359h (no organic haps) derrick green devthane 379 hs converter Ingredients Reproductive effects : High exposures to xylene in some animal studies, often at maternally toxic levels, have affected embryo/fetal development. The significance of this finding to humans is not known. Mutagenicity : No mutagenic effects are anticipated Teratogenicity : No teratogenic effects are anticipated 9.02 9.40 VOC gr. / ltr. 291.43 112.85 % Volatile by Volume 34.96 13.00 Flash Point 80 f 135 f Boiling Range 208-595 293-293 HMIS *330 *321 DOT, proper shipping name UN1263, paint, 3, PGIII UN1866, resin solution, combustible liquid, PGIII Product Codes with % by Weight (ANSI Section 2) Chemical Name 4-heptanone, 2,6-dimethylethane, 1,1',1''-methylidenetris(oxy)-trisacetic acid, butyl ester c.i. pigment green 7 benzene, dimethyltitanium oxide 2-propenoic acid, 2-methyl-, 2-hydroxyethyl ester, polymer with ethenylbenzene, 2-ethylhexyl 2-propeno and methyl 2-methyl-2propenoate hexane, 1,6-diisocyanato-, homopolymer formaldehyde c.i. pigment yellow 42 acetic acid, 1,1-dimethylethyl ester butanamide, 2-((2-methoxy-4-nitrophenyl)azo) -n-(2-methoxyphenyl)-3-oxosolvent naphtha (petroleum), light aromatic 1-butanol propanoic acid, 3-ethoxy-, ethyl ester sulfuric acid, barium salt castor oil hexane, 1,6-diisocyanatoacetic acid, c6-8-branched alkyl esters benzene,1,2,4-trimethylanti-settling agent polyamide Common Name diisobutyl ketone ethyl orthoformate butyl acetate phthalo green pigment xylene titanium dioxide acrylic polymer CAS. No. 108-83-8 122-51-0 123-86-4 1328-53-6 1330-20-7 13463-67-7 26916-05-2 aliphatic polyisocyanate formaldehyde yellow iron oxide tert-butyl acetate pigment yellow 74 light aromatic solvent naphtha n-butanol ethyl 3-ethoxypropionate barium sulfate castor oil, raw hexamethylene diisocyanate oxo-heptyl acetate pseudocumene anti-settling agent rheological additive 28182-81-2 50-00-0 51274-00-1 540-88-5 6358-31-2 64742-95-6 71-36-3 763-69-9 7727-43-7 8001-79-4 822-06-0 90438-79-2 95-63-6 Sup. Conf. Sup. Conf. Form: 359D, Page 2 of 3, prepared 05/06/08 359F65DGF 1-5 1-5 5-10 1-5 .1-1.0 1-5 40-50 379C0910 5-10 .1-1.0 90-95 LT .01 1-5 1-5 1-5 1-5 1-5 5-10 1-5 10-20 .1-1.0 1-5 .1-1.0 1-5 1-5 1-5 Chemical Hazard Data Common Name diisobutyl ketone ethyl orthoformate butyl acetate phthalo green pigment xylene titanium dioxide acrylic polymer aliphatic polyisocyanate formaldehyde yellow iron oxide tert-butyl acetate pigment yellow 74 light aromatic solvent naphtha n-butanol ethyl 3-ethoxypropionate barium sulfate castor oil, raw hexamethylene diisocyanate oxo-heptyl acetate pseudocumene anti-settling agent rheological additive Footnotes: C=Ceiling - Concentration that should not be exceeded, even instantaneously. (ANSI Sections 2, 8, 11, and 15) CAS. No. 108-83-8 122-51-0 123-86-4 1328-53-6 1330-20-7 13463-67-7 26916-05-2 28182-81-2 50-00-0 51274-00-1 540-88-5 6358-31-2 64742-95-6 71-36-3 763-69-9 7727-43-7 8001-79-4 822-06-0 90438-79-2 95-63-6 Sup. Conf. Sup. Conf. S=Skin - Additional exposure, over and above airborn exposure, may result from skin absorption. 8-Hour TWA 25 ppm not est. 150 ppm not est. 100 ppm 10 mg/m3 not est. not est. not est. 5 mg/m3 200 ppm not est. not est. 20 ppm not est. 10 mg/m3 not est. 0.005 ppm not est. 25 ppm not est. 10 mg/m3 ACGIH-TLV STEL C not est. not est. not est. not est. 200 ppm not est. not est. not est. 150 ppm not est. not est. not est. not est. not est. not est. not est. not est. 0.3 ppm not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. n/a=not applicable not est=not established CC=CERCLA Chemical S not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. 8-Hour TWA 50 ppm not est. 150 ppm not est. 100 ppm 10 mg/m3 not est. not est. 0.75 ppm 10 mg/m3 200 ppm not est. 500x ppm 100 ppm not est. 5 mg/m3 not est. not est. not est. not est. not est. 5 mg/m3 ppm=parts per million mg/m3=milligrams per cubic meter Sup Conf=Supplier Confidential Form: 359D, Page 3 of 3, prepared 05/06/08 OSHA-PEL STEL C not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. 2 ppm not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. S not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. S2=Sara Section 302 EHS S3=Sara Section 313 Chemical S.R.Std.=Supplier Recommended Standard S.R. Std. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. S2 S3 CC n n n n n n n n y n n n n n n n n n n n n n n n n n y n n n y n n n n y n n n y n y n n n n y n y n n n y n y n n y n n n y n n n n H n n n n y n n n y n n n n n n n n y n n n n M n n n n n n n n n n n n n n n n n n n n n n N n n n n n y n n y n n n n n n n n n n n n n I n n n n n y n n y n n n n n n n n n n n n n O n n n n n n n n y n n n n n n n n n n n n n H=Hazardous Air Pollutant, M=Marine Pollutant P=Pollutant, S=Severe Pollutant Carcinogenicity Listed By: N=NTP, I=IARC, O=OSHA, y=yes, n=no (ANSI Section 3) (ANSI Section 4) Inhalation : Remove to fresh air. Restore and support continued breathing. Get emergency medical attention. Have trained person give oxygen if necessary. Get medical help for any breathing difficulty. Skin contact : Wash thoroughly with soap and water. If any product remains, gently rub petroleum jelly, vegetable or mineral/baby oil onto skin. Repeated applications may be needed. Remove contaminated clothing. Wash contaminated clothing before re-use. Dispose of contaminated leather items, such as shoes and belts. If irritation occurs, consult a physician. Eye contact : Flush immediately with large amounts of water, especially under lids for at least 15 minutes. If irritation or other effects persist, obtain medical treatment. Ingestion : If swallowed, obtain medical treatment immediately. FIRE-FIGHTING MEASURES (ANSI Section 5) Fire extinguishing media : Dry chemical or foam water fog. Carbon dioxide. Closed containers may explode when exposed to extreme heat or fire. Vapors may ignite explosively at ambient temperatures. Vapors are heavier than air and may travel long distances to a source of ignition and flash back. Vapors can form explosive mixtures in air at elevated temperatures. Closed containers may burst if exposed to extreme heat or fire. May decompose under fire conditions emitting irritant and/or toxic gases. Fire fighting procedures : Water may be used to cool and protect exposed containers. Firefighters should use full protective clothing, eye protection, and self-contained breathing apparatus. Selfcontained breathing apparatus recommended. Hazardous decomposition or combustion products : Carbon monoxide, carbon dioxide, oxides of nitrogen, oxides of sulfur, ammonia, aldehydes, toxic gases, barium compounds. Cyanides. (ANSI Section 6) HANDLING AND STORAGE (ANSI Section 7) Handling and storage : Store below 80f. Store below 100f (38c). Keep away from heat, sparks and open flame. Keep away from direct sunlight, heat and all sources of ignition. Other precautions : Use only with adequate ventilation. Do not take internally. Keep out of reach of children. Avoid contact with skin and eyes, and breathing of vapors. Wash hands thoroughly after handling, especially before eating or smoking. Keep containers tightly closed and upright when not in use. Empty containers may contain hazardous residues. Ground equipment when transferring to prevent accumulation of static charge. EXPOSURE CONTROLS/PERSONAL PROTECTION (ANSI Section 8) Respiratory protection : Control environmental concentrations below applicable exposure standards when using this material. When respiratory protection is determined to be necessary, use a NIOSH/MSHA (Canadian z94.4) Approved elastomeric sealing- surface facepiece respirator outfitted with organic vapor cartridges and paint spray (dust/mist) prefilters. Determine the proper level of protection by conducting appropriate air monitoring. Consult 29CFR1910.134 For selection of respirators (Canadian z94.4). Ventilation : Provide dilution ventilation or local exhaust to prevent build-up of vapors. Use explosionproof equipment. Use non-sparking equipment. Personal protective equipment : Eye wash, safety shower, safety glasses or goggles. Impervious gloves, impervious clothing, face shield, apron. STABILITY AND REACTIVITY (ANSI Section 10) Under normal conditions : Stable see section 5 fire fighting measures Materials to avoid : Oxidizers, acids, reducing agents, bases, aldehydes, ketones, halogens, amines, carbon tetrachloride (at elevated temperatures), aluminum, nitric acid, metal compounds, lewis acids, mineral acids. Conditions to avoid : Elevated temperatures, moisture, contact with oxidizing agent, storage near acids, sparks, open flame, ignition sources. Hazardous polymerization : Will not occur may polymerize in presence of aliphatic amines. TOXICOLOGICAL INFORMATION (ANSI Section 11) Supplemental health information : Contains a chemical that is moderately toxic by ingestion. Contains a chemical that may be absorbed through skin. Excessive inhalation of fumes may lead to metal fume fever characterized by a metallic taste in mouth, excessive thirst, coughing, weakness, fatigue, muscular pain, nausea, chills and fever. Notice - reports have associated repeated and prolonged occupational overexposure to solvents with permanent brain and nervous system damage. Intentional misuse by deliberately concentrating and inhaling the contents may be harmful or fatal. Other effects of overexposure may include toxicity to liver, kidney, central nervous system, blood. 313K The information contained herein is based on data available at the time of preparation of this data sheet which ICI Paints believes to be reliable. However, no warranty is expressed or implied regarding the accuracy of this data. ICI Paints shall not be responsible for the use of this information, or of any product, method or apparatus mentioned and you must make your own determination of its suitability and completeness for your own use, for the protection of the environment, and the health and safety of your employees and the users of this material. Complies with OSHA hazard communication standard 29CFR1910.1200. EMERGENCY TELEPHONE NO. (800) 545-2643 FIRST-AID MEASURES ACCIDENTAL RELEASE MEASURES Steps to be taken in case material is released or spilled : Comply with all applicable health and environmental regulations. Eliminate all sources of ignition. Ventilate area. Ventilate area with explosion-proof equipment. Spills may be collected with absorbent materials. Use non-sparking tools. Evacuate all unnecessary personnel. Place collected material in proper container. Complete personal protective equipment must be used during cleanup. Large spills - shut off leak if safe to do so. Dike and contain spill. Pump to storage or salvage vessels. Use absorbent to pick up excess residue. Keep salvageable material and rinse water out of sewers and water courses. Small spills use absorbent to pick up residue and dispose of properly. 925 Euclid Avenue Cleveland, Ohio 44115 Primary route(s) of exposure : Inhalation, skin contact, eye contact, ingestion. Effects of overexposure : Inhalation : Irritation of respiratory tract. Prolonged inhalation may lead to mucous membrane irritation, fatigue, drowsiness, dizziness and/or lightheadedness, headache, uncoordination, nausea, vomiting, diarrhea, abdominal pain, chest pain, blurred vision, flu-like symptoms, coughing, sneezing, difficulty with speech, apathy, central nervous system depression, anesthetic effect or narcosis, difficulty of breathing, allergic response, fever and chills, tremors, abnormal blood pressure, severe lung irritation or damage, liver damage, kidney damage, pulmonary edema, pneumoconiosis, loss of consciousness, respiratory failure, asphyxiation, death. Possible sensitization to respiratory tract. Skin contact : Irritation of skin. Prolonged or repeated contact can cause dermatitis, defatting, blistering, allergic response, severe skin irritation, severe skin irritation or burns. Possible sensitization to skin. Eye contact : Irritation of eyes. Prolonged or repeated contact can cause conjunctivitis, blurred vision, tearing of eyes, redness of eyes, severe eye irritation, severe eye irritation or burns, corneal injury. Ingestion : Ingestion may cause lung inflammation and damage due to aspiration of material into lungs, mouth and throat irritation, drowsiness, dizziness and/or lightheadedness, headache, uncoordination, nausea, vomiting, diarrhea, gastro-intestinal disturbances, abdominal pain, visual disturbances, apathy, central nervous system depression, anesthetic effect or narcosis, burns of the mouth, throat, stomach, liver damage, kidney damage, pulmonary edema, loss of consciousness, respiratory failure, death. Medical conditions aggravated by exposure : Eye, skin, respiratory disorders, lung disorders, asthma-like conditions, respiratory disorders. ORGANIC ZINC-RICH EPOXY PRIMER HAZARDS IDENTIFICATION prepared 08/02/04 ICI Paints North America MATERIAL SAFETY DATA SHEET Carcinogenicity : The international agency for research on cancer (IARC) has evaluated ethylbenzene and classified it as a possible human carcinogen (group 2b) based on sufficient evidence for carcinogenicity in experimental animals, but inadequate evidence for cancer in exposed humans. In a 2 year inhalation study conducted by the national toxicology program (NTP), ethylbenzene vapor at 750 ppm produced kidney and testicular tumors in rats and lung and liver tumors in mice. Genetic toxicity studies showed no genotoxic effects. The relevance of these results to humans is not known. Reproductive effects : High exposures to xylene in some animal studies, often at maternally toxic levels, have affected embryo/fetal development. The significance of this finding to humans is not known. Mutagenicity : Triethylenetetramine has demonstrated weak mutagenic activity in standard in vitro tests, and has caused embryo- fetal toxicity and fetal malformations when fed to rats. Triethylenetetramine did not exhibit carcinogenic potential in life-time mouse skin painting studies. Teratogenicity : No teratogenic effects are anticipated Physical Data Product Code 313B0250 313C0910 ECOLOGICAL INFORMATION (ANSI Section 12) No ecological testing has been done by ICI paints on this product as a whole. DISPOSAL CONSIDERATIONS (ANSI Section 13) Waste disposal : Dispose in accordance with all applicable regulations. Avoid discharge to natural waters. REGULATORY INFORMATION (ANSI Section 15) As of the date of this MSDS, all of the components in this product are listed (or are otherwise exempt from listing) on the TSCA inventory. This product has been classified in accordance with the hazard criteria of the CPR (controlled products regulations) and the MSDS contains all the information required by the CPR. (ANSI Sections 1, 9, and 14) Description Wt. / Gal. do not use, use dc313b0250d instead catha coat 313 organic zinc-rich epoxy primer clear converter Ingredients 24.77 7.54 VOC gr. / ltr. 334.95 338.66 % Volatile by Volume 41.44 41.11 Flash Point 90 f 110 f Boiling Range 244-304 243-304 HMIS *231 *320 DOT, proper shipping name paint, 3, UN1263, PGIII paint, combustible liquid, UN 1263, PGIII Product Codes with % by Weight (ANSI Section 2) Chemical Name benzene, ethyl2-heptanone 1,2,-ethanediamine, n,n'-bis(2-aminoethyl)zinc oxide benzene, dimethyloxirane,2,2'-(( (1-methylethylidene) bis (4,1-phenyleneoxymethylene) )) bisphenol, 4,4'-(1-methylethylidene)bis-, polymer with 2,2'-((1-methylethylidene)bis (4,1-phenyleneoxymethylene))bis(oxirane) fatty acids, c18-unsatd., dimers, reaction products with polyethylenepolyamines 1-butanol zinc sulfuric acid, barium salt amine adduct Chemical Hazard Data Common Name ethylbenzene methyl amyl ketone triethylenetetramine zinc oxide xylene diglycidyl ether of bisphenol a epoxy resin polyamide resin n-butanol zinc barium sulfate amine adduct Footnotes: C=Ceiling - Concentration that should not be exceeded, even instantaneously. Common Name ethylbenzene methyl amyl ketone triethylenetetramine zinc oxide xylene diglycidyl ether of bisphenol a epoxy resin polyamide resin n-butanol zinc barium sulfate amine adduct CAS. No. 100-41-4 110-43-0 112-24-3 1314-13-2 1330-20-7 1675-54-3 25036-25-3 68410-23-1 71-36-3 7440-66-6 7727-43-7 Sup. Conf. 313B0250 .1-1.0 5-10 313C0910 20-30 1-5 1-5 1-5 1-5 1-5 40-50 10-20 70-80 1-5 10-20 (ANSI Sections 2, 8, 11, and 15) CAS. No. 100-41-4 110-43-0 112-24-3 1314-13-2 1330-20-7 1675-54-3 25036-25-3 68410-23-1 71-36-3 7440-66-6 7727-43-7 Sup. Conf. S=Skin - Additional exposure, over and above airborn exposure, may result from skin absorption. ACGIH-TLV 8-Hour TWA STEL C 100 ppm 125 ppm not est. 50 ppm not est. not est. not est. not est. not est. 2 mg/m3 10 mg/m3 not est. 100 ppm 150 ppm not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. 20 ppm not est. not est. not est. not est. not est. 10 mg/m3 not est. not est. not est. not est. not est. n/a=not applicable not est=not established CC=CERCLA Chemical S not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. 8-Hour TWA 100 ppm 100 ppm not est. 5 mg/m3 100 ppm not est. not est. not est. 100 ppm not est. 5 mg/m3 not est. ppm=parts per million mg/m3=milligrams per cubic meter Sup Conf=Supplier Confidential Form: 313K, Page 2 of 2, prepared 08/02/04 OSHA-PEL STEL C not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. S not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. S2=Sara Section 302 EHS S3=Sara Section 313 Chemical S.R.Std.=Supplier Recommended Standard S.R. Std. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. not est. S2 S3 CC n n n n n n n n n n n n y n n y y n n n y y n n y n n n y n n n y y n n H y n n n y n n n n n n n M n n n n n n n n n n n n N n n n n n n n n n n n n I y n n n n n n n n n n n O n n n n n n n n n n n n H=Hazardous Air Pollutant, M=Marine Pollutant P=Pollutant, S=Severe Pollutant Carcinogenicity Listed By: N=NTP, I=IARC, O=OSHA, y=yes, n=no 第 3 章:安装 概述 本章描述根据 Derrick 设备的型号和设备关联的图号而推荐使用的安装步骤。离心机装运时已完全 装配完毕。但是,为确保运输安全,旋转总成用运输托架加以支撑。旋转总成必须落到底座上,然 后将轴承轴台牢固地固定到底座上。 安全 设备安装和操作之前,必须阅读并领会本手册所有安全信息。设备安装、操作和维护的警示牌在手 册第 2 章中做了概括。 安装之前,请查看本章关于设备搬运的相关信息。如果不遵守正确的设备搬运规程,可能导致人员 伤亡和/或设备受损。 警示!提升时要确保设备正确地平衡和定位,以防损坏设备部件,只能在指定的起 吊点固定吊绳。起吊时不能将吊绳固定在任何其它位置。 警示!确保起吊装置的起吊能力足以安全处理待吊设备的重量。离心机要缓慢平稳 地放低就位,落地动作过猛会使设备受损。 警示!离心机定位到最终安装现场之前不得拆除运输托架。 储存 如果离心机不立即进行安装,要按以下内容对控制柜、旋转总成和电机妥善保存。 控制柜 为使控制柜免受天气和灰尘影响,应加盖涂油防水布并在满足以下条件的室内存放: 温度:50°F — 86°F (10°C — 30°C) 相对湿度:20% — 50% 10 年 7 月 30 日 3-1 DE-7200VFD 离心机 安装 控制柜(续) 如果控制柜在初次起动之前要存放很长时间,请按以下方式存放: 1. 每隔六个月接通控制柜电源,通电 1 到 2 小时。 2. 为降低控制柜柜内湿度,可在柜内放置可更换的干燥剂或小型加热源(例如白炽灯泡等)。 旋转总成和电机 为使离心机免受天气和灰尘影响,应加盖涂油防水布并在满足以下条件的室内存放: 温度:50°F — 86°F (10°C — 30°C) 相对湿度:20% — 50% 1. 按本章后面的描述,将旋转总成落放在底座上。 2. V 形主传动皮带不要张紧。 3. 每隔三个月,要手动旋转转鼓总成至少 20 次,同时阻止传输装置的电机一道旋转;然后对主轴 承和传输装置的轴承涂敷润滑脂。 4. 每存放三个月都要手动旋转转鼓和传输装置的电机轴 5 到 10 转。如果存放时间超过 1 年,要在 初次起动之前对电机轴承再次涂敷润滑脂。 5. 如果电机配备有内部加热器,应接通加热器电源并赋能。 安装顺序 以下是离心机的安装步骤和顺序。根据用户实际使用的安装设施以及同类设备的安装经验,所列安 装顺序可能会有变动调整。 1. 设备安装和操作之前,必须阅读并领会本手册第 2 章中的所有安全信息。 2. 设备提升和定位之前,必须阅读并领会本章中的设备搬运规程。 3. 在安装现场对设备进行定位和找平。 4. 拆除运输件,将旋转总成轴承轴台落到底座上并与底座牢固固定。 5. 调整传动皮带(参见第 5 章内容)。 6. 连接液体排放管线。 7. 如果使用排料槽,请将排料槽与固体排料斜槽连接。 8. 安装进料部件,将挠性进料管与进料管连接并与液体端法兰平齐。 9. 选择并安装进料泵。 10. 连接设备的电源,并将转鼓电机、传输装置电机以及进料泵电机与控制柜内的端子块连接。 11. 将传感器电缆与传感器接线盒连接好并插好插头。 12. 对于防爆型控制柜,需将吹扫装置接好压缩空气。 3-2 10 年 7 月 30 日 安装 13. 起动和操作步骤请参见第 4 章的内容。. 要求的净空与定位 设备周围要有足够的空间,以便进行维护、检验和调整工作。 代表性操作维护工作包括以下内容: 1. 接近并操作系统的控制盘。 2. 打开和关闭控制柜柜门(见图 3-1)。 3. 打开和关闭顶盖。 4. 对旋转总成的轴承进行润滑。 5. 检查齿轮箱并注油。 6. 连接和断开进料管和液体排出管。 7. 拆除和安装进料管(见图 3-2)。 图 3-1:打开控制柜柜门和电气盘所需要的净空 设备的定位与固定 安装离心机时要求使用支撑基板。根据图 3-2 对安装现场进行布置并定位基板。底板有 1-9/16” x 1-9/16” (40mm x 40mm) 定心杆。它们与安装平台要么栓接要么焊接,便于正确定位并防止离心机 移动。将离心机落到基板上时,要确保定心杆与每个振动隔离器底部的开口啮合。 10 年 7 月 30 日 3-3 DE-7200VFD 离心机 图 3-2:离心机安装现场的布置 安装 3-4 10 年 7 月 30 日 安装 图 3-3:离心机的固定 液体和固体排出斜槽 制做液体和固体排出斜槽时,要考虑以下设计要求: 参见第 8 章总体配置图确定斜槽的尺寸和安装 孔的配置。 液体排出斜槽 制做该斜槽时,要确保斜槽尽量笔直。微小的弯曲可以接受,但要记住:任何弯曲都会限制液体流 出离心机的流速。 固体排出斜槽 固体端的斜槽一定要设计有足够大的坡度,以便斜槽进行自清洁。如果这一点无法做到,则应考虑 到清洁方法,定期去除斜槽上累积的固体物料。 设备找平 为使离心机达到满意的工作效果,安装时必须对其正确地找平。设备必须沿长宽两边找平(见图 33)。推荐使用双脚水平仪或鱼雷尺。对设备做垫平处理时要求使用不可压缩的垫片。 10 年 7 月 30 日 3-5 DE-7200VFD 离心机 安装 设备找平(续) 图 3-3:离心机找平 放低并固定旋转总成 注意!橡胶带拆除后不能丢弃在轴承轴台之间、盖子和底座上。当设备发生搬动移位 时必须重新扎好这些橡胶带,以防底座和旋转总成的轴承发生损坏。 离心机经过最终定位和找平之后,必须拆除轴承轴台和底座之间的软胶带以及机箱盖与机箱之间的 硬胶带。这些胶带可以避免旋转总成的轴承在设备搬动移位时发生损坏。 请按以下步骤拆除橡胶带: 1. 拆除固定顶盖和两侧的所有螺栓,但不要拆除盖子两端的螺栓。 2. 拆除固定轴承轴台与底座的螺栓以及固定轴台上下两半之间的螺栓(见图 3-4)。 3. 在每个轴台上半部分安装两个顶栓(见图 3-5),然后拧动螺栓穿过轴台的下半部分。 3-6 10 年 7 月 30 日 安装 图 3-4:轴台与机箱盖的连接 图 3-5:运输件的位置 4. 顺时针方向旋转顶栓将轴台顶起足够拆除所有软硬橡胶带的空间,然后拆除这些橡胶带。 5. 清理轴台下半部分和底座的安装面,然后在两个表面上涂敷薄薄一层滑脂或防锈剂。 6. 确保底座上的对正销孔清洁,并且锥形扩孔器可自由插入孔中。 7. 将四个对正销插入相应的孔中。 10 年 7 月 30 日 3-7 DE-7200VFD 离心机 安装 放低并固定旋转总成(续) 8. 按逆时针方向均等转动顶栓可以将轴台缓慢地落到底座上,在轴台接触到底座之前,先使用对 正销对轴台正确定位。轴台与底座完全接触并且安装孔完全对齐后,将顶栓拆除。 9. 将两个轴台固定螺栓(见图 3-4)插入每个轴台的上半部分,按照第 5 章所描述的适用的扭矩 技术规格均匀用力上紧螺栓。 10. 使用黄铜材质的小锺将对正销完全敲入并坐到轴承轴台和底座上;然后将带有垫圈和弹簧垫圈 的安装螺栓插入孔中。逐渐用力上紧螺栓直到达到第 5 章规定的扭矩。不要紧固对正销上的螺 母。 11. 安装并紧固机箱盖两侧所有的螺栓。 12. 根据第 5 章“预防性维护”的内容调整传动皮带的张紧度。 进料和排料管的连接 离心机失衡时为避免离心机和配管受损,要求使用振动隔离器。因此,所有进料和排料管都必须使 用挠性连接管。新水水源与进料部件上的冲洗接头连接,以便在停车前对离心机进行冲洗。冲洗管 上必须安装截流阀。 随离心机一道提供的进料部件(见图 3-6)具有内螺纹接头便于连接用户的进料管和冲洗管以及一 个用于隔离振动的集成挠性短接。液体排出斜槽由用户提供,也要求使用振动隔离器。如果使用固 体排出斜槽,必须将它与挠性接头连接。有关液体和固体排出斜槽的连接法兰尺寸与螺栓规格,可 参见第 8 章的总体配置图。 图 3-6:进料部件 新水水源 要求新水水管上安装球型截流阀,以便在需要时以及在停车前进行设备清理时可以对料浆进行稀 释。 3-8 10 年 7 月 30 日 安装 压缩空气 如果控制柜在危险环境下工作,吹扫系统要求使用 120 PSI 经过滤的干燥压缩空气。关于风管尺寸 和压缩空气的流量,请参见手册第 10 章的内容。 进料泵 要求用户使用正排量进料泵向离心机输送料浆。推荐使用具有固定传动比齿轮箱的螺杆泵和最大 30HP 的变频器专用驱动电机。电机工作能力必须达到 180—2700 RPM,速度范围在 6—90 Hz, 同时还要满足所有其它应用要求,包括电压、频率和危险区域分级等。选择泵的尺寸、电机以及齿 轮箱传动比时,必须考虑当泵的转子速度(由制造商决定)足够低时仍能输送所需的最大流量,防 止转子和/或定子加速磨损。 泵必须按照本章电源连接摂部分的描述与离心机控制系统连接,以便通过离心机对其操作进行监 控。 电源连接 警示!有危险的电压。如果馈电分相,一定要在离心机送电之前确保定相正确。 连接选项 根据图 3-7 对应的视图将工厂的三相电源与控制柜连接。无危险区域的控制柜在控制柜内连接;危 险区域则必须在控制柜右侧的电气盘上连接。 注意:电源或者连接单重计电缆,或者连接两根小直径轻型电缆之间的分芯。用于分芯输入连接的 轻计电缆通常易于处理。两种选择所要求的输入电缆敷设元件如下所示: 选项 1:每相一根 4/0 AWG 电缆,一个 3” NPT 电缆堵头 选项 2:每相两根 2 AWG 电缆,两个 2” NPT 电缆堵头 如果输入按选项 2 所述对分(见图 3-8),要确保相同的相/颜色使用组导体。如需更更多与电气连 接和额定值有关的信息,请参见第 8 章中的电气示意图。 10 年 7 月 30 日 3-9 DE-7200VFD 离心机 安装 电源连接(续) 无危险区域的控制柜 危险区域的控制柜 图 3-7:电源连接 图 3-8:对分输入电源的连接 该设备要求使用熔断主电源。设备的熔断接线必须大小合适并且满足国家电气法规(NEC)和其它 所有适用的州/当地法规要求。 接线的补充要求如下: 3-10 10 年 7 月 30 日 安装 1. 熔断装置要具有充足的断开能力,要能够消除电源系统最大的电流故障。 2. 控制柜和传感器系统的接线盒中的接地端必须与已知地线连接。 转鼓、传输装置和进料泵的电机的连接 转鼓和传输装置驱动电机要求使用三相电源并做接地连接。电源源自与控制柜内端子块的连接。同 样,用户的进料泵电机必须与离心机控制系统连接以便对其操作进行控制。 将转鼓、传输装置和进料泵的电机按图 3-9 所示与控制柜左侧底部的端子块连接。控制系统操作进 料泵驱动电机,可使其达到 30HP。 图 3-9:转鼓、传输装置和泵的电机的电气连接 10 年 7 月 30 日 3-11 DE-7200VFD 离心机 安装 极性的测试 警示! 确保电机旋转方向正确。 传输装置电机如果极性出错将造成传输装置旋转速 度出错,并造成物料处理问题。 在以下情况中,极性非常关键。确保所有电机旋转方向都正确。通过简单查看固体物料是否排出固 体端并不能确保极性一定正确! 如果传输装置电机接线有误,传输装置会根据转鼓和传输装置的速度设定情况出现堵塞或满溢。按 以下方法对所有接头的极性是否正确进行测试: 1. 对离心机送电。 2. 在传输装置差动速度为 5RPM 时,以 20RPM 的转速下运行转鼓。 3. 确认转鼓、传输装置、进料泵和空调冷凝电机的旋转方向是否如下: a. 转鼓:从风扇端看呈逆时针方向旋转。 b. 传输装置:从风扇端看呈顺时针方向旋转。 c. 进料泵:按制造商资料。 d. 空调冷凝器:从风扇端看呈顺时针方向旋转。 4. 如遇旋转方向颠倒,可切断电源并交换控制柜内端子块上的三根电源导线中的任意两个进行纠 正(参见图 3-9 和第 8 章中的电气示意图)。 警示!离心机必须在指定的电压等级条件下工作。 警示!可能有高压。 确保设备的熔断电源是断开的。电气连接时,要切断电源并挂 牌上锁,以防意外送电。 警示!电气连接必须符合国家电气法规(NEC)和所有适用的地方性法规。违反这 些法规规定会造成可能导致人员受伤和设备损坏的不安全条件。要确保所有电气和 导线管连接均牢固可靠。 传感器的连接 使用用户提供的电缆连接传感器。电缆一端按图 3-10 所示与传感器接线盒内的端子连接,另一端 与离心机所带插塞连接(见图 3-11)。将导线与插塞对应编号的端子连接(1 到 16 号)。接线完 成之后,将电缆插入控制柜左侧上面的插座内。 3-12 10 年 7 月 30 日 安装 吹扫系统压缩空气的连接 对于防爆型控制柜,需按要求的压力和流量向吹扫控制装置提供压缩空气。根据第 10 章 EXPO 技术 公司 MiniPurge 吹扫装置技术资料的规定连接压缩空气。 设备起动 离心机初次起动和操作步骤请参见第 4 章的内容。 警示!设备装有运输件时不得运行。 图 3-10:传感器系统接线盒的连接 10 年 7 月 30 日 3-13 DE-7200VFD 离心机 安装 图 3-11:传感器系统的插塞连接 3-14 10 年 7 月 30 日 第 4 章:操作指导 概述 本章中的操作步骤只能由经过培训并且胜任高速旋转设备操作的人员执行。本章介绍离心机初次起 动和正常起动、操作、停车和紧急停车的步骤。 本章在起动和操作步骤的内容之后,描述了控制屏 的详细情况,便于帮助操作人员和技师理解离心机的操作情况并能够完全利用其产能。 离心机设计为只能用于采购时规定的用途。如需在任何其它领域应用,均需事先向 Derrick 公司工 程设计部门咨询。 操作安全 警示!开始对设备进行操作之前,所有操作和维护人员必须阅读并领会本手册中的 所有安全信息。 警示!设备起动之前,首先要确保所有盖板均已关闭且得到牢固固定,并且所有人 员均已远离设备。 警示!确保所有运输件均已拆除并且轴承轴台已正确紧固。 警示!打开盖板或拆除防护板之前,必须让机器惯性滑行直至完全停止转动。 警示!如果出现异常噪音或振动时,不得对离心机进行操作。 必须随时确认振动开 关和其它安全装置工作正常。 09 年 10 月 30 日 4-1 DE-7200VFD 离心机 操作指导 吹扫系统(仅针对危险环境) 只有危险环境下操作的离心机才配备吹扫系统。起动时,吹扫系统将控制柜内部所有气体吹出并保 持控制柜内的空气正压,防止可能的爆炸性气体进入。控制柜内感应到足够的空气压力时,吹扫系 统的运行被启动。之后进行 14 分钟的快速吹扫,空气流速为 15CFM(立方英寸/分钟),同时吹 扫系统保证不向控制柜内部送电。快速吹扫结束时,吹扫系统闭合向控制柜内部通入电流的主接触 器。接着在离心机运行时开始进行连续的 2 立方英寸/分的吹扫,并且在离心机运行之后继续进行 吹扫。最好能够使控制柜保持带压状态。无论任何时候发现控制柜的压力缺失,主接触器将立即断 开并断开电源。在重新送电赋能之前,再次进行 14 分钟的快速吹扫。 初次起动 设备安装完成后第一次起动时或者设备重新配置之后,都要按照初次起动的步骤进行操作。 1. 检查是否所有工具、资料和运输件已经清除,现场没有妨碍操作的物品。 2. 确定所有人员均远离设备。 3. 确认所有操作人员和维护人员均已阅读并领会第 2 章中的全部操作和安全信息。 4. 确认设备已正确安装完毕,所有运输托架均已拆除,并且轴承轴台均已根据第 3 章规定的扭矩 紧固妥当。 5. 对于防爆型控制柜,要打开压缩空气吹扫系统。 6. 对离心机送电。将出现以下屏显(在防爆型控制柜上,吹扫作业完成后显示): 7. 在离心机不运行的情况下,进行以下安全检查,确保控制柜与离心机之间连接正确。 操作接线盒与控制柜上的紧急停车按钮,检查控制盘上的紧急停车报警信息。 拔出紧急停车按钮,清除报警信息。 用橡胶锺或生皮锺在水平方向轻敲振动开关,检查控制盘上的 High Vibration Fault(高振动 故障)信息。 按下振动开关上的复位按钮,清除报警信息。 8. 选择 Cent(离心机)。Status(状态)确定设备待运行。起动之前,对任何缺陷及时纠正。如 果状态令人满意,点击右上角返回 Home(主页)屏显。 4-2 09 年 10 月 30 日 操作指导 9. 选择 Setup(设置),然后点击 Pump Setup(泵的设置)查看泵的操作信息。如果需要,可修 改任何操作信息,然后点击右上角返回 Setup(设置)屏显。选择 Home(主页)返回主页屏 显。 10. 选择 Operation(操作)显示以下屏显: 11. 使用上下箭头按钮,将 Bowl Input RPM(转鼓输入转速)设定为 20 RPM,将 Conveyor Input RPM(传输装置输入转速)设定为 5 RPM。确认转鼓、传输装置、进料泵和空调冷凝电机的旋 转方向是否如下: 转鼓:从风扇端看呈逆时针方向旋转。 传输装置:从风扇端看呈顺时针方向旋转。 进料泵:按制造商资料。 空调冷凝器:从风扇端看呈顺时针方向旋转。 12. 如遇旋转方向颠倒,可切断电源并交换控制柜内端子块上的三根电源导线中的任意两个进行纠 正(参见第 2 章和第 8 章中的电气示意图)。 13. 根据下面的正常起动步骤起动离心机,从第 4 步开始。 正常起动 1. 先不送电,打开盖板并手动旋转转鼓总成,检查转鼓是否能够自由旋转并且感觉不到任何摩 擦。 2. 关闭盖板,按照要求的扭矩上紧盖板螺栓(参见第 5 章),确认所有防护板均已就位。 3. 设备通电之前,确认所有人员均已远离设备,所有防护板均已就位。 4. 打开压缩空气开始控制柜的吹扫作业,这一步骤仅针对防爆型控制柜。 09 年 10 月 30 日 4-3 DE-7200VFD 离心机 操作指导 正常起动(续) 5. 对离心机送电。将出现以下屏显(在防爆型控制柜上,吹扫作业完成后显示): 6. 在 Home(主页)显示页面上选择 Operation(操作)显示以下页面: 7. 使用上下箭头,将转鼓和传输装置的输入转速设定为需要的速度。 注意!转鼓速度设定不得低于 750 RPM。 8. 进料泵控制有两种选择。如果要求用 PLC 进行自动控制,选择 Torque(扭矩)。泵的流量(单 位是加仑/分钟)将根据转鼓和传输装置的扭矩百分比自动改变。选择 Flow(流量)对泵的流 量(加仑/分钟)进行设定。注意一点:即使设定了流量,但如果感应到的扭矩过大,PLC 也将 改变泵的流量甚至关停泵的运行。 9. 选择 START(起动)开动离心机。注意:转鼓和传输装置的速度将逐渐升高直到达到各自的设 定值,并且转鼓和传输装置的扭矩百分比也将升高。 10. 当转鼓速度达到设定值时,选择 Pump START(泵起动)起动进料泵,并且将物料缓慢地引入 离心机。 注意!只有当转鼓的实际速度达到设定的 120 RPM 之内时,泵才会起动。 4-4 09 年 10 月 30 日 操作指导 11. 按照要求调整进料速率、转鼓速度和/或传输装置的速度,优化离心机的操作。查看和监控离心 机的运行特征(包括空调装置的状态、运行经时、VFD 数据等)时,选择 Data(数据)显示页 面。 注意!根据传输装置的差动速度设定,当转鼓速度高于 300 RPM 时,传输装置的电 机可能反转。 操作 应提前掌握进料料浆的特点以及需要达到的分离程度。这些信息可用来对离心机运行时所要求的转 鼓速度、传输装置差动速度以及进料速率等进行设定和修改(除非设定为自动控制)。连续监控离 心机的控制盘指示情况以及进料料浆的状况对于达到要求的排液澄清度和固体干燥度都是十分重要 的。传输装置扭矩升高表示需要调低一两个运行参数使扭矩降低。相反,如果传输装置的扭矩降 低,则表示可以提高速度和/或增加进料速率。运行参数应根据要求进行调整,目的是优化离心机 的运行操作,防止由于转鼓或传输装置扭矩过大使设备自动停车。 Operation(操作)屏(见图 4-1)使操作人员能够查看转鼓、传输装置和泵目前的操作信息,并且 根据需要对参数进行调整,以满足变化的运行条件。通过该屏显,操作人员可以查看并设定转鼓和 传输装置的转速和扭矩百分比,设定进料泵的流量,并且查看轴承的温度。使用上下箭头或者在数 字键板上输入实际的数字可以调整传输装置和转鼓的速度。另外,还有离心机停车、显示 VFD 操 作屏、选择状态、清理、故障、报警和主页屏等选项。 图 4-1 :操作屏(第 1 张) 09 年 10 月 30 日 4-5 DE-7200VFD 离心机 操作指导 操作(续) 图 4-1:操作屏(第 2 张) 以下参数会影响离心机的操作: 进料速率; 液池的深度; 转鼓的速度; 传输装置的速度。 对一个参数进行调整可能使废液达到要求的澄清度并使固体达到要求的干燥度。进一步调整可能达 到需要的性能。各个操作参数之间是相互关联的,理解这一点十分重要。修改一个参数指标可能会 造成保证进一步进行调整的影响。 除液池深度以外,其它参数均可在离心机工作时进行调整。操作人员在继续做其它调整之前可以检 查一个参数修改后所产生的效果。以下部分描述了每个参数修改后可以达到的效果。 进料速率的调整 在 Operation(操作)屏上选择 Manual(手动)时,操作人员可在操作屏上手动输入所需的进料速 率。如果料浆的粘度和密度都很低,提高进料速率可以加快物料处理速度。但是,随着进料速率的 提高,物料在转鼓中的停留时间会减少,造成液体排出时固体含量增加。另外,传输装置的扭矩可 能增大,这表明传输装置由于在目前的速度下输送的固体量增大而加重负荷。如果要降低传输装置 的扭矩,可以降低转鼓的速度,可以降低进料速率,或者提高传输装置的速度使固体排出速度加 快。控制盘上显示进料速率的设定值和实际值,可以帮助操作人员进行调整。 4-6 09 年 10 月 30 日 操作指导 转鼓的速度 转鼓速度越快,固体通过液池在转鼓外壁沉积的速度越快,并且送出离心机的速度越快,但是处理 速度过快会造成固体排料中的含湿量增大。为了降低固体中的含湿量,泥浆必须延长在转鼓中的停 留时间,因为固体物料从固体排出口送出之前需要较长的沉积处理时间。相反,降低转鼓速度可能 有利于从厚重料浆仅分离出高密度或大粒度的固体物料。 转鼓速度的设定值和实际值在控制盘上都有显示。转鼓的扭矩百分比在控制盘上也有显示。该信息 对优化转鼓速度达到需要的固体干燥度和优化处理速度都很有帮助。 传输装置的差动速度 如果接线的极性正确无误,传输装置会对在 Operation(操作)屏上所做的设定值做出正确的反 应。修改传输装置的差动速度可以调整固体物料的排出速率。一般而言,差动速度越慢,固体干燥 度越高,但固体排出速率越慢。提高传输装置的速度会减少干燥时间,使固体排料的含湿度增大。 降低传输装置的速度则使固体排料的含湿量减小。但是,如果传输装置的速度过慢,会使固体物料 沉积在转鼓内,可能使其过载。 提高传输装置的差动速度会减少干燥时间,增大固体的含湿量。降低传输装置的差动速度会增加固 体沉降时间,并增大固体的干燥度。 传输装置速度的设定值和实际值在控制盘上都有显示。另外,传输装置的扭矩百分比也有显示,有 助于优化传输装置的速度,达到所需的固体干燥度和处理速度。 由于传输装置的差动速度是相对于转鼓速度设定值由 PLC 进行控制,因此电气元件接线极性的正确 性十分关键。无论转鼓的速度设定如何,电气极性都将决定传输装置电机的实际速度和旋转方向。 例如:如果转鼓的速度设定为 2000 RPM,传输装置的差动速度设定为 60,则传输装置电机将以1120 RPM 倒转。 转鼓—传输装置速度关系正确与否取决于电气接线的极性正确与否。如果极性接反了,上述同样的 2000 RPM 转鼓速度会造成传输装置实际差动速度大约为 17,而不是设定的 60。 液池的深度 液体转鼓头上有六个可调节的溢流堰(见图 4-2),方便对液池深度进行设定;所有排污口的设定 必须相同。液池太深会缩小转鼓固料排出端的砂滩面积,一般会造成固体排料的含湿量较高。相 反,如果液池深度设定较浅,会增大砂滩区面积,使固体排料更干燥。 液池深度只能在离心机完全停止运行并且被禁用时才能进行调整。基于这个原因,液池深度通常最 后进行调整。连同进料速率、转鼓速度和传输装置速度的调整一道使用时,工厂所做的液池深度设 定通常能够取得令人满意的结果。但是,如果通过其它方式不能达到所需要的结果,就要求对液池 深度重新进行调整。 09 年 10 月 30 日 4-7 DE-7200VFD 离心机 操作指导 图 4-2:溢流堰板的调整 按以下方式调整液池深度: 警示!除非转鼓处于完全静止的状态,否则不得打开离心机机盖或对离心机进行任何 调整/维护。 1. 按照本章后面描述的正常停车步骤执行离心机的停车、切断电源和挂牌上锁。 2. 拆除机箱盖入口侧的通道板。 3. 松开固定溢流堰板的螺钉,移动溢流堰板,使其达到所需的开口尺寸,然后按照第 5 章规定的 扭矩重新上紧螺钉。 4. 将六块溢流堰板都设定为同样的位置。 5. 重新将通道板安装到机箱盖上。 差动速度/传输装置的扭矩 一般而言,传输装置速度越快,传输装置的扭矩就会越低,因为固体排出速度会加快并且含湿量通 常会增大。传输装置的速度必须缓慢降低,操作时必须格外当心,每进行下一步减速之前必须使其 达到稳定状态。传输装置速度减慢使固体能够在转鼓内停留更长时间。如果输入速率超过排出速 率,固体会沉积在转鼓内。因此,必须随时监控扭矩变化,防止出现过载。 扭矩极限设定值可以控制自动减少进料和离心机停车。随着传输装置扭矩的增大,进料速率逐渐降 低。如果扭矩继续升高,进料速率会加速降低。当达到传输装置最大扭矩设定值时,离心机停车。 在某些传输装置速度条件下,驱动电机必须逆转,以适应相对于转鼓的差动速度关系。如果出现这 种情况,离心机控制系统会自动对进料泵进行控制,降低其流量。Operation(操作)屏上显示信 息“Automatic Flowrate(自动流量)”,提醒操作人员进料泵处于自动控制状态。 4-8 09 年 10 月 30 日 操作指导 进料速率降低后,20 秒计时器起动。计时器的计时到时后,对应于修改后的流量,将使用新的传 输装置差动速度。达到新的差动速度时,进料泵的速率将返回先前的速率。然后进料泵恢复手动控 制。该动作使进料泵脱离自动控制,并且将 Automatic Flowrate(自动流量)信息从屏显上清除。 报警与故障信息 离心机运行时,如遇有需要操作人员处理的异常情况,会出现一条提示信息。报警信息表示必须优 先解决和处理的情况,否则离心机会自动停车。故障信息则告知操作人员要求自动停车的故障已经 出现。报警信息及其原因和纠正措施可参见第 5 章的内容。 轴承的温度 轴承温度趋势可在 Bearing Temperature(轴承温度)屏显上的图形中查看到(见图 4-3)。温度 根据预设的时间段进行更新,滚动按钮方便检查温度随时间变化的趋势。固体端和液体端的温度显 示在屏显的右边。从 Bearing Temperature(轴承温度)屏还可以访问 Motor Torque(电机扭矩) 屏。 操作人员可使用屏显右下方的按钮返回 Operation(操作)屏或 Home(主页)屏。 图 4-3:轴承温度屏显 电机扭矩的趋势 转鼓和传输装置的扭矩趋势可以在 Motor Torque(电机扭矩)趋势屏上的图形中查看到(见图 44)。扭矩根据预设的时间段(一分钟)进行更新,滚动按钮方便检查温度随时间变化的趋势。转 鼓和传输装置的扭矩均显示在屏显的右边。从 Motor Torque(电机扭矩)屏还可以访问 Bearing Temperature(轴承扭矩)屏。操作人员可使用屏显右下方的按钮返回 Operation(操作)屏或 Home(主页)屏。 09 年 10 月 30 日 4-9 DE-7200VFD 离心机 操作指导 图 4-4:电机扭矩趋势屏 系统诊断 内置的系统诊断可以连续分析控制系统是否出现误操作。诊断屏(见图 4-5)显示离心机关键部件 的故障,有助于进行故障排除。转鼓、传输装置和泵的 VFD(变频驱动器)以及速度和温度传感器 目前的工作状态都在此屏显示。主轴承温度传感器和转鼓速度传感器的模拟信号读数(mA)显示 在屏显的底部。可以从 Home(主页)屏访问此屏和三个 VFD 的屏显。 图 4-5:诊断屏 4-10 09 年 10 月 30 日 操作指导 性能状态 目前的性能信息显示在 Centrifuge Status(离心机状态)屏上(见图 4-6)。显示的参数包括:轴 承温度、转鼓和离合器的速度与传感器的状况、安全装置(如振动开关、紧急停车开关、转鼓超速 保护装置等)的状态、空调的工作情况,以及运行时间等。显示空调压缩电机的工作状态、蒸发器 鼓风电机以及制冷器的压力。退出此屏返回前一个屏显。 故障通过颜色的变化(由绿变红)表示出 来,并有对应的文字显示。 图 4-6:离心机的状态屏 报警 Alarm(报警)屏(见图 4-7)允许操作人员查看并确认活跃报警信息。每个报警都列有其状态、 收到的日期和时间,以及相应的描述。屏显底部的按钮方便在报警列表中滚动。报警信息可以单独 确认,可以同时确认所有报警信息。报警可按照发生的顺序进行分类,另有返回 Operation(操 作)或 Home(主页)屏的按钮。 09 年 10 月 30 日 4-11 DE-7200VFD 离心机 操作指导 图 4-7:报警屏 VFD的状态 每台 VFD 都有状态屏(见图 4-8 到 4-10),便于查看目前的 VFD 状态信息。在 Operation(操 作)屏选择时,状态屏方便操作人员查看是否有报警出现、功率输出、电机旋转方向(向前或停 止)、VFD 内部温度、电机和转鼓速度以及电机的扭矩等操作要素的情况。点击温度信息组显示 VFD 的温度趋势屏(见图 4-11)。 图 4-8:转鼓的 VFD 屏 4-12 09 年 10 月 30 日 操作指导 图 4-9:传输装置的 VFD 屏 图 4-10:泵的 VFD 屏 09 年 10 月 30 日 4-13 DE-7200VFD 离心机 操作指导 VFD的状态(续) 图 4-11:VFD 的温度趋势屏 VFD的故障复位 Fault Reset(故障复位)屏(图 4-12)告知操作人员每台 VFD(无论有无故障)均已准备就绪, 并且允许对有故障的 VFD 进行复位。该屏显可从 Clean Out(清理)或 Operation(操作)屏进行 选择。如果传输装置的扭矩过高造成泵的流量降低,Operation(操作)或 Clean Out(清理)屏上 会显示“Flowrate Reduction(流量降低)”的信息,通知操作人员泵正在流量已降低的情况下操 作。该信息还会出现在 Fault Reset(故障复位)屏上。消除流量降低的原因后,在 Fault Reset (故障复位)屏上选择 RESET(按钮),使泵恢复正常流量。任何故障处理之后,重新起动离心 机之前都必须先确认设备已完全停下来。 图 4-12:故障复位屏 4-14 09 年 10 月 30 日 操作指导 设置屏 设置屏(见图 4-13)便于操作人员查看 PLC 和控制盘(人机界面)中安装的软件版本、转鼓和差 动速度的设定值,以及进料泵的特征等,并且设定个人偏好。操作人员可调整控制盘显示屏的亮度 并且选择其它屏显上的温度单位(°C 或°F)。 提供有选择 Login(登录)、Diagnostics(诊断)或 Home(主页)屏选项。如果选择 Login(登 录),将出现输入用户名和密码的提示,此屏只对经过授权的人员有效。一旦进入此屏显,授权人 员可设定或修改转鼓、传输装置和泵的 VFD 的相关参数。 图 4-13:设置屏 泵的设置屏 泵的操作特征可以在 Pump Setup(泵的设置)屏(见图 4-14)中查看。根据泵和驱动电机的操作 技术要求所键入的信息会显示出来,告知操作人员目前电机和泵的有关信息。 图 4-14:泵的设置屏 09 年 10 月 30 日 4-15 DE-7200VFD 离心机 操作指导 登录 可以从 Setup(设置)屏(见图 4-13)访问 Login(登录)屏(见图 4-15)。 便于授权人员输入显 示受限屏所要求的密码。这些屏显方便管理人员对控制离心机运行的操作特征和阈值重新进行设 定。 图 4-15:登录屏 清理 清理屏(见图 4-16)用来对转鼓和/或传输装置的操作参数进行设定,目的是对阻碍转鼓和/或传输 装置旋转的累积的工艺物料进行清除。通过这个屏显,操作人员可以选择需要进行清理的转鼓和传 输装置的转速。清理时,实际的转速和扭矩百分比显示低于设定值。有自动清理或手动清理两种选 项。 如果清理过程到时间完成或者由操作人员停止,会显示 Operation(操作)屏或 Fault(故障)屏。 图 4-16:清理屏 4-16 09 年 10 月 30 日 操作指导 如果泵速自动降低无法清除传输装置中的固体物料,扭矩将持续上升,离心机将停车。然后应当采 用清理步骤来清除压紧的固体物料并使离心机返回运行状态。下面将对两种清理选项做出阐释: 自 动清理和手动清理。 自动清理 选择自动清理选项时,系统将在预设的时间段内进行清理作业。转鼓以 300 RPM 的速度向前转 动,同时传输装置则在 8 到 30 RPM 速度之间变化同样向前转动。清理时如遇过大阻力,系统将中 止并提醒操作人员自动清理作业无法对离心机进行清理。要求操作人员介入,重复自动清理操作。 手动清理 如果选择手动清理,操作人员应当在转鼓速度设定为 0 RPM 时向前向后点动传输装置。但是,如 果需要,操作人员也可选择一道操作转鼓与传输装置。传输装置逆向旋转由计时器控制,到达预设 的时间段后终止逆转操作。手动清理模式主要的目的是通过点动传输装置达到清除压紧的物料。 正常停车 正常停车步骤用于控制停车操作。在进行包括清理、润滑、检查、或调整等在内的常规工作时要求 设备正常停车。 注意!对转鼓正确地停车并冲洗可以防止下次起动时出现较大振动。 09 年 10 月 30 日 4-17 DE-7200VFD 离心机 操作指导 正常停车 步 1 步骤 停止进料泵。 开始时继续加新水冲洗,将传输装置和转鼓上的所有固体物料冲洗干净。进料泵停车后继 续冲洗 3 到 5 分钟。无论停车时间有多长,转鼓减速直到停车过程中传输装置均要按照 预设的差动速度运行。此操作可以在停车时清理转鼓。离心力可以使冲洗水在冲洗过程中 2 不断对转鼓内壁进行冲洗。 停车期间随着速度逐渐降低,固体斜槽也能得到冲洗。机箱铰接侧的连接件方便连接软 管,对旋转总成的外部和机箱总成的内部都进行清洗。 3 4 转鼓速度降到 200 RPM 以下时,传输装置的齿轮箱驱动电机自动停车。 离心机静止不动(这一过程在转鼓电机断开电源后还需要 10 多分钟)后,离心机需重新 起动 20—30 秒时间,以便清除水环坍缩时脱落的固体物料。 5 执行自动清理操作步骤。 6 断开设备的熔断电源,闭锁设备电源并挂牌上锁。 7 对于带吹扫系统的控制柜,关闭到控制柜吹扫装置的压缩空气。 自动停车 离心机具有设备保护用的内置安全部件。这些部件确保离心机在受到损坏之前能够自动停车。以下 部分介绍了这些自动停车保护部件。 过度振动 离心机过度振动将使振动开关断开离心机运行继电器的电源并使设备停车。起动时或正常运行时, 由于转鼓壁上附着的饼料塌落或其它失衡条件的作用,都会造成出现振动过度。重新起动设备之 前,先要按下振动开关上的复位按钮,然后采用上述正常起动步骤进行操作。 正常起动时如果持续跳闸,可用新水冲洗转鼓,同时执行自动清理步骤。 4-18 09 年 10 月 30 日 操作指导 主轴承的温度 温度传感器安装在液体端和固体端的主轴承上,并且与 PLC 连接。轴承温度会连续显示 在 Operation(操作)屏上。当轴承温度超过 225°F (107°C)时,控制盘上会显示报警信息。如果温度 升至 250°F (120°C),会出现故障信息,离心机会停车。轴承温度过高通常表明轴承失灵,原因可 能是润滑不充分或润滑过度、受到污染或磨损严重。主轴承更换步骤请参见第 5 章的内容。 转鼓转速过快 传感器探测转鼓的转速并向 PLC 提供输入信号,PLC 在 Operation(操作)和 Bowl VFD(转鼓变 频驱动器)屏上连续显示转鼓的实际速度。速度升至 3100 RPM 时显示故障信息,离心机立即停 车。如果要重新起动离心机,先要让转鼓惯性滑行直到完全停止,然后按照第 5 章的描述检查并消 除超速原因。问题纠正之后,采用上述正常起动步骤重新起动设备,并且再次检查离合器的速度。 传输装置离合器脱扣 传感器侦测位于齿轮箱轴上的半边齿轮箱扭矩限制离合器的旋转速度。传感器向 PLC 提供输入信 号,PLC 在 Status(状态)屏和 Conveyor VFD(传输装置 VFD)屏上持续显示实际的离合器速 度。如果传输装置驱动电机与离合器之间的差动速度达到 50 RPM,离合器速度传感器将向 PLC 提 供输入信号,PLC 使控制盘显示离合器的脱扣报警信息。显示故障信息后离心机立即停车。 重新 起动离心机之前,要让转鼓惯性滑行直到完全停止,并按第 5 章的描述消除任何缺陷。缺陷纠正过 后,采用上述正常起动步骤重新起动设备,并且再次检查离合器的速度(如 Conveyor VFD [传输 装置变频驱动器] 屏所示)。 紧急停车 出现紧急情况需要停止离心机时,可按下控制柜或离心机上的 EMERGENCY STOP(紧急停车) 按钮,在 Operation(操作)屏上选择 STOP(停止),或者断开设备的熔断电源。 按下 EMERGENCY STOP(紧急停车)按钮可立即分离转鼓、传输装置和泵的电机的电源,并使 转鼓惯性滑行直到完全停止。根据转鼓的速度和转鼓内物料的多少,该过程需要 15 分钟以上时 间。如需转鼓停车更快,可按下 Operation(操作)屏的 STOP(停止)按钮或者显示 Bowl VFD (转鼓变频驱动器)屏,然后按下 BOWL IS COASTING TO A STOP(转鼓正在惯性滑行停车) 按钮。但是,按下该按钮之前,必须先清除所有报警/故障信息。 09 年 10 月 30 日 4-19 DE-7200VFD 离心机 第 5 章:维护 概述 本章描述 DE-7200 VFD 离心机预防性和纠正性维护的步骤。显而易见的步骤已做省略。离心机开 始维护之前,首先要对设备停车、闭锁电源并挂牌上锁。 警示!可能有高压。必须断开设备的熔断电源,进行任何设备维护时必须切断电源并 挂牌上锁。 警示!如果不佩戴安全护目镜,可能导致眼睛受重伤或者永久性失明。进行维护工作 时必须一直佩戴安全护目镜。 预防性维护 预防性维护包括检查、清理和润滑工作。这些常规性工作能够确保设备实现最长使用寿命和无故障 操作。本章中的维护计划有一定灵活性,应当根据用户工厂对设备的操作经验适当进行调整。维护 记录应当保管好,这有助于制定预防性维护计划,并且在设备使用过程中实行监控并调整计划。制 定预防性维护计划时,要考虑以下因素: 负载循环 环境温度 操作环境 下表列出了推荐的预防性维护计划。有关适用的润滑剂及用量,可参见下页的润滑图表。 09 年 10 月 30 日 5-1 DE-7200VFD 离心机 维护 预防性维护(续) 预防性维护的计划 工作 频率 检查进料管的连接是否泄漏,并根据要求紧固连接法兰。 每班 检查排液管的连接处是否泄漏。紧固连接处防止出现泄漏。 每班 对主轴承进行润滑(图 5-1)。 每 40 小时 对传输装置的轴承进行润滑(图 5-1)。 每 500 小时 检查传输装置驱动齿轮箱的机油。 每 500 小时 检查传输装置驱动齿轮箱的机油(见图 5-1)。 每 2500 小时 拆下进料部件总成,清理管内壁,然后重新安装好。 每 40 小时 检查并清除机箱内外沉积的固体物料。 每 40 小时或按需 要。 拆下皮带的盖板,检查皮带是否损坏,并检查/调整皮带的张紧度。 每 160 小时 检查传输装置驱动电机和齿轮箱的轴之间的离合器联轴节。 按照 mfctr*技术 要求 根据制造商建议进行检查(参见第 10 章)。 润滑轴承 主轴承、传输装置轴承、转鼓驱动电机和传输装置驱动电机都配备有润滑接头。润滑之前要对每个 接头进行清理,然后注入规定的类型和数量的滑脂(见图 5-1 列表)。 警示!只能使用规定的滑脂产品。连接油枪之前,先将接头内看得到的所有滑脂痕迹 清除。 5-2 09 年 10 月 30 日 维护 编号 位置 1 主轴承 2 传输装置的轴 承 3 转鼓驱动电机 4 传输装置驱动 电机 5 传输装置驱动 齿轮箱 数量 润滑间隔 滑脂类型 应用注意 6 cm3 (3 个冲程) 40 小时 壳牌 Albida EP2 离心机运行 手动油枪 滑脂流出出口 500 小时 壳牌 Albida EP2 离心机静止 手动油枪 离心机静止 润滑详情请参见第 10 章中 Marathon 电气公司 的手册。 离心机静止 5 夸脱(4.9 升) 2500 小时 美孚 SHC629 经过 500 小时运行后第一 次换机油。要在离心机静 止时更换机油;如果油温 感觉较温,请检查油位 (见本章“齿轮箱油位的 检查”部分)。 图 5-1:轴承润滑点 检查齿轮箱油位 每运行 500 小时,当齿轮箱变温热时都要检查油位。按以下方式检查油位: 1. 对离心机停车、闭锁电源并挂牌上锁。 2. 拆除固定顶盖的螺钉,打开盖子。 3. 旋转齿轮箱直到外壳上的凹口到达上死点位置(见图 5-2)。 4. 拆除注油塞,检查油位是否到达开口位置。如果油位达低,加入推荐的机油。 09 年 10 月 30 日 5-3 DE-7200VFD 离心机 维护 5. 重新安装注油塞,然后上紧。 6. 关闭并紧固顶盖。 图 5-2:检查齿轮箱油位 齿轮箱机油的更换 机油更换间隔时间在图 5-1 中有所列出。请按以下方式更换机油: 1. 对离心机停车、闭锁电源并挂牌上锁。 2. 拆除固定顶盖的螺钉,打开盖子。 3. 将能装 5 夸脱(4.9 升)机油的合适的容器放到齿轮箱的下面。 4. 旋转齿轮箱直到一个排油塞被转到齿轮箱的底部。 5. 拆下齿轮箱顶部的两个塞子,让空气流入方便排油操作。 6. 拆下齿轮箱底部的塞子进行排油。 7. 将齿轮箱内的机油完全排空后,重新装好并上紧底部的塞子。 8. 将齿轮箱加满所列出类型和数量的机油。 9. 重新安装顶部注油塞,然后上紧。 10. 关闭并紧固顶盖。 5-4 09 年 10 月 30 日 维护 构件的维护 离心机开始维护之前,首先要对设备停车、闭锁电源并挂牌上锁。 警示!可能有高压。必须断开设备的熔断电源,进行任何设备维护时必须切断电源并 挂牌上锁。 警示!如果不佩戴安全护目镜,可能导致眼睛受重伤或者永久性失明。进行维护工作 时必须一直佩戴安全护目镜。 传动皮带 如果查出传动皮带出现损坏或老化,必须定期张紧和更换。请按以下方式张紧和/或更换皮带; 警示!拆除皮带防护板之前,必须先让旋转总成惯性滑行直到完全停止。 1. 对离心机停车、闭锁电源并挂牌上锁。 2. 拆除皮带防护板。 3. 松开固定扭矩限位器离合器一半与传输装置驱动电机轴的定位螺钉和安装螺钉(见图 5-3),将 离合器一半朝电机方向滑动直到看见电机轴的端部。 4. 松开固定转鼓驱动电机与底座,转动张紧螺栓松开皮带,然后从转鼓端拆除皮带,并且拆除传 输装置驱动电机与传输装置轴之间的电机皮带轮。 5. 在转鼓驱动电机和转鼓皮带轮上安装新的皮带。 6. 旋转张紧螺栓,在皮带上作用张紧力。对皮带作用充分的张紧力,以便在皮带中心点作用 17 磅 (75 N)的力时皮带能够达到 1/2”(13mm)的挠度(见图 5-4)。正确的张紧度可以防止皮带 没有过载轴承时不会打滑。设定正确的张紧度之后,上紧电机底座固定螺栓对电机加固。 09 年 10 月 30 日 5-5 DE-7200VFD 离心机 维护 传动皮带(续) 图 5-3:传输装置驱动离合器 图 5-4:传动皮带的张紧度 7. 将驱动电机离合器一半滑回与齿轮箱一半啮合,并且将离合器两半之间的间隙设定为大约 0.1875” 到 0.250” (4.8mm 到 6.4mm),然后轴向定位离合器,使十字轴的中心点与接近开关对 齐。 8. 旋转电机轴离合器直到定位螺钉与轴键对齐,然后紧固定位螺钉。用 184 英尺·磅 (250 Nm)的 力上紧电机离合器一半上的安装螺钉。 9. 安装并固定皮带防护板。 5-6 09 年 10 月 30 日 维护 旋转总成的维护 对旋转总成进行维护时要求对其进行拆解,并且只能对从机箱里拆除的旋转总成进行维护。离心机 运行时如果出现异常噪音或振动,表明主轴承或传输装置轴承可能出现缺陷。如果这种情况明显, 应当检查轴承是否松动。有必要,可按本章后面的描述进行更换。 拆卸 旋转总成必须拆除,彻底进行清理、更换轴承,或检查和维护。请按以下所述拆除旋转总成: 警示!为避免人员受重伤,设备维护和/或调整之前必须将设备切断、挂牌上锁、断 开电源,并且停止转动。 1. 停止进料,对离心机停车、闭锁电源并挂牌上锁。让旋转总成惯性滑行直至完全停止转动。 2. 断开进料管与进料部件法兰的连接。 3. 拆下固定皮带防护板与机箱之间的螺钉,将防护板抬起并拆除。 4. 拆除固定机箱盖与机箱的螺钉,打开机箱盖。 5. 松开固定扭矩限位器离合器一半与传输装置驱动电机轴的螺钉(见图 5-5),将联轴节一半朝电 机方向滑动直到看见电机轴的端部,拆除十字轴。 6. 松开固定转鼓驱动电机与底座的螺母,转动张紧螺栓放松皮带,将皮带从转鼓皮带轮上拆下。 7. 拆下液体端和固体端固定轴台与底座的螺栓、防松垫片以及平垫片(见图 5-6)并且从轴台拆下 对正销。 8. 将起吊能力至少为 4000 磅 (1800 kg) 的葫芦绕在旋转总成上。 9. 对吊索找好平衡,确保总成提升时能够保持水平,然后缓慢地提高旋转总成直到离开底座。 10. 将旋转总成放低并落到一个能够支撑其重量的托架上。 11. 对旋转总成进行拆解,达到检查、修理及更换部件需要拆解到的程度。 09 年 10 月 30 日 5-7 DE-7200VFD 离心机 维护 拆卸(续) 图 5-5:传输装置挠性联轴节 图 5-6:轴承轴台 清理、检查和修理 1. 将传输装置和转鼓总成内外的泥浆和碎屑冲洗干净,然后用过滤后的压缩空气吹干。去除所有 锈渍,方便进行检查。 2. 如果传输装置已拆除,检查传输装置是否有变形或刮板擦伤、毛剌或者其它明显损伤。对任何 微小的表面缺陷可做现场处理。如果传输装置有明显的变形或者严重缺陷并且无法再使用,要 予以更换。 5-8 09 年 10 月 30 日 维护 3. 检查耐磨插件是否有明显磨损。如果发现插件高度受损,请使用工具 G0009149 更换插件。为 帮助保持动态平衡,必须同时更换位置相对的一对插件。 4. 检查传输装置齿轮箱端的驱动套和 V 形环是否有擦伤、变形或明显磨损迹象。更换需要更换的 部件。 5. 检查转鼓总成头上的固体排料耐磨插件和溢流板是否破裂、破损、或其它损坏,使用工具 G0009149 更换损坏明显的部件。 6. 检查转鼓内部和外部是否有擦伤、划伤或其它可能影响性能的损伤。对微小的缺陷做现场处 理;如果损坏无法修复,请更换转鼓。 7. 检查主轴承和传输装置轴承是否松动、是否有异常响动或摩擦。请根据本章更换步骤的内容更 换任何有缺陷的轴承。 8. 检查轴台是否有腐蚀、变形、缺口、裂缝、毛剌、断裂或其它缺陷。修理任何微小的缺陷,发 现严重缺陷或裂缝时进行更换。 安装 1. 使用提升能力至少为 3500 磅 (1600 kg) 的合适的葫芦将旋转总成从托架上提起并降到带轴台的 底座上,并与安装孔对齐。 2. 使用黄铜锤将对正销完全抵进轴台和底座内,不要上紧对正销上的螺母。 3. 将带有垫片的安装螺栓插入孔内。根据本章扭矩紧固件的技术规格所规定的扭矩分多次上紧螺 栓。 4. 根据本章“传动皮带的张紧”的内容在电机和转鼓皮带轮之间安装并张紧传动皮带。 5. 将十字轴插入半个齿轮箱离合器,并且将半个电机离合器滑回与半个齿轮箱啮合好。将离合器 两半之间的间隙设定为大约 0.1875”到 0.250” (4.8mm 到 6.4mm),然后用 184 英尺·磅 (250Nm)的力紧固一半电机离合器上的安装螺钉。 6. 将皮带防护板安装到电机和转鼓总成皮带轮的上面并紧固。 7. 根据“预防性维护”中的润滑图表对主轴承进行润滑,润滑步骤如下: a. 接通电源,起动离心机,并且将转鼓速度调整到 500 rpm。 b. 一边观察轴承温度,一边将新的滑脂注入轴台直到滑脂从皮带侧的轴台下半部分上的排油口 流出来。 8. 关闭机箱盖并紧固螺钉,从盖子的中心开始向外朝两头紧固螺钉。 9. 将进料管与进料部件法兰连接。 10. 接通电源,起动离心机(参见第 4 章的内容)。小心对离心机的工况进行监控,检查是否有任 何异常噪音。 主轴承的更换 旋转总成的端部用装配在轴台内的滚柱轴承支撑。主轴承必须成套更换。也就是说,如果发现一个 轴承出现缺陷,必须同时更换两个轴承。 09 年 10 月 30 日 5-9 DE-7200VFD 离心机 维护 拆卸 必须拆下旋转总成以便拆卸轴承。请按以下方式拆除旋转总成和主轴承: 警示!为避免人员受重伤,设备维护和/或调整之前必须将设备切断、挂牌上锁、断 开电源,并且停止转动。 1. 停止进料,对离心机停车、闭锁电源并挂牌上锁。 让旋转总成惯性滑行直至完全停止转动。 2. 拆下固定皮带防护板与底座之间的螺钉,将防护板抬起并拆除。 3. 拆除固定机箱盖与机箱的螺钉,打开机箱盖。 4. 用水管将机箱内部和旋转总成外部的工艺物料残留物清洗干净。 5. 松开固定扭矩限位器离合器一半与传输装置驱动电机轴的安装螺钉和定位螺钉,将离合器一半 朝电机方向滑动直到看见电机轴的端部,然后拆除挠性十字轴。 6. 断开进料管与进料部件法兰的连接。 7. 松开固定转鼓驱动电机与底座的螺母,转动张紧螺栓放松皮带,将皮带从转鼓皮带轮上拆下。 8. 拆除离心机底座上不锈钢接线盒的盖子(见图 5-7),然后断开固体端和液体端温度传感器导线 与端子块的连接。 9. 松开液体端和固体端温度传感器弯头上的联接螺母(见图 5-8),将电线从导管中拔出。将导线 盘绕并固定好,避免拆卸旋转总成时造成干扰。 10. 断开速度传感器的连接电缆。 11. 拆下液体端和固体端固定轴台与底座的对正销、螺栓、防松垫片以及平垫片(见图 5-9)。 12. 将起吊能力至少为 4000 磅 (1800 kg) 的葫芦绕在旋转总成上。 13. 对吊索找好平衡,确保总成提升时能够保持水平,然后缓慢地提高旋转总成直到离开底座。 14. 将旋转总成放低并落到一个能够支撑其重量的托架上。 15. 支撑好轴台的下半部分,将固定上下两部分轴台的螺钉拆除。在两个部分之间撬动,将轴台两 半分离并拆开。 16. 松开固定半部分离合器与齿轮箱轴的安装螺钉,拆除这半部分离合器。 17. 拆除固定皮带轮与转鼓法兰的螺钉,将皮带轮拆除。 18. 拆除固定输入法兰与齿轮箱外壳之间的螺钉,拆除法兰。从输入法兰拆下 O 形环并废弃不用。 19. 松开固定外壳(见图 5-10)与传输装置驱动齿轮箱轴的定位螺钉,然后拆除外壳、滑脂调节器 以及齿轮箱轴上的间隔圈。 20. 使用合适的拆卸工具将固体端轴承从齿轮箱轴上拆下。 5-10 09 年 10 月 30 日 维护 21. 拆除固定夹环(图 5-11)与液体转鼓头之间的螺钉,松开固定夹环的定位螺钉,然后拆除卡 环。 22. 从转鼓头拆除毡环、填密环、O 形环以及固定环。 图 5-7:传感器系统接线盒的连接 图 5-8:固体端温度和温度传感器 09 年 10 月 30 日 5-11 DE-7200VFD 离心机 维护 拆卸(续) 图 5-9:液体端轴承轴台的上半部分 23. 使用合适的拆卸工具将液体端轴承从转鼓头轴上拆下。 24. 从轴上拆下抛油环和 O 形环。 图 5-10:固体端轴承的详图 5-12 09 年 10 月 30 日 维护 图 5-11:液体端轴承的详图 清理、检查和修理 1. 使用适当的清洁剂/去油剂对所有部件进行清理,然后用经过过滤的压缩空气吹干。去除所有锈 渍,方便进行检查。 2. 检查所有部件是否有影响重返操作适配性的划伤、缺口、毛刺或变形。对任何微小的表面缺陷 可做现场处理。更换已明显变形或有严重缺陷并且无法再继续使用的部件。 3. 使用千分尺测量液体转鼓头和传输装置驱动轴颈的关键尺寸。如果液体端轴颈尺寸过小,请更 换液体转鼓头。 如果固体端轴颈尺寸过小,要更换传输装置的驱动齿轮箱。 4. 检查轴台是否有腐蚀、变形、缺口、裂缝、毛剌、断裂或其它缺陷。修理任何微小的缺陷,发 现严重缺陷或裂缝时进行更换。 5. 更换所有不易修理的部件。 6. 更换所有 O 形环、密封件和轴承。 7. 将所有清洁的部件放入干净的塑料袋,避免受到污染。 09 年 10 月 30 日 5-13 DE-7200VFD 离心机 维护 安装 1. 按以下方式安装固体端主轴承: a. 使用轴承加热器或高温油浴器中,将主轴承内圈加热到大约 230°F(110°C)。戴好隔热手 套将内圈滑到轴颈上。 b. 根据图 5-1 所示在轴承上敷好滑脂并将其装到内圈上(见图 5-10)。 c. 让间隔圈的宽间隔区对着轴承(图 5-12),然后在齿轮箱轴上安装间隔圈和滑脂调节器。 d. 将外壳和速度传感器凸轮滑到齿轮箱轴上。如图所示将速度传感器设定为离外壳端部 11/4”,然后上紧定位螺钉固定凸轮。 e. 将 O 形环装到输入法兰上(见图 5-10),然后将输入法兰定位到齿轮箱外壳上。根据本章 “扭矩紧固件的技术规格”的要求安装并紧固螺钉将法兰固定好。 f. 将皮带轮滑到轴上并抵住输入法兰。根据本章“扭矩紧固件的技术规格”的要求用螺钉固定 皮带轮与输入法兰。 g. 将离合器的固定半幅滑到齿轮箱的轴上,安装螺钉要松着。 2. 按以下方式安装液体端主轴承并重新安装旋转总成: a. 将 O 形环(见图 5-11)和抛油环安装到液体转鼓头的轴颈上。 b. 按照图 5-1 所示将轴承敷满滑脂,然后将其装到并抵住液体转鼓头的轴。 c. 在液体转鼓头轴上安装固定环、O 形环、填密环以及毡环。 d. 在液体转鼓头上安装卡环并用螺钉固定。根据本章“扭矩紧固件的技术规格”所规定的扭矩 紧固卡环定位螺钉。 3. 将上下两半轴台装配到各自的主轴承上,并根据本章“扭矩紧固件的技术规格”所规定的扭矩 分多次上紧螺栓。 4. 用葫芦从托架提起旋转总成并放到离心机上直到轴台接触到底座。 5. 使用黄铜材质的小锺将对正销完全敲入并坐到轴承轴台和底座上;然后将安装螺栓和防松垫圈 插入孔中。根据本章“扭矩紧固件的技术规格”所要求的扭矩分多次操作紧固螺栓。不要紧固 对正销上的螺母。 6. 在电机和转鼓总成的皮带轮上安装传动皮带,并根据本章“传动皮带的张紧”的要求张紧传动 皮带。 7. 将十字轴插入齿轮箱离合器半幅中并且定位齿轮箱离合器半幅,使其后面与皮带轮的前面对齐 (见图 5-12)。 8. 将电机离合器半幅滑入齿轮箱半幅内与之啮合,将离合器两半之间的间隙设定为大约 0.1875” 到 0.250” (4.8mm 到 6.4mm),然后轴向定位离合器,使十字轴的中心点与接近开关对齐。 5-14 09 年 10 月 30 日 维护 图 5-12:齿轮箱轴上安装皮带轮和离合器 9. 旋转电机轴离合器直到定位螺钉与轴键对齐,然后紧固定位螺钉。用 184 英尺·磅 (250 Nm)的 力上紧离合器两半之间的安装螺钉。 10. 解开并重新连接温度传感器导线与接线盒内端子块的接线(见图 5-7),然后重新装好接线盒的 盖子。 11. 将速度传感器的电缆与传感器的接近开关连接好。 12. 将皮带防护板安装到电机和转鼓总成皮带轮的上面,并用螺钉与底座固定。 13. 根据图 5-1 所示按照以下步骤对主轴承进行润滑: a. 接通电源,起动离心机,将转鼓速度调整到 500 rpm。 b. 一边观察轴承温度,一边将新的滑脂注入轴台直到滑脂从皮带侧的轴台下半部分上的排油口 流出来。 14. 停下离心机。 15. 旋转总成完全停下来以后,关闭机箱盖并紧固螺钉,从盖子的中心开始向外朝两头紧固螺钉。 16. 将进料管与进料部件法兰连接。 17. 接通电源,起动离心机(参见第 4 章的内容)。小心对离心机的工况进行监控,检查是否有任 何异常噪音。 09 年 10 月 30 日 5-15 DE-7200VFD 离心机 维护 传输装置轴承的更换 该步骤描述传输装置轴承的更换方法。此步骤要求将传输装置总成从转鼓总成分离。离心机运行时 如果出现异常噪音或振动,表明轴承可能出现缺陷。如果这种情况明显,应当拆下传输装置,检查 轴承是否松动。如有必要,可进行更换。 拆卸 传输装置液体端由传输装置外壳内安装的滚柱轴承支撑。固体端由传输装置驱动齿轮箱的轴承支 撑。如果发现液体端轴承有缺陷,应当检查齿轮箱的轴是否松动。如果发现轴有松动,必须更换齿 轮箱大轴的轴承。 请按以下方式拆下传输装置的轴承: 警示!为避免人员受重伤,设备维护和/或调整之前必须将设备切断、挂牌上锁、断 开电源,并且停止转动。 1. 对离心机停车、闭锁电源并挂牌上锁。让旋转总成惯性滑行直至完全停止转动。 2. 断开进料管与进料部件的连接。 3. 拆下固定皮带防护板与底座之间的螺钉,将防护板抬起并拆除。 4. 拆除固定机箱盖与机箱的螺钉,打开机箱盖。 5. 根据本章齿轮箱拆卸步骤所述拆下传输装置的驱动齿轮箱。 6. 提起旋转总成的液体端直到旋转总成垂直(见图 5-13),然后将固体端放到坚固的平直表面 上。进行剩余的拆卸作业时,仍需在垂直位置对旋转总成保持适当的支撑。 7. 拆除固定液体转鼓头与转鼓总成的螺钉,并在转鼓头周围四个位置安装顶丝。 8. 将合适的葫芦套到液体转鼓头上,顺时针方向分多次均匀用力转动顶丝,将转鼓头与转鼓总成 分离,然后使用葫芦将转鼓头提起并与转鼓总成分离。 注意!传输装置刮板与转鼓内衬之间的间距只有 1.5 MM。进行后面的操作时,如果 感觉到有阻力,不能再继续提升,否则会损坏传输装置的刮板。 9. 将合适的葫芦套到传输装置上,缓慢地将传输装置提起并与转鼓总成分离。 10. 水平将传输装置放低到能够承受其重量的托架上。 11. 拆除固定轴承箱与传输装置的螺钉(见图 5-14),将两个顶丝安装到外壳相反的两侧。均匀用 力上紧顶丝,将轴承箱抽出并分离。 5-16 09 年 10 月 30 日 维护 拆卸(续) 图 5-13:从转鼓总成拆下传输装置 12. 拆下固定密封盖与轴承箱的螺钉,然后拆下密封盖与轴封。 13. 使用合适的拆卸工具将轴承从轴承箱分离然后从轴承箱拆除第二个轴封。 14. 轴承和轴封应废弃不用。 清理、检查和修理 1. 使用适当的清洁剂/去油剂对所有部件进行清理,然后用经过过滤的压缩空气吹干。去除所有锈 渍,方便进行检查。 2. 检查所有部件是否有影响重返操作适配性的划伤、缺口、毛刺或变形。对任何微小的表面缺陷 可做现场处理。更换已明显变形或有严重缺陷并且无法再继续使用的部件。 3. 检查传输装置是否变形,刮板是否有擦伤、毛剌或其它明显损伤。对任何微小的表面缺陷可做 现场处理。如果传输装置有明显的变形或者严重缺陷并且无法再使用,要予以更换。 09 年 10 月 30 日 5-17 DE-7200VFD 离心机 维护 清理、检查和修理(续) 图 5-14:传输装置的轴承详图 8. 检查传输装置的耐磨插件是否有明显磨损。如果发现插件有较大损坏,要及时更换。为帮助保 持动态平衡,必须同时更换位置相对的一对插件。 9. 检查液体转鼓头上的固体排料耐磨插件和溢流板是否破裂、破损、或其它损坏,并更换损坏明 显的部件。 10. 检查传输装置齿轮箱端的驱动套和 V 形环是否有擦伤、变形或明显磨损迹象。更换需要更换的 部件。 11. 使用千分尺测量液体转鼓头传输装置轴颈和轴承箱膛孔的关键尺寸。如果液体端轴颈尺寸过 小,请更换液体转鼓头。如果膛孔过大,请更换轴承箱。 12. 更换所有不易修理的部件。更换所有轴封和轴承。 13. 将所有清洁的部件放入干净的塑料袋,避免受到污染。 安装 该步骤描述液体端传输装置轴承的安装方法。如果发现齿轮箱轴承松动,必须更换齿轮箱或重装 (参见本章“齿轮箱的维护”部分的内容)。 按以下方式安装液体端的传输装置轴承: 1. 将新的轴封装入轴承箱(见图 5-14)内,然后将轴承插入并抵住轴承箱。 5-18 09 年 10 月 30 日 维护 2. 在密封盖内安装新的轴封,然后将密封盖装配到轴承箱上。用六角头螺钉将部件固定在一起。 3. 将装配好的轴承箱安装到传输装置上,并用螺钉固定。 注意!传输装置刮板与转鼓内衬之间的间距只有 1.5 MM。在后面的操作中,将传输 装置放入转鼓总成中时一定要格外小心,避免碰到转鼓内衬,否则会损坏传输装置 的刮板。 4. 将传输装置垂直吊起(见图 5-13),然后插入垂直转鼓总成中。 5. 吊起液体转鼓头,然后放低并落到传输装置上,小心当传输装置轴颈伸入轴承内圈时不要损坏 轴承。用螺钉固定液体转鼓头与转鼓总成。 6. 吊起装配好的旋转总成,将其水平定位到能够支撑其重量的托架上。 7. 根据本章“齿轮箱的维护”所述的齿轮箱安装步骤安装齿轮箱并注油。 8. 关闭机箱盖并紧固螺钉,从盖子的中心开始向外朝两头紧固螺钉。 9. 将皮带防护板安装到电机和转鼓总成皮带轮的上面并紧固。 10. 将进料管与进料部件法兰连接。 11. 接通电源,起动离心机(参见第 4 章的内容)。小心对离心机的工况进行监控,检查是否有任 何异常噪音。 齿轮箱的拆卸与安装 此操作必须由经过适当培训并且胜任工作的人员进行。为避免对轴承和离心机内部构件造成污染, 此作业必须在干净的环境下进行。 拆卸 必须拆卸旋转总成彻底进行清理、检查和维护。请按以下所述拆除旋转总成: 警示!为避免人员受重伤,设备维护和/或调整之前必须将设备切断、挂牌上锁、断开 电源,并且停止转动。 1. 停止进料,对离心机停车、闭锁电源并挂牌上锁。让旋转总成惯性滑行直至完全停止转动。 2. 拆下固定皮带防护板与底座之间的螺钉,将防护板抬起并拆除。 3. 拆除固定机箱盖与底座的螺钉,打开机箱盖。 4. 用水管将机箱内部和旋转总成外部的工艺物料残留物清洗干净。 09 年 10 月 30 日 5-19 DE-7200VFD 离心机 维护 拆卸(续) 5. 松开固定扭矩限位器离合器一半与传输装置驱动电机轴的螺钉,将离合器一半朝电机方向滑动 直到看见电机轴的端部,然后拆除挠性十字轴。 6. 断开进料管与进料部件的连接。 7. 松开固定转鼓驱动电机安装板与离心机底座的螺母,转动张紧螺栓放松皮带,将皮带从转鼓皮 带轮上拆下。 8. 拆下液体端和固体端固定轴台与底座的对正销、螺栓、防松垫片以及平垫片(见图 5-15)。 图 5-15:轴承轴台的连接 9. 拆除离心机底座上不锈钢接线盒的盖子(见图 5-16),然后断开固体端和液体端温度传感器导 线与端子块的连接。 10. 松开传感器弯头上的联接螺母(见图 5-17),将电线从导管中拔出。 将导线盘绕并固定好,避 免拆卸旋转总成时造成干扰。 11. 断开速度传感器的连接电缆。 12. 将起吊能力至少为 4000 磅 (1800 kg) 的葫芦绕在旋转总成上。 13. 对吊索找好平衡,确保总成提升时能够保持水平,然后缓慢地提高旋转总成直到离开底座。 14. 将旋转总成放低并落到一个能够支撑其重量的托架上。 15. 拆除固定固体端轴台上下两半的螺钉。在撬动分离上下两半轴台时要对下半幅轴台良好支撑, 然后将轴台两半与主轴承分离。 16. 注意离合器半幅在齿轮箱轴上的位置,松开固定离合器半幅与齿轮箱轴的安装螺钉,然后拆下 离合器半幅。 17. 拆除固定皮带轮与输入法兰的螺钉,将皮带轮拆除。 18. 拆除固定输入法兰与齿轮箱外壳之间的螺钉(见图 5-18),拆除法兰。 5-20 09 年 10 月 30 日 维护 图 5-16:温度传感器的连接 图 5-17:温度和速度传感器—固体端 09 年 10 月 30 日 5-21 DE-7200VFD 离心机 维护 拆卸(续) 图 5-18:输入法兰、速度传感器的凸轮、固体端主轴承 19. 注意齿轮箱轴上各个部件的朝向,从轴上拆下外壳(连接有速度传感器凸轮)、滑脂调节器和 间隔圈。 20. 通过液体端两个排污口拆除传输装置上相隔 180°的两个 M12 螺钉。将两块板装到排污口上 (见图 5-19),将一个 M12 长螺钉穿过每块板并轻轻上紧螺钉。这些板有助于在从转鼓总成抽 出齿轮箱时使传输装置保持不动。 21. 拆除传输装置上的两个管塞件(见图 5-20),然后抽出固定齿轮箱轴与传输装置的定位销。 22. 拆除固定齿轮箱与转鼓总成的 20 个 M16 内六角头螺钉(见图 5-21)。 23. 拆除外壳上的四个 M16 六角头螺栓,润滑顶丝并装到两个相隔 180 度并且带有螺纹的孔中。 24. 将齿轮箱从转鼓总成顶出时,要连接一个至少能起吊 550 磅(250 kg)的合适的葫芦来支撑齿 轮箱。 25. 交替拧动第 23 步中所安装的每个顶丝,缓慢地将齿轮箱抽出直到完全离开转鼓总成。 5-22 09 年 10 月 30 日 维护 拆卸(续) 图 5-19:传输装置保持板的安装 图 5-20:拆除固定齿轮箱轴与传输装置的定位销 09 年 10 月 30 日 5-23 DE-7200VFD 离心机 维护 图 5-21:齿轮箱的拆卸 安装 按以下步骤安装齿轮箱: 1. 按照前面“拆卸”步骤所述方式,使用合适的吊具,对更换的齿轮箱总成水平进行支撑。轻敲 齿轮箱上所有的孔并进行清理。 清除齿轮箱所有配合面上的保护性涂料。 2. 将新的 O 形环安装到齿轮箱上(见图 5-22),然后在 O 形环和轴上涂上薄薄一层防粘润滑 剂。 3. 拆除固定两块保持板的 M12 螺钉并将这两块板拆除,暂时安装这两块板是为了在拆除齿轮箱时 能够使传输装置保持不动。在刚才从传输装置上拆下的螺钉上涂敷乐泰防粘润滑剂,然后重新 装好螺钉。 4. 旋转齿轮箱的轴直到键与传输装置上的键槽对正。 5. 将螺母和窄垫片装到顶栓上,然后将其插入相隔 180 度的齿轮箱法兰上的穿通孔中。将螺栓拧 入转鼓总成上的齿轮箱总成安装孔内。 6. 交替拧动每个螺母,缓慢而均匀地将齿轮箱送进转鼓总成。 7. 当齿轮箱完全抵住转鼓时,将顶栓拆除,安装 20 个 M16 内六角头螺钉固定齿轮箱。根据本章 “扭矩紧固件的技术规格”所要求的扭矩紧固螺钉。 8. 将四个 M16 六角头螺栓穿过齿轮箱穿通孔插入转鼓上对应的孔中,然后根据本章“扭矩紧固件 的技术规格”紧固螺栓。 9. 将撬棍插入齿轮箱轴上的定位销孔中,小心将孔对正,方便插入定位销。 5-24 09 年 10 月 30 日 维护 10. 在定位销和管塞件上涂敷防粘剂。将销子插入传输装置和齿轮箱的轴内,然后将管塞装到传输 装置上带螺纹的孔中将销子卡住。 图 5-22:齿轮箱 O 形环的位置 警示!在以下操作中,请使用轴承加热器或清洁热油浴器对轴承内圈进行加热。不能 使用喷灯直接加热,否则会使轴承受损。 11. 主轴承内圈出厂前安装在齿轮箱轴上。但是,如果要重新安装已经拆除的齿轮箱,要按以下方 式安装新的内圈: a. 使用轴承加热器或高温油浴器中,将主轴承内圈加热到大约 230°F(110°C)。 b. 戴好隔热手套将内圈滑到轴颈上。 c. 着手安装主轴承之前,先让内圈冷却下来。 12. 根据图 5-1 中的润滑图表在轴承上涂满滑脂,然后将其安装到内圈上。 13. 让间隔圈的宽间隔区对着轴承(图 5-23),然后在齿轮箱轴上安装间隔圈和滑脂调节器。 14. 将外壳和速度传感器凸轮滑到齿轮箱轴上。如图所示将速度传感器设定为离外壳端部 1-1/4”, 然后上紧定位螺钉固定凸轮。 15. 将 O 形环插入输入法兰然后将输入法兰定位在齿轮箱外壳上。根据本章“扭矩紧固件的技术规 格”的要求安装并紧固螺钉。 09 年 10 月 30 日 5-25 DE-7200VFD 离心机 维护 拆卸(续) 16. 将上下两半轴台放到主轴承上,根据本章“扭矩紧固件的技术规格”的要求安装并紧固螺钉。 17. 将皮带轮滑到轴上并且抵住输入法兰,根据本章“扭矩紧固件的技术规格”的要求安装并紧固 螺钉。 18. 将离合器的固定半幅滑到齿轮箱的轴上,安装螺钉要松着。 图 5-23:齿轮箱轴上安装皮带轮 19. 按以下方式将旋转总成重新装到离心机内: a. 在轴台和离合器底座的配合面上涂敷防锈剂。 b. 用葫芦从托架提起旋转总成并放到离心机上直到轴台接触到底座。 c. 将对正销插入轴台,使用黄铜材质的锤子将销子敲入并抵住底座;不要上紧对正销上的螺 母。 d. 在轴台螺栓上涂敷防粘剂,并将带垫圈的螺栓通过轴台插入底座。根据本章“扭矩紧固件的 技术规格”所规定的扭矩分多次上紧螺栓。 20. 在电机和转鼓皮带轮上安装传动皮带,并根据本章“传动皮带的张紧”的要求张紧传动皮带。 21. 将十字轴插入齿轮箱离合器半幅中并且定位齿轮箱离合器半幅,使其后面与皮带轮的前面对齐 (见图 5-24)。 5-26 09 年 10 月 30 日 维护 图 5-24:齿轮箱轴上安装离合器 22. 将电机轴离合器半幅滑入齿轮箱半幅内与之啮合,将离合器两半之间的间隙设定为大约 0.1875” 到 0.250” (4.8mm 到 6.4mm),然后轴向定位离合器,使十字轴的中心点与接近开关对齐。 23. 旋转电机轴离合器直到定位螺钉与轴键对齐,然后紧固定位螺钉。用 184 英尺·磅 (250 Nm)的 力紧固两半离合器之间的安装螺钉。 24. 解开并重新连接传感器导线与接线盒内端子块的接线,然后重新装好接线盒的盖子。 25. 根据图 5-1 所示按照以下步骤对主轴承进行润滑: a. 接通电源,起动离心机,并且将转鼓速度调整到 500 rpm。 b. 一边观察轴承温度,一边将新的滑脂注入轴台直到滑脂从皮带侧的轴台下半部分上的排油口 流出来。 26. 给齿轮箱加满推荐的机油(参见本章“齿轮箱机油的更换”部分)。运行传输装置 10 到 15 分 钟,让齿轮箱机油温热后重新检查油位。 注意!为避免漏油,每次拔掉塞子后都要更换齿轮箱注油塞上黄铜材质的垫圈。 27. 关闭机箱盖并紧固螺钉,从盖子的中心开始向外朝两头紧固螺钉。 28. 将皮带防护板安装到电机和转鼓总成皮带轮的上面并紧固。 29. 将进料管与进料部件法兰连接。 30. 接通电源,起动离心机(参见第 4 章的内容)。小心对离心机的工况进行监控,检查是否有任 何异常噪音。 09 年 10 月 30 日 5-27 DE-7200VFD 离心机 维护 扭矩紧固件的技术规格 只能使用 Derrick 公司认可的扭矩紧固件。使用劣等的未经 Derrick 公司认可的扭矩紧固件可能造成 人员受重伤和/或设备受损。另外,如果使用未经认可的扭矩紧固件,将使包括书面或暗示的对设备 的有效保证作废。关于扭矩紧固件类型的选用和 Derrick 离心机使用方面的问题,请与 Derrick 公司 联系。 警示!使用劣等的未经 Derrick 公司认可的扭矩紧固件可能造成人员受重伤和/或设备 受损。 下页示出了推荐在离心机上使用的各种类型和尺寸的紧固件的锁紧扭矩技术规格。 按以下方式上紧紧固件: 1. 只能使用经过校验的扭矩扳手。 2. 如果需要紧固的螺栓超过一颗,要交替对每颗螺栓进行紧固。 3. 必须分多次达到最终扭矩的紧固。 扭矩紧固件 类型 位置 扭矩 英尺·磅 英寸·磅 牛顿·米 M16 主轴承轴台上下两半 144 1726 195 M16 反驱动齿轮箱轴套到转鼓总成 136 1628 184 M12 转鼓与反驱动齿轮箱电机到底座 41 496 56 M8 传输装置轴承护圈到轴承箱 12 142 16 M10 传输装置轴承箱到传输装置 32 381 43 M10 溢流堰板到液体转鼓头 24 283 32 M10 顶盖到机箱 24 283 32 M16 液体转鼓头到转鼓总成 136 1628 184 M16 反驱动齿轮箱到转鼓总成 100 1204 136 M10 皮带轮到反驱动齿轮箱上的安装法兰 24 283 32 M6 皮带轮安装法兰到反驱动齿轮箱 12 142 16 M24 主轴承轴台到底座 502 6018 680 M12 进料管到轴台 55 650 75 5-28 09 年 10 月 30 日 维护 推荐的备品备件 下表列出了支持一台 DE-7200 离心机两年运行所需的备品备件的清单。清单包括最易磨损的部 件,但是无法对所有部件可能更换的时间做出预判。要根据用户对类似设备的使用经验来确定完整 的备件库存量。 制定备件库存计划时,要考虑以下因素: 负载循环 环境温度 操作环境 部件号 描述 易消耗 两年 数量 底座 - 16601-00 G0007725 锥销 否 4 G0007726 毡带 否 1 G0007727 毡带 否 2 转鼓 - 16603-00 G0007808 滚柱轴承,液体端 是 1 G0007809 毯环 否 1 G0007810 填密环,液体端 否 1 G0007811 O形环,卡环 否 1 G0007813 O形环,液体端 否 3 G0007827 犁 是 4 G0007832 螺钉,内六角头 否 6 G0007820 密封环 否 1 G0007821 密封环 否 1 G0007822 滚柱轴承,固体端 是 1 G0007823 填密件,O形环,齿轮箱 否 1 G0007829 O形环,主动轮 否 1 G0007763 螺栓,六角头 否 12 G0007729 平垫片 否 12 09 年 10 月 30 日 5-29 DE-7200VFD 离心机 维护 部件号 描述 易消耗 两年 数量 机箱与盖子- 16602-00 G0007759 密封带 否 1 G0007752 橡胶密封件 否 1套 G0007767 压力弹簧 否 2 16995-00 耐磨板 否 1套 传输装置 - 16604-00 G0007875 轴封 否 1 G0007876 轴封 否 1 G0007877 滚柱轴承,传输装置 否 1 G0007883 唇封,V形环 否 1 皮带防护板 - 16605-00 G0007751 螺钉,内六角头 否 4 G0007855 防松垫片 否 4 G0007856 橡胶隔离器 否 4 是 1 进料部件总成 - 16606-00 G0007888 进料管 其它驱动部件- 16621-00 G0007964 传动皮带 否 5 G0008994 过载离合器 否 1 其它部件 - 16674-00 G0008986 齿轮油 是 2加仑 G0008185 滑脂盒 是 20管 否 2 否 1 齿轮装置 - 16672-00 G0008169 密封环 电气部件清单 - 16593-00 G0007265 5-30 RTD传感器 09 年 10 月 30 日 维护 部件号 G0007861 描述 速度传感器 易消耗 两年 数量 否 1 控制柜 - 16472-00-002 G0007698 熔断器,60A,J级 否 3 G0007981 熔断器,1.5A 否 3 G0007225 熔断器,150A,J级 否 2 G0007632 熔断器,225A,T级 否 3 G0002910 熔断器,2.5A 否 2 G0002911 熔断器,7A 否 1 G0003493 熔断器,15A 否 3 G0002301 空气滤净器元件,DX 是 1 G0002302 空气滤净器元件,BX 是 1 G0008005 门锁闩 否 4 G0008349 PLC电池 是 1 G0007228 PLC 否 1 G0007232 内在安全栅,振动开关 否 1 G0007233 内在安全栅,RTD传感器 否 1 G0007234 内在安全栅,速度传感器 否 1 G0003504 电涌抑制器 否 1 G0007863 鼠标 否 1 G0007231 以太网开关,6端口 否 1 G0008825 操作界面(控制盘) 否 1 G0002881 空调装置,12,000 BTU 否 1 G0003552 电源 否 1 09 年 10 月 30 日 5-31 DE-7200VFD 离心机 维护 描述 部件号 易消耗 两年 数量 电气控制盘 - 16607-00 G0002909 延时熔断器,1.25A 否 1 G0004195 延时熔断器,0.5A 否 2 G0003789 内在安全栅 否 1 故障排除 尽管设备故障未必是因为操作错误造成的误动作所致,但其它原因也会造成设备出现不必要的停 车,所以应当尽快予以纠正。本章介绍的故障排除步骤有助于维护技师对误操作进行隔离并及时进 行纠正。 故障排除步骤 故障原因分析应当遵循从最简单原因向复杂原因分析的逻辑顺序。最难处理的是无法预见的停车或 不能起动。在处理复杂可能性之前,应当首先消除显见的误操作原因。 由于一个误操作可能有不止一个原因,因此维护技师必须按顺序消除所有可能的故障原因并且在每 一步故障排查过程中都及时采取纠正措施。在修改操作步骤是最佳做法的地方,将提供适应的建 议。 离心机不可预见地停车一般都是由于电源中断使驱动电机停止工作所造成的。离心机电气控制系统 的关键部位均装有安全元件,确保当包括电机温度、振动、或传输装置的扭矩等在内的安全参数超 出允许范围时关停电动机。停电原因可能不止一个,其中包括现场电源故障。 故障排除图表 故障排除表包括故障模式、可能的原因以及推荐做法。本步骤中的所有电气连接检查必须在离心机 断开电源的情况下进行。进行任何电气连接之前,首先要对设备闭锁电源并挂牌上锁。 警示!电气连接检查必须在离心机断开电源的情况下进行。进行电气连接检查之前, 首先要闭锁电源并挂牌上锁。 除故障排查表以外,维护技师还应参考本章后面的示意图及第 6 章中适用的示意图和接线图及第 1 章中的操作描述和理论帮助进行故障排除。 5-32 09 年 10 月 30 日 维护 DE-7200 离心机的故障排除 可能的原因 隔离步骤与补救行动 故障模式 1:液体情况可以接受,但固体饼料太薄 进料中固体含量不足 提高进料速率。 增大溢流堰开口(参见第 4 章)。 降低差动速度。 进料速率降低 提高进料速率。 检查进料泵;如果需要,检查磨损情况并更换已磨损部件。 检查泵轴密封情况,并纠正任何缺陷。 选择 Fault Reset(故障复位)屏上的 RESET (复位)按钮对 流量进行复位。 故障模式 2:液体质量不好,饼料可以接受 转鼓速度太低 提高转鼓速度。 降低进料速率。 进料中固体量过高 降低进料中的固体量,如有可能,可加入稀释流。 进料特征改变 降低进料中的固体量或优化设备设定值,如调整转鼓速度、差 动速度和溢流堰开口等。 固体含湿量增高 重新优化设备的设定值。 降低进料速率。 增大溢流堰开口(参见第 4 章)。 降低差动速度。 传输装置刮板磨损过度,通过 固体排料口检查刮板情况。 拆除并解体转鼓,检查传输装置刮板的情况(传输装置的拆卸 可参见“传输装置轴承的更换”部分的内容)。修理,如果需 要可更换传输装置。 故障模式 3:过度振动 09 年 10 月 30 日 5-33 DE-7200VFD 离心机 维护 DE-7200 离心机的故障排除 可能的原因 隔离步骤与补救行动 转鼓总成由于机械磨损不平 拆除并解体转鼓,检查传输装置刮板的情况(传输装置的拆卸 均、部件磨损或传输装置刮板 可参见传输装置轴承的更换摂部分的内容)。修理,如果需要 变形而失衡。 可更换传输装置。 故障模式 3: 过度振动(续) 传输装置的轴承由于润滑不充 拆除并解体转鼓,检查传输装置的轴承(参见“传输装置轴承 分、异物进入密封件或磨损异 的更换”部分的内容)。更换传输装置的轴承。 常而出现缺陷。 转鼓总成主轴承出现缺陷。 拆卸旋转总成,并更换轴承(参见本章“主轴承的更换”部分 的内容)。 转鼓和/或传输装置内固体物料 堆积过度 进行清理操作(参见“预防性维护”部分的内容)。 故障模式 4: 没有液体排出,进料未经处理就流出液体排料口 固体物料堆积在刮板之间;固 体物料不能运到排料口,而是 停下进料泵和转鼓总成的驱动电机,让传输装置的电机保持运 随液体一道排出。 则重新起动离心机。 行,用水冲洗设备。如果转鼓完全停止之前有固体物料排出, 打开顶盖,将软管插入液体和固体排料口,用水冲洗转鼓内部 (最好用热水)。 如果经过冲洗仍无法成功将堵塞物清除,则要拆下旋转总成并 拆下传输装置以便彻底进行清理。(参见“传输装置轴承的更 换”部分的内容)。 故障模式 5:电耗高,设备堵塞 固体物料堆积在机箱内。 打开顶盖,彻底清理机箱内部、转鼓外部和固体排料斜槽。 故障模式 6:设备经过短暂的停车后在起动后又出现堵塞 由于进料管有固体物料沉积, 造成进料中的固含过高 进行清理操作(参见“预防性维护”部分的内容)。 设备停车后立即清洗进料管,防止今后反复堵塞。 故障模式 7:起动时由于功率消耗过大造成设备停车 5-34 09 年 10 月 30 日 维护 DE-7200 离心机的故障排除 可能的原因 排料斜槽堵塞。 隔离步骤与补救行动 清理排料斜槽内所有沉积的固体物料。 故障模式 8:主轴承温度过高 润滑不充分 润滑轴承(参见“预防性维护”部分的内容)。 滑脂过多 取下滑脂接头,直接吹经过过滤的压缩空气清除滑脂。 所用的滑脂不正确 采用推荐的滑脂进行润滑(参见“预防性维护”部分的内 容)。 轴承有缺陷 更换两个主轴承(参见“主轴承的更换”部分的内容)。 报警和故障信息 如果出现提醒操作人员有异常情况发生的信息,要求操作人员采取措施。报警信息表示必须优先解 决和处理的情况,否则离心机会自动停车。故障信息则告知操作人员要求自动停车的故障已经出 现。 有关故障和报警信息及其原因和纠正措施请参见下表。 报警与故障信息 原因 纠正措施 空调压缩电机过载故障 电机牵引电流过大 更换有缺陷的空调压缩电机,或者消除其它过电流原 因。 空调内部风扇的电机过载故障 电机牵引电流过大 更换有缺陷的内部风扇电机,或者消除其它过电流原 因。 空调制冷剂压力高低故障 检查制冷剂压力;压力高表明制冷剂加 压力高时请减少制冷剂加入量;压力低则需纠正系统 入过多,压力低表明系统有泄漏。 泄漏问题并重加制冷剂。 转鼓超过最高速度,停车 09 年 10 月 30 日 5-35 DE-7200VFD 离心机 维护 报警与故障信息 原因 纠正措施 速度传感器连接不当/松动或者速度传感 如果 Bowl VFD(转鼓变频驱动器)状态屏显上的读 数大约为 4000 RPM,请检查连接情况(参见第 3 部 分);如果连接牢固,请更换传感器。 器有缺陷。 Bowl VFD(转鼓变频驱动器)使转鼓超 过最高的预设速度极限。 更换转鼓的 VFD,重新起动离心机,同时密切监控速 度。 转鼓高扭矩报警,降低进料速率 转鼓扭矩超过预设极限。 降低进料速率。 转鼓高扭矩故障和停车,进行清理并降低进料速率。 转鼓扭矩超过预设极限。 自动停车后,采取清理步骤去除沉积的固体物料,在 降低进料速率的条件下重新起动离心机。 转鼓 VFD 报警,参见用户手册中“故障排除部分”的内容。 转鼓 VFD 有缺陷 按下 STOP(停止),关掉电源再接通。如果报警未 清除,请更换转鼓 VFD。 转鼓 VFD 通讯错误 转鼓 VFD 不能与 PLC 进行通讯 确认以太网电缆旁边的绿色 LED 灯点亮,表示 hub 是 正常的。 检查转鼓 VFD 与 PLC 之间的连接并纠正任何缺陷。 如果未发现其它缺陷,更换转鼓 VFD。 转鼓 VFD 驱动 OL 报警,参见用户手册中“故障排除部分”的内容。 转鼓驱动电机索引电流过大 更换有缺陷的电机,或者消除其它过电流原因。 转鼓 VFD 故障和停车,参见用户手册中“故障排除部分”的内容。 发现 VFD 故障,导致停车 检查并更换转鼓 VFD。 转鼓 VFD 接地报警,参见用户手册中“故障排除部分”的内容。 转鼓电机有接地通道。 检查转鼓电机的接地情况以及与驱动装置输出的连 接,纠正缺陷。 转鼓 VFD 缺相报警,参见用户手册中“故障排除部分”的内容。 发现 VFD 和电机之间的一个相有接地。 5-36 检查 VFD 和电机之间的接线,纠正缺陷。 09 年 10 月 30 日 维护 报警与故障信息 原因 纠正措施 检查电机绕组是否有接地相;如有接地,将其清除, 或者更换电机。 转鼓 VFD 电源损耗报警,参见用户手册中“故障排除部分”的内容。 馈电电源损耗或电源电压低 监控并纠正馈电电源缺陷。 转鼓 VFD 欠电压报警,参见用户手册中“故障排除部分”的内容。 馈电电源损耗或电源电压低 监控并纠正馈电电源缺陷。 与转鼓速度传感器的通讯故障 速度传感器连接不当/松动或者速度传感 器有缺陷。 如果 Bowl VFD(转鼓变频驱动器)状态屏显上的读 数大约为 4000 RPM,请检查连接情况(参见第 3 部 分);如果连接牢固,请更换传感器。 PLC 上的连接不正确 检查所有接触器是否按本章描述牢固插好。 速度传感器的变送器/内在安全栅有缺陷 检查并更换有缺陷的变送器/内在安全栅。 泵的 VFD 有缺陷 检查并更换有缺陷的 VFD。 与液体端轴承温度传感器的通讯有故障 温度传感器的连接不正确或松动 如果读数保持为大约 392°F (200°C),请检查并更正 接线(参见第 3 章和第 8 章的电气示意图)。 PLC 上的连接不正确 检查所有 PLC 接头的是否按第 3 章描述牢固插好。 温度传感器有缺陷 如果读数保持为大约 392°F (200°C),说明传感器有 缺陷,请更换。 液体端变送器/内在安全栅有缺陷或连接 不好 检查连接情况和/或更换有缺陷的变送器。 转鼓 VFD 有缺陷 检查并更换有缺陷的 VFD。 与固体端轴承温度传感器的通讯有故障 温度传感器的连接不牢固或已断开 如果读数保持为大约 392°F (200°C),请检查并更正 接线(参见第 3 章和第 8 章的电气示意图)。 PLC 上的连接不正确 检查所有接触器是否按本章描述牢固插好。 温度传感器有缺陷 如果读数保持为大约 392°F (200°C),说明传感器有 缺陷,请更换。 09 年 10 月 30 日 5-37 DE-7200VFD 离心机 维护 报警与故障信息 原因 纠正措施 与固体端轴承温度传感器的通讯有故障(续) 液体端变送器/内在安全栅连接不好或变 送器有缺陷 如果读数保持为大约 392°F (200°C),请检查并更正 接线;更换有缺陷的变送器。 转鼓 VFD 有缺陷 检查并更换有缺陷的 VFD。 从内存卡下载到控制器的控制程序 从内存卡重装 PLC 程序已完成 起动离心机并恢复运行。 控制器内部电池电量低,请更换 PLC 电池连接不牢固 检查连接情况,如果需要,请更正。 PLC 电池电量低 更换电池。 传输装置高扭矩报警,降低进料速率 传输装置扭矩超过预设极限。 降低进料速率。 传输装置高扭矩故障和停车,进行清理并降低进料速率。 传输装置扭矩超过预设极限。 自动停车后,采取清理步骤去除沉积的固体物料,在 降低进料速率的条件下重新起动离心机。 传输装置 VFD 报警,参见用户手册中“故障排除部分”的内容。 温度传感器信号电缆已断开 检查并纠正接线(参见第 3 章及第 8 章的电机示意 图)。 VFD 温度太高。 检查 Conveyor VFD(传输装置变频驱动器)状态屏 的温度及报警情况;对离心机停车、闭锁电源并挂牌 上锁,确定过热原因并纠正。 VFD 负荷太高。 降低泵的进料速率。 传输装置 VFD 通讯错误 传输装置 VFD 不能与 PLC 进行通讯 确认以太网电缆旁边的绿色 LED 灯点亮,表示 hub 是 正常的。 检查转鼓 VFD 与 PLC 之间的连接并纠正任何缺陷。 如果未发现其它缺陷,更换传输装置的 VFD。 传输装置 VFD 故障和停车,参见用户手册中“故障排除部分”的内容。 发现 VFD 故障,导致停车 5-38 检查并更换传输装置的 VFD。 09 年 10 月 30 日 维护 报警与故障信息 原因 纠正措施 传输装置的 VFD 接地报警,参见用户手册中“故障排除部分”的内容。 传输装置的电机有接地通道。 检查传输装置电机的接地情况以及与驱动装置输出的 连接,纠正缺陷。 传输装置 VFD 缺相报警,参见用户手册中“故障排除部分”的内容。 发现 VFD 和电机之间的一个相有接地。 检查 VFD 和电机之间的接线,纠正缺陷。 检查电机绕组是否有接地相;如有接地,将其清除。 传输装置 VFD 电源损耗报警,参见用户手册中“故障排除部分”的内容。 馈电电源损耗或电源电压低 监控并纠正馈电电源缺陷。 传输装置 VFD 欠电压报警,参见用户手册中“故障排除部分”的内容。 馈电电源损耗或电源电压低 监控并纠正馈电电源缺陷。 电气柜高温报警 PLC 侦测到控制柜内温度高 检查空调装置是否工作,修理或更换有缺陷的空调。 通过降低转鼓速度、传输装置差动速度和/或泵的进料 速率来降低负荷。 检查 VFD 温度(参见第 4 章);更换有缺陷的 VFD。 电气柜高温故障和停车 由于控制柜内温度高,PLC 使离心机停 车 检查空调装置是否工作,修理或更换有缺陷的空调。 通过降低转鼓速度、传输装置差动速度和/或泵的进料 速率来降低负荷。 检查 VFD 温度(参见第 4 章);更换有缺陷的 VFD。 控制柜内温度太高,造成停车 检查空调装置是否工作,按指示修理或更换。检查控 制柜内部,消除任何造成高温的原因。 消除高温原因后重新起动离心机。 紧急停车开关被激活,停车 09 年 10 月 30 日 5-39 DE-7200VFD 离心机 维护 报警与故障信息 原因 按下 EMERGENCY STOP(紧急停车) 纠正措施 消除紧急停车原因,然后重新起动离心机。 高振动故障和停车,纠正问题并按下 Reset(复位)按钮 振动过度造成振动开关脱扣,使电源中 旋转总成过载或堵塞,产生失衡状况。消除振动过度 断,离心机停车。 的原因并重新起动离心机。 液体端主轴承高温报警 温度传感器的连接不牢固或已断开 如果读数保持为大约 392°F (200°C),请检查并更正 接线(参见第 3 章和第 8 章的电气示意图)。 轴承润滑不充分 对轴承进行润滑(参见本章“预防性维护”的内 容)。 滑脂过多 取下滑脂接头,直接吹经过过滤的压缩空气清除滑 脂。 所用的滑脂不正确 采用推荐的滑脂进行润滑(参见本章“预防性维护” 的内容)。 轴承有缺陷 更换两个主轴承(参见本章“主轴承的更换”部分的 内容)。 液体端主轴承高温故障和停车 轴承润滑不充分 对轴承进行润滑(参见本章“预防性维护”的内 容)。 滑脂过多 取下滑脂接头,直接吹经过过滤的压缩空气清除滑 脂。 所用的滑脂不正确 采用推荐的滑脂进行润滑(参见本章“预防性维护” 的内容)。 轴承有缺陷 更换两个主轴承(参见本章“主轴承的更换”部分的 内容)。 泵的 VFD 报警,参见用户手册中“故障排除部分”的内容。 泵的 VFD 需要重启动 按下 STOP(停止),关掉电源再接通。如果报警未 清除,请更换泵的 VFD。 泵的 VFD 通讯错误 泵的 VFD 不能与 PLC 进行通讯 5-40 确认以太网电缆旁边的绿色 LED 灯点亮,表示 hub 是 09 年 10 月 30 日 维护 报警与故障信息 原因 纠正措施 正常的。 检查转鼓 VFD 与 PLC 之间的连接并纠正任何缺陷。 如果未发现其它缺陷,更换泵的 VFD。 泵的 VFD 驱动 OL 报警,参见用户手册中“故障排除部分”的内容。 泵的驱动电机索引电流过大 更换有缺陷的电机,或者消除其它过电流原因。 泵的 VFD 报警,参见用户手册中“故障排除部分”的内容。 发现 VFD 故障,导致停车 检查并更换泵的 VFD。 泵的 VFD 接地报警,参见用户手册中“故障排除部分”的内容。 泵的电机有接地通道。 检查泵的电机及与驱动装置输出的连接是否有接地; 拆除接地连接。 泵的 VFD 缺相报警,参见用户手册中“故障排除部分”的内容。 发现 VFD 和泵的电机之间的一个相有接 地。 检查 VFD 和电机之间的接线,纠正缺陷。 检查电机绕组是否有接地相;如有接地,将其清除, 或者更换电机。 更换 VFD 泵的 VFD 电源损耗报警,参见用户手册中“故障排除部分”的内容。 馈电电源损耗或电源电压低 监控并纠正馈电电源缺陷。 泵的 VFD 欠电压报警,参见用户手册中“故障排除部分”的内容。 馈电电源损耗或电源电压低 监控并纠正馈电电源缺陷。 固体端主轴承高温报警 轴承润滑不充分 对轴承进行润滑(参见本章“预防性维护”的内 容)。 滑脂过多 取下滑脂接头,直接吹经过过滤的压缩空气清除滑 脂。 所用的滑脂不正确 采用推荐的滑脂进行润滑(参见本章“预防性维护” 的内容)。 轴承有缺陷 09 年 10 月 30 日 更换两个主轴承(参见本章“主轴承的更换”部分的 5-41 DE-7200VFD 离心机 维护 报警与故障信息 原因 纠正措施 内容)。 固体端主轴承高温故障和停车 轴承润滑不充分 对轴承进行润滑(参见本章“预防性维护”的内 容)。 滑脂过多 取下滑脂接头,直接吹经过过滤的压缩空气清除滑 脂。 所用的滑脂不正确 采用推荐的滑脂进行润滑(参见本章“预防性维护” 的内容)。 轴承有缺陷 更换两个主轴承(参见本章“主轴承的更换”部分的 内容)。 控制元件指示器 提供了各种指示器,用来显示控制柜元件的操作状态。图 5-25 到 5-28 对这些元件做了定义和指 示。在适用的部分还增加了纠正措施,帮助操作人员进行故障分析。 控制柜内有危险的高电压。由于检查指示器时要求打开控制柜的柜门并且将控制柜的吹扫系统做旁 通处理,因此只允许由经过培训并且合格的人员进行这些操作。打开控制柜柜门并且对吹扫系统做 旁通处理之前,格外要注意周围环境不得有危险烟雾存在。 警示!有危险的电压。只允许由经过培训并且合格的人员在通电的情况下打开控制 柜的柜门。 警示!危险性气体会造成爆炸。打开控制柜柜门之前,先要确定周围环境没有任何 可能引起爆炸的气体存在。 5-42 09 年 10 月 30 日 维护 图 5-25:VFD 指示器 09 年 10 月 30 日 5-43 DE-7200VFD 离心机 维护 控制元件指示器(续) 图 5-26:PLC 指示器 5-44 09 年 10 月 30 日 维护 图 5-27:变送器/内在安全栅指示器 电源指示器 09 年 10 月 30 日 5-45 DE-7200VFD 离心机 第 8 章:参考图纸 本章包括买方所购 Derrick 设备的工程设计图纸。这些图纸有助于进行故障排除、修理和部件订 购。 图号 标题 16590-00-003 General Arrangement - XP Centrifuge 16590-00-004 General Arrangement - Non-XP Centrifuge 16601-00-001 Base Parts List 16602-00-001 Case and Cover Parts List 16603-00-001 Bowl Parts List 16604-00-001 Conveyor Parts List 16605-00-001 Belt Guard Parts List 14394-00-007 Electrical Wiring Schematic - 460/480V 60 Hz Non-XP Centrifuge 14394-00-009 Electrical Wiring Schematic - 460/480V 60 Hz XP Centrifuge 14394-00-011 Electrical Wiring Schematic – 380/400V 50Hz XP Centrifuge 14394-00-012 Electrical Wiring Schematic - 575/600V 60 Hz XP Centrifuge 14394-00-013 Electrical Wiring Schematic – 380/400V 50Hz Non-XP Centrifuge 16606-00-001 Feed Component Assembly 16618-00 Junction Box Assembly 16621-00 Drive Components Parts List 16593-00 Base Sensor System Parts List 16798-00 Repair Tool Kit 16607-00 XP Electrical Control Panel 16472-00-002 Control Enclosure Assembly, 460/480V 60 Hz XP Centrifuge 16472-00-003 Control Enclosure Assembly, 380/400V 50 Hz XP Centrifuge 16472-00-004 Control Enclosure Assembly, 575/600V 60 Hz XP Centrifuge 16472-00-005 Control Enclosure Assembly, 460/480V 60Hz Non XP Centrifuge 09 年 10 月 30 日 1-1 DE-7200VFD 离心机 8 D C B A ITEM 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 QTY X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 3 2 1 1 3 3 1 6 7 1 2 2 2 6 3 1 1 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 2 3 1 1 1 8 2 1 1 1 1 1 1 1 8 1 1 2 35 28 13 1 1 1 1 1 1 2 2 6 2 1 1 1 2 8 4 1 1 1 3 3 1 1 1 1 2 1 3 1 1 7 PART NUMBER 16472-01-002 16396-01-008 16400-01-003 16401-01-002 16402-01-001 16404-01-004 16404-02-004 16404-03-004 16404-01-003 16405-01 16597-01 16598-01 G0002881 16403-01 17006-01 15197-01-003 G0007573 G0007690 G0007689 G0007588 G0002603 G0002604 16607-02 G0008966 G0008891 G0008941 G0008942 G0007213 G0005309 G0007221 G0007698 G0007223 G0007998 G0008507 G0008562 G0009839 G0007214 G0007224 G0007225 G0007631 G0007632 G0007645 G0009286 G0007918 17244-02 G0007999 G0007231 G0007228 G0003552 G0003504 G0003494 G0002910 G0002911 G0007976 17006-02 G0008000 G0008001 G0008002 G0007338 G0007650 G0008010 G0007244 G0005325 G0007865 G0008006 IMP-116B-02X02 G0004679 G0003565 NPLE-50X200S-4 G0002300 G0002716 G0002714 G0009927 G0008003 G0008004 G0008009 15181-01-001 G0004364 G0008007 G0008964 G0007846 G0007848 G0007852 G0007850 G0009238 G0007851 G0007849 G0008005 G0004444 G0004418 16627-01-001 G0007252 PAN-TM3S10-C G0003519 G0009727 G0007951 G0007952 G0007953 G0007954 G0007955 G0004970 G0007701 G0007633 G0007256 IMP-116B-04X04 CRH-ECD-284 G0008267 G0008892 G0008893 G0008890 DESCRIPTION ASSEMBLY COMPLETE ENCLOSURE ASSEMBLY DOOR ASSEMBLY COVER ASSEMBLY STAND ASSEMBLY COMPONENT PANEL (UPPER) COMPONENT PANEL (LOWER) COMPONENT PANEL (BOTTOM) COMPONENT MOUNT ASSY DISPLAY SCREEN MOUNT ENCLOSURE MOUNTING BRACKET AIR FILTER MOUNTING BRACKET AIR CONDITIONER, 12,000 BTU/HR 460/60/3 A/C SUPPORT ANGLE INDUSTRIAL MOUSE W/CABLE INLET CONE EXTENSION DRIVE, 150 HP 460VAC 60 HZ DRIVE, 60 HP 460VAC 60 HZ DRIVE, 30 HP 460VAC 60 HZ AIR CONDITIONER COOLING MOTOR FAN WHEEL, 8" BACKWARD CURVED INLET CONE EX-PROOF ENCLOSURE BLOCK,PWR DISTR-4 POLE (1)#4-500MCM BLOCK,PWR DISTR-3 POLE 2/0-#14 POWER DIST. BLOCK, INCOMING POWER DIST. BLOCK COVER GROUND LUG, INCOMING GROUND BUS BAR, INCOMING 7PT FUSE BLOCK, 60 AMP 3P CLASS J FUSE, 60 AMP CLASS J FUSE COVER, INDICATING DIN RAIL, 35MM X 5 1/2 TERMINAL BLOCK END BARRIER - 6mm TERMINAL BLOCK GREY 4PT TERMINAL BLOCK JUMPER FUSE BLOCK, 30 AMP 3P CLASS CC FUSE BLOCK, 200 AMP 1P CLASS J FUSE, 150 AMP CLASS J TYPE HSJ FUSE HOLDER, 400 AMP 1P CLASS T FUSE, 225 AMP CLASS T DIN RAIL, 35MM X 5 BARRIER, INTRINSIC SAFE-VIBR SWITCH+E-STOP BARRIER, INTRINSIC SAFE-RTD SENSOR BARRIER, INTRINSIC SAFE-SPEED SENSOR DIN RAIL, 35MM X 16 ETHERNET SWITCH, 6 PORT PLC, COMPACTLOGIX PROCCESSOR POWER SUPPLY, 24VDC, 5 AMP SURGE SUPPRESSOR, 120V 60HZ TRANSFORMER, 500VA, 460V PRI/120V SEC FUSE, TIME DELAY 2.5A 600VAC FUSE, TIME DELAY 7.0A 250VAC OPERATOR INTERFACE - 120VAC PROGRAMMED USB CABLE ASSEMBLY WIRE DUCT, 1/2 X 2 X 6 WIRE DUCT, 1/2 X 2 X 10 1/2 WIRE DUCT, 1/2 X 2 X 33 1/8 WIRE DUCT, 1/2 X 2 X 30 3/4 WIRE DUCT, 1/2 X 2 X 28 7/8 WIRE DUCT, 1/2 X 2 X 34 3/8 NAMEPLATE, EMERGENCY STOP BUTTON, EMERGENCY STOP PURGE UNIT W/RELIEF VALVE RELIEF VALVE (SERIAL # OF PURGE REQUIRED) 1/8 90 DEG STREET ELBOW, BRASS 1/8 X 3/16 HOSE BARB AIR FILTER, DX 1/2 X 2 PIPE NIPPLE, SST AIR FILTER, BX 1/2 X 1 1/2 PIPE NIPPLE, SST 1/2 90 DEG ELBOW, SST AIR REGULATOR 1/2 90 DEG STREET ELBOW, BRASS 1/2 X 1/2 HOSE BARB AIR HOSE DISPLAY SCREEN PROTECTIVE COVER O-RING, PROTECTIVE COVER 1/4-20 SEALING PAN HEAD SCREW 2 1/2" CORD FITTING CONNECTOR HOUSING INSERT TERMINAL, FEMALE INSERT TERMINAL, MALE CONNECTOR HOOD CABLE GLAND, HOOD (7-17MM) CONNECTOR COVER, HOUSING CONNECTOR COVER, HOOD DOOR LATCH 1/2" CABLE GLAND XP 1/2" CABLE FITTING (.25-.375" OD) CABLE ASSEMBLY WIRE DUCT FASTENER MOUNT WIRE SADDLE, SMALL WIRE SADDLE, MEDIUM CABLE, GEXOL 16 AWG-6C (6 FT) ASSY W/ XP GLAND ETHERNET CABLE X 8 1/2 (ETH SW-PLC) ETHERNET CABLE X 62 (ETH SW-PNL VIEW) ETHERNET CABLE X 84 (ETH SW-60HP) ETHERNET CABLE X 104 (ETH SW-150HP) ETHERNET CABLE X 178 (ETH SW-30HP) HANDLE,COVER LUG, CRIMP #6 AWG LUG, CRIMP #1 AWG LUG, CRIMP #2 AWG 1/4 90 DEG STREET ELBOW, BRASS 1/4 DRAIN PLUG 1/2 X 1/4 NPT HOSE BARB BLOCK,PWR DISTR-1 POLE 2/0-#14 W/ADDER COVER,DISTR BLOCK-FOR G0008891/8892 COVER,DISTR BLOCK-FOR G0008966 G0007995 G0002301 G0002302 G0008792 G0003493 G0007229 G0007230 G0002873 G0002874 SHPP-100 SHPP-150 SHPP-200 SHPP-250 G0007258 COMPACT FLASH MEMORY CARD AIR ELEMENT, DX (REPLACEMENT ONLY) AIR ELEMENT, BX (REPLACEMENT ONLY) FUSE, TIME DELAY-3.0 AMP CLASS CC FUSE, TIME DELAY-15 AMP CLASS CC PLC POWER SUPPLY PLC END BARRIER COVER, CONTROL TRANSFORMER FUSE PULLER, CONTROL TRANFORMER 1" NPT PLUG 1 1/2" NPT PLUG 2" NPT PLUG 2 1/2" NPT PLUG REDUCER, 3" TO 2" NPT 6 ITEM 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 QTY 1 1 1 8 1 1 3 1 1 1 1 1 1 1 1 PART NUMBER TBS2535 CRH-EL296 G0009272 G0008563 G0002711 G0008349 G0009324 G0009974 17420-01 G0009291 G0012168 G0012122 S4PE-EL-100 G0012167 G0012166 5 4 DESCRIPTION CORD FITTING, 3/4" CORD FITTING, 90 DEGREE SENSOR CABLE TERMINAL BLOCK-4 COND. ORANGE 1/2" CORD FITTING PLC BATTERY TERMINAL BLOCK-4PT COND. YELLOW/GRN SENSOR, RTD A/C THERMOSTAT MOUNTING BRACKET A/C EVAPORATOR FAN (REPLACEMENT PART ONLY) COVER, WATER/DUST VALVE,CHECK 1" NPT FEMXFEM BRASS ELBOW,PIPE-1" FPT 90DEG 150# 304 SS NIPPLE, PIPE-1"XCLOSE SCHED40 304SS ARRESTOR, SPARK UNIV SST 3 2 16 13 D 57 10 SPECIAL TOOL: PURGE PRESSURE MEASURING KIT-G0008378 55 49 11 50 118 117 48 60 59 43 45 06 62 101 34 44 63 42 81 134 133 82 76 74 73 69 72 71 58 138 139 03 137 35 136 140 36 77 116 115 37 40 61 14 07 C 02 05 27 26 41 130 28 08 88 29 24 30 32 25 31 108 74 64 66 21 76 22 20 56 53 75 67 51 65 113 68 132 12 47 79 15 52 B 83 84 23 85 REV 1 DESCRIPTION ITEM 30 WAS G0007217; ITEM 31 WAS G0007218; ADDED ITEMS. BY CCS 2 3 4 ITEM 03 WAS 16400-01-001; QUANTITY WAS 5 ON ITEM 88. CCS CCS CCS ADDED ITEMS 117-132; ITEM 43 WAS G0007232; ITEM 44 WAS G0007233; ITEM 45 WAS G0007234. CCS 86 45 87 54 45 5 114 70 ITEM 16 WAS 15197-01-001 PER DRR#2563; ADDED ITEMS 133, 134, & 135; ITEM 73 WAS G0009927; ITEM 71 & 71 QTY WAS 1; ITEM 74 QTY WAS 2 8 ADDED ITEMS 136-140 MODIFIED ITEMS 29 (WAS G0007610), 34 (WAS G0007012), 35 (WAS G0007216), 36 (WAS G0007237), 54 (WAS G0008825), 128 (WAS G0007868), 130 (WAS G0008572), 131 (WAS G0008544), 132 (WAS G0008571) 9 AND 133 (WAS G0009973). CHANGED QTY ON ITEMS 90 (WAS 2), 129 (WAS 3) AND 132 (WAS 1). 10 ITEM 95 WAS G0002967; 111 WAS G0002966; QTY ITEM 129 WAS 3; UPDATED DESCRIPTION OF 89,90;108 11 ITEM 02: 16396-01-008 WAS 16396-01-003 7 129 91 17 18 89 GEOMETRIC CHARACTERISTIC SYMBOLS 38 80 39 105 19 107 FLATNESS c STRAIGHTNESS ROUNDNESS CYLINDRICITY PARALLELISM PERPENDICULARITY ANGULARITY RUNOUT POSITION CONCENTRICITY SYMMETRY TOLERANCES UNLESS SPECIFIED DEC MM (2) PLACE DEC. +/- .0100 +/- .254 (3) PLACE DEC. +/- .0050 +/- .127 (4) PLACE DEC. +/- .0002 +/- .005 106 ANGLES.............+/- .1 6 5 4 3 DJK 2/4/2010 5/5/2011 BKS 8/5/11 JMB 4/11/12 DMM EJR 7/10/12 10/8/12 THE DESIGNS AND INFORMATION CONTAINED ON THIS DRAWING OR COPIES REMAIN THE EXCLUSIVE PROPERTY OF DERRICK CORPORATION BUFFALO, NEW YORK U.S.A. AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK CORPORATION. THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT, OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK, OR BY OTHERS FOR THE SPECIFIC REASON OUTLINE IN THE TRANSMITTAL WHETHER WRITTEN OR VERBAL. DRAWN R fjmonroe 4/11/2007 CHECKED CCSMITH QA 5/9/2007 DERRICK CORPORATION TITLE A CONTROL ENCLOSURE ASSEMBLY DE-7200 EX-PROOF 460/480/60/3 MFG APPROVED SIZE FILECOPY D +/- .1 Y SCALE 1:10 DO NOT SCALE DRAWING 7 DATE 8/13/2007 8/23/2007 ADDED ITEMS 112 THRU 116.ADDED NOTE 5/12/2008 ITEM 15 WAS 16609-01; ITEM 55 WAS G0007863; ITEM 22 WAS 16622-01. 11/3/2008 ITEM 54 WAS G0007245; ITEM 24 WAS G0008261; ITEM 25 WAS G0008262; ITEM 26 WAS G0007210; ITEM 27 WAS G0007211; ITEM 109 WAS G0008264; ITEM 110 WAS G0008265; ITEM 111 WAS G0008266; ITEM 91 CCS 12/18/2008 WAS 16627-01; ITEM 80 WAS G0003529. 6 09 8 1 2 REV DWG NO 11 16472-00-002 SHEET 1 1 OF 1 CENT,MAN,C-RM 8 D C B A ITEM 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 QTY X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 6 2 2 6 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 2 3 1 1 1 8 8 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 3 2 3 7 2 1 3 2 2 2 2 3 1 1 3 3 3 1 1 1 1 1 35 28 13 2 8 4 1 1 1 1 4 1 1 1 1 1 1 DRAWING NUMBER 16472-01-003 16396-01-003 16400-01-003 16401-01-002 16402-01-001 16404-01-004 16404-02-004 16404-03-004 16404-01-003 16405-01 16597-01 16598-01 G0002881 16403-01 15197-01-003 G0009358 G0009359 G0009360 G0007588 G0002603 G0002604 16607-01 G0008941 G0007213 G0005309 G0007998 G0008507 G0007214 G0007224 G0007631 G0007645 G0009286 G0007918 17244-02 G0007999 G0007231 G0007228 G0003552 G0003504 G0008800 G0002911 G0007976 G0008000 G0008001 G0008002 G0007338 G0007650 G0008010 G0007244 G0005325 G0007865 G0008006 IMP-116B-02X02 G0004679 G0003565 NPLE-50X200S-4 G0002300 G0002716 G0002714 G0009927 G0008003 G0008004 G0008009 15181-01-001 G0004364 G0008007 G0008005 G0004444 G0002711 16627-01-001 G009767 G0007846 G0007848 G0007852 G0007850 G0009238 G0007851 G0007849 IMP-116B-04X04 CRH-ECD-284 G0008267 17006-01 17006-02 G0008891 G0008892 G0008966 G0008942 G0008964 G0008563 G0008562 G0009324 G0009477 G0009476 G0009357 G0001651 G0007227 16894-01-002 G0009356 17306-01 G0009354 G0009530 G0008792 G0003493 G0007951 G0007952 G0007953 G0007954 G0007955 G0007252 PAN-TM3S10-C G0003519 G0004970 G0008893 G0008890 G0009753 G0007229 G0007230 G0007995 G0009563 G0002301 G0002302 G0002873 G0002874 NPLE-75 COND G0009972 7 DESCRIPTION ASSEMBLY COMPLETE ENCLOSURE ASSEMBLY DOOR ASSEMBLY COVER ASSEMBLY STAND ASSEMBLY COMPONENT PANEL (UPPER) COMPONENT PANEL (LOWER) COMPONENT PANEL (BOTTOM) COMPONENT MOUNT ASSEMBLY DISPLAY SCREEN MOUNT ENCLOSURE MOUNTING BRACKET AIR FILTER MOUNTING BRACKET AIR CONDITIONER, 12,000 BTU/HR 460/60/3 A/C SUPPORT ANGLE INLET CONE EXTENSION DRIVE, 150 HP 380VAC 50HZ DRIVE, 60 HP 380VAC 50HZ DRIVE, 30 HP 380VAC 50HZ AIR CONDITIONER COOLING MOTOR FANWHEEL, 8" BACKWARD CURVED INLET CONE EX-PROOF ENCLOSURE POWER DIST. BLOCK, INCOMING GROUND LUG, INCOMING GROUND BUS BAR, INCOMING DIN RAIL, 35MM X 5 1/2 TERMINAL BLOCK END BARRIER FUSE BLOCK, 30 AMP 3P CLASS CC FUSE BLOCK , 200 AMP 1P CLASS J FUSE HOLDER, 400 AMP 1P CLASS T DIN RAIL, 35MM X 5 BARRIER, INTRINSIC SAFE-VIBR SWITH + E-STOP BARRIER, INTRINSIC SAFE-RTD SENSOR BARRIER, INTRINSIC SAFE-SPEED SENSOR DIN RAIL, 35MM X 16 ETHERNET SWITCH, 6 PORT PLC, COMPACTLOGIX PROCESSOR POWER SUPPLY, 24VDC 5 AMP SURGE SUPPRESSOR, 120V 60HZ TRANSFORMER, 500VA, 400V PRI/115V SEC FUSE, TIME DELAY-7.0A 250VAC OPERATOR INTERFACE-120VAC - PRPOGRAMMED WIRE DUCT, 1 1/2 X 2 X 6 WIRE DUCT, 1 1/2 X 2 X 10 1/2 WIRE DUCT, 1 1/2 X 2 X 33 1/8 WIRE DUCT, 1 1/2 X 2 X 30 3/4 WIRE DUCT, 1 1/2 X 2 X 28 7/8 WIRE DUCT, 1 1/2 X 2 X 34 3/8 NAMEPLATE, EMERGENCY STOP BUTTON, EMERGENCY STOP PURGE UNIT W/RELIEF VALVE RELIEF VALVE (SERIAL # OF PURGE REQUIRED) 1/8 90 DEG STREET ELBOW, BRASS 1/8 X 3/16 HOSE BARB AIR FILTER, DX 1/2 X 2 PIPE NIPPLE, SST AIR FILTER, BX 1/2 X 1 1/2 PIPE NIPPLE, SST 1/2 90 DEG ELBOW, SST AIR REGULATOR 1/2 90 DEG STREET ELBOW, BRASS 1/2 X 1/2 HOSE BARB AIR HOSE DISPLAY SCREEN PROTECTIVE COVER O-RING, PROTECTIVE COVER 1/4-20 SEALING PAN HEAD SCREW DOOR LATCH 1/2" CABLE GLAND 1/2" CABLE FITTING CABLE ASSEMBLY CABLE, GEXOL 16 AWG-6C (6FT) ASSY W/ XP GLAND CONNECTOR HOUSING INSERT TERMINAL, FEMALE INSERT TERMINAL, MALE CONNECTOR HOOD CABLE GLAND, HOOD (7-17MM) CONNECTOR COVER, HOUSING CONNECTOR COVER, HOOD 1/4 90 DEG STREET ELBOW, BRASS 1/4 DRAIN PLUG 1/2 X 1/4 NPT HOSE BARB INDUSTRIAL MOUSE W/CABLE CABLE ASSEMBLY BLOCK, POWER DISTR-3 POLE 2/0#14 BLOCK, POWER DISTR-3 POLE 2/0 #14 W/ADDER BLOCK, POWER DISTR-4 POLE (1)#4-500MCM POWER DIST. BLOCK COVER 2 1/2" CORD FITTING TERMINAL BLOCK-4 COND ORANGE TERMINAL BLOCK-4 COND GREY TERMINAL BLOCK-4 COND YELLOW/GREEN FUSE BLOCK, 100A 600V 3P CLASS T FUSE, 90 AMP 600V CLASS T FUSE, 200 AMP 600V CLASS J FUSE, TIME DELAY-3-2/10 AMP CLASS CC MODULE, DIODE-DOUBLE-100 AMP JUMPER, BUS FUSE, 250 AMP 600V CLASS T STAND OFF, FUSE HOLDER FUSE BLOCK, 200 AMP 600V 3P CLASS T FUSE, 125 AMP 600V CLASS T FUSE, TIME DELAY-3.0 AMP CLASS CC FUSE, TIME DELAY-15 AMP CLASS CC ETHERNET CABLE X 8 1/2 (ETH SW-PLC) ETHERNET CABLE X 62 (ETH SW-PNL VIEW) ETHERNET CABLE X 84 (ETH SW-60HP) ETHERNET CABLE X 104 (ETH SW-150HP) ETHERNET CABLE X 178 (ETH SW-30HP) WIRE DUCT FASTENER MOUNT WIRE SADDLE, SMALL WIRE SADDLE, MEDIUM HANDLE, COVER COVER, DISTR BLOCK-FOR G0008891/8892 COVER, DISTR BLOCK FOR G0008966 STOPPING PLUG M 63 PLC POWER SUPPLY PLC END BARRIER COMPACT FLASH MEMORY CARD LUG, CRIMP-1 AWG #10 STUD AIR ELEMENT, DX (REPLACEMENT ONLY) AIR ELEMENT, BX (REPLACEMENT ONLY) COVER, CONTROL TRANSFORMER FUSE PULLER, CONTROL TRANSFORMER COND NIPPLE SENSOR CABLE 6 ITEM 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 QTY 1 2 1 1 1 1 1 1 2 1 1 3 3 1 1 1 1 1 DRAWING NUMBER G0008349 G0008449 G0007258 TBS2535 CRH-EL296 G0009974 17420-01 G0009291 G0008813 G0009197 G0008807 G0008451 G0008455 G0009467 G0009466 G0009751 G0009752 G0009568 5 4 DESCRIPTION PLC BATTERY (REPLACEMENT ONLY) ADAPTER/REDUCER 1"- M25 REDUCER, 3" TO 2" NPT 3/4" CORD FITTING CORD FITTING, 90 DEG SENSOR, RTD A/C THERMOSTAT MOUNTING BRACKET A/C EVAPORATOR FAN STOPPING PLUG M25 ADAPTER/REDUCER 1.5"- M40 STOPPING PLUG M40 ADAPTER/REDUCER 2"-M50 STOPPING PLUG M50 ADAPTER/REDUCER 2.5" - M63 STOPPI NG PLUG M63 ADAPTER/REDUCER 3" -M50 STOPPING PLUG M50 ADAPTER/REDUCER 3"-M63 7 2 1 D 13 15 SPECIAL TOOL-PURGE PRESSURE MEASURING KIT-G0008378 46 91 44 40 61 90 89 10 41 39 82 38 34 02 132 32 33 131 06 11 49 112 27 72 63 73 50 48 43 65 03 61 47 58 59 60 66 96 22 97 101 100 14 98 30 C 67 99 07 28 23 29 24 25 08 05 87 86 92 93 84 85 51 21 20 19 53 52 57 75 54 62 12 36 37 116 117 42 95 74 B 17 76 78 77 16 68 69 70 THE DESIGNS AND INFORMATION CONTAINED ON THIS DRAWING OR COPIES REMAIN THE EXCLUSIVE PROPERTY OF DERRICK CORPORATION BUFFALO, NEW YORK U.S.A. AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK CORPORATION. THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT, OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK, OR BY OTHERS FOR THE SPECIFIC REASON OUTLINE IN THE TRANSMITTAL WHETHER WRITTEN OR VERBAL. 88 DRAWN ccs 79 81 5 DESCRIPTION BY ITEM 15 WAS 15197-01-001 PER DRR# 2563; ADDED ITEMS 131, 132 & 133; ITEM 60 WAS G0008008; DJK ITEM 58 & 61 QTY WAS 1; ITEM 59 QTY WAS 2 ITEM 25 WAS G0007610;42 WAS G0008825;69 WAS G0004418 QTY 1; 71 WAS G0002967;QTY 90 WAS 1;101 WAS G0009353;115 WAS G0002966;124 WAS SHPP-100;125 WAS SHPP-150; 126 WAS DMM SHPP-200; 127 WAS SHPP-250; 131 WAS G0009973; ADDED ITEMS 134-143 4 3 DATE A CONTROL ENCLOSURE ASSEMBLY DE-7200 EX-PROOF 380/400/3 MFG 1 6 TITLE QA 80 09 REV R DERRICK CORPORATION 6/28/2010 CHECKED 18 2 8 3 APPROVED 5/5/2011 SIZE D 7/2/2012 SCALE 2 REV FILECOPY DWG NO N 1:10 2 16472-00-003 SHEET 1 1 OF 1 CENT, MAN 8 D C B A ITEM 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 QTY X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 3 1 3 3 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 2 3 1 1 1 8 8 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 3 2 2 3 2 6 3 2 1 2 2 2 1 1 3 6 3 3 8 4 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 2 6 2 1 1 PART NUMBER 16472-01-004 16396-01-003 16400-01-003 16401-01-002 16402-01-001 16404-01-004 16404-02-004 16404-03-004 16404-01-003 16405-01 16597-01 16598-01 G0002881 16403-01 15197-01-003 G0009350 G0009351 G0009352 G0007588 G0002603 G0002604 16607-03 G0008941 G0007213 G0007610 G0007221 G0007223 G0007998 G0007012 G0007214 G0007645 G0009286 G0007918 17244-02 G0007999 G0007231 G0007228 G0003552 G0003504 G0004986 G0002911 G0008825 G0008000 G0008001 G0008002 G0007338 G0007650 G0008010 G0007244 G0005325 G0007865 G0008006 IMP-116B-02X02 G0004679 G0003565 NPLE-50X200S-4 G0002300 G0002716 G0002714 G0009927 G0008003 G0008004 G0008009 15181-01-001 G0004364 G0008007 G0008005 G0004444 G0004418 16627-01-001 G0007846 G0007848 G0007852 G0007850 G0009238 G0007851 G0007849 IMP-116B-04X04 CRH-ECD-284 G0008267 17006-01 17006-02 G0008891 G0008892 G0008966 G0008942 G0008964 G0008057 G0007222 G0009183 G0008563 G0008572 G0009324 G0009481 G0009480 G0007227 16894-01-002 17306-01 G0009477 G0009476 G0007631 G0009353 G0007589 G0008893 G0008890 G0008792 G0009451 G0007229 G0007230 G0008349 G0007995 G0002873 G0002874 G0007951 G0008122 G0007952 G0008123 G0008121 G0002301 G0002302 G0007701 G0007633 G0007256 G0002966 TBS2535 7 DESCRIPTION ASSEMBLY COMPLETE ENCLOSURE ASSEMBLY DOOR ASSEMBLY COVER ASSEMBLY STAND ASSEMBLY COMPONENT PANEL (UPPER) COMPONENT PANEL (LOWER) COMPONENT PANEL (BOTTOM) COMPONENT MOUNT ASSEMBLY DISPLAY SCREEN MOUNT ENCLOSURE MOUNTING BRACKET AIR FILTER MOUNTING BRACKET AIR CONDITIONER, 12,000 BTU/HR 460/60/3 A/C SUPPORT ANGLE INLET CONE EXTENSION DRIVE, 150 HP 600VAC 60 HZ DRIVE, 60 HP 600VAC 60 HZ DRIVE, 30 HP 600VAC 60 HZ AIR CONDITIONER COOLING MOTOR FANWHEEL, 8" BACKWARD CURVED INLET CONE EX-PROOF ENCLOSURE POWER DIST. BLOCK, INCOMING GROUND LUG, INCOMING GROUND BUS BAR, INCOMING FUSE BLOCK, 60 AMP CLASS J FUSE COVER, INDICATOR DIN RAIL, 35MM X 5 1/2 TERMINAL BLOCK END BARRIER FUSE BLOCK, 30 AMP 3P CLASS CC DIN RAIL, 35MM X 5 BARRIER, INTRINSIC SAFE-VIBR SWITCH+E-STOP BARRIER, INTRINSIC SAFE-RTD SENSOR BARRIER, INTRINSIC SAFE-SPEED SENSOR DIN RAIL, 35MM X 16 ETHERNET SWITCH, 6 PORT PLC, COMPACTLOGIX PROCESSOR POWER SUPPLY, 24VDC, 5 AMP SURGE SUPPRESSOR, 120V 60HZ TRANSFORMER, 500VA, 600PRI/120V SEC FUSE, TIME DELAY 7.0A 250 VAC OPERATOR INTERFACE - 120 VAC WIRE DUCT, 1 1/2 X 2 X 6 WIRE DUCT, 1 1/2 X 2 X 10 1/2 WIRE DUCT, 1 1/2 X 2 X 33 1/8 WIRE DUCT, 1 1/2 X 2 X 30 3/4 WIRE DUCT, 1 1/2 X 2 X 28 7/8 WIRE DUCT, 1 1/2 X 2 X 34 3/8 NAMEPLATE, EMERGENCY STOP BUTTON, EMERGENCY STOP PURGE UNIT W/RELIEF VALVE RELIEF VALVE (SERIAL # OF PURGE UNIT REQUIRED) 1/8 90 DEG STREET ELBOW, BRASS 1/8 X 3/16 HOSE BARB AIR FILTER, DX 1/2 X 2 PIPE NIPPLE, SST AIR FILTER, BX 1/2 X 1 1/2 PIPE NIPPLE, SST 1/2 90 DEG ELBOW, SST AIR REGULATOR 1/2 90 DEG STREET ELBOW, BRASS 1/2 X 1/2 HOSE BARB AIR HOSE DISPLAY SCREEN PROTECTIVE COVER O-RING, PROTECTIVE COVER 1/4-20 SEALING PAN HEAD SCREW DOOR LATCH 1/2" CABLE GLAND 1/2" CABLE FITTING CABLE ASSEMBLY CONNECTOR HOUSING INSERT TERMINAL, FEMALE INSERT TERMINAL, MALE CONNECTOR HOOD CABLE GLAND, HOOD (7-17MM) CONNECTOR COVER, HOUSING CONNECTOR COVER, HOOD 1/4 X 90 DEG STREET ELBOW, BRASS 1/4 DRAIN PLUG 1/2 X 1/4 NPT HOSE BARB INDUSTRIAL MOUSE W/CABLE CABLE ASSEMBLY BLOCK, PWR DISTR-3 POLE 2/0 #14 BLOCK, PWR DISTR-1 POLE 2/0 #14 W/ADDER BLOCK, PWR DISTR-4 POLE (1)#4-500MCM POWER DIST. BLOCK COVER 2 1/2" CORD FITTING TRANSFORMER, 350VA 480V PRI/120 SEC FUSE, 50 AMP CLASS J FUSE, TIME DELAY2.0A 600 VAC TERMINAL BLOCK-4 COND. ORANGE TERMINAL BLOCK GROUND-BLUE 4PT TERMINAL BLOCK GROUND-YELLOW/GREEN 4PT FUSE HOLDER, 100A 600V 2P CLASS J FUSE, 100A/600V CLASS J MODULE, DIODE-DOUBLE 100 AMP JUMPER, BUS STAND OFF, FUSE HOLDER FUSE HOLDER, 100A 600V 3P CLASS T FUSE, 90 AMP 600V CLASS T FUSE HOLDER 400 AMP 1P CLASS T FUSE, 175 AMP CLASS T FUSE, TIME DELAY 3.0 AMP CLASS CC COVER, DIST. BLOCK-FOR G0008891/8892 COVER DIST. BLOCK-FOR G0008966 FUSE, TIME DELAY 3.0 AMP CLASS CC FUSE, TIME DELAY 5.0 AMP CLASS CC PLC POWER SUPPLY PLC END BARRIER PLC BATTERY REPLACEMENT COMPACT FLASH MEMORY CARD COVER, CONTROL TRANSFORMER FUSE PULLER, CONTROL TRANSFORMER ETHERNET CABLE X 8 1/2 (ETH SW-PLC) ETHERNET CABLE X 62 (ETH SW-PNL VIEW) ETHERNET CABLE X 84 (ETH SW-60 HP) ETHERNET CABLE X 104 (ETH SW-150 HP) ETHERNET CABLE X 178 (ETH SW-30 HP) AIR ELEMENT, DX (REPLACEMENT ONLY) AIR ELEMENT, BX (REPLACEMENT ONLY) LUG, CRIMP #6 AWG LUG, CRIMP #1 AWG LUG, CRIMP #2 AWG CABLE GLAND 3/4" CORD FITTING 6 ITEM 126 127 128 129 130 131 132 133 134 135 136 137 138 139 QTY 1 1 2 35 28 13 2 1 3 1 1 1 1 1 PART NUMBER CRH-EL296 G0002967 G0004970 G0007252 PAN-TM3S10-C G0003519 SHPP-100 SHPP-150 SHPP-200 SHPP-250 G0007258 17420-01 G0009973 G0009291 5 4 DESCRIPTION CORD FITTING, 90 DEG ELBOW CABLE, GEXOL 16 AWG-16C (6 FT) HANDLE, COVER WIRE DUCT FASTENER MOUNT WIRE SADDLE, SMALL WIRE SADDLE, MEDIUM 1" NPT PLUG 1 1/2" NPT PLUG 2" NPT PLUG 2 1/2" NPT PLUG REDUCER, 3" TO 2" NPT A/C THERMOSTAT MOUNTING BRACKET SENSOR, RTD A/C EVAPORATOR FAN 3 2 1 13 15 D 82 SPECIAL TOOL-PURGE PRESSURE MEASURING KIT-G0008378 109 108 37 38 11 46 39 36 32 33 92 10 49 34 06 61 71 72 73 66 63 43 64 50 47 74 03 45 58 65 88 48 75 96 76 77 14 128 97 101 98 99 102 C 30 100 94 86 95 23 24 02 25 85 26 83 89 05 27 84 67 19 20 21 70 53 81 54 22 93 42 12 91 29 41 40 90 120 57 B 17 52 16 68 69 07 87 THE DESIGNS AND INFORMATION CONTAINED ON THIS DRAWING OR COPIES REMAIN THE EXCLUSIVE PROPERTY OF DERRICK CORPORATION BUFFALO, NEW YORK U.S.A. AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK CORPORATION. THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT, OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK, OR BY OTHERS FOR THE SPECIFIC REASON OUTLINE IN THE TRANSMITTAL WHETHER WRITTEN OR VERBAL. DRAWN 78 ccs R DERRICK CORPORATION 4/7/2010 CHECKED TITLE QA 79 18 80 09 CONTROL ENCLOSURE ASSEMBLY DE-7200 EX-PROOF 575/600/60/3 MFG 08 APPROVED SIZE REV 1 8 7 6 5 DESCRIPTION ITEM 15 WAS 15197-01-001 PER DRR# 2563; ADDED ITEMS 137, 138 AND 139; ITEM 60 WAS G0008008; ITEM 58 & 61, QTY WAS 1; ITEM 59 QTY WAS 2 4 3 BY A DATE D DJK 5/5/2011 SCALE 2 REV FILECOPY DWG NO N 1:10 1 16472-00-004 SHEET 1 1 1 CENT, MAN OF 7 6 Parts List D C B A 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 3 2 1 1 3 3 1 6 2 2 2 2 2 6 3 1 1 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 8 1 1 1 1 1 1 8 1 1 1 1 1 35 28 13 1 1 1 1 1 1 2 2 6 2 1 4 8 1 1 1 1 1 3 3 1 1 DRAWING NUMBER 16472-01-005 16396-01-003 16400-01-003 16402-01-001 16404-01-004 16404-02-004 16404-03-004 16404-01-003 16405-01 G0002881 16403-01 16609-01 15197-01-003 G0007573 G0007690 G0007689 G0007588 G0002603 G0002604 G0008966 G0008891 G0008941 G0008942 G0007213 G0005309 G0007221 G0007698 G0007223 G0007998 G0008507 G0009324 G0008563 G0007214 G0007224 G0007225 G0007631 G0007632 G0007984 G0009286 G0007918 17244-02 G0007999 G0007231 G0007228 G0003552 G0003504 G0003494 G0002910 G0002911 G0007976 17006-01 G0008000 G0008001 G0008002 G0007338 G0007650 G0008010 G0007244 G0005325 15181-01-001 G0004364 G0008007 G0007846 G0007852 G0007850 G0009238 G0007849 G0007851 G0008005 G0007848 16623-01 16623-02 16401-01 G0007246 G0007252 PAN-TM3S10-C G0003519 17006-02 G0007951 G0007952 G0007953 G0007954 G0007955 G0004970 G0007701 G0007633 G0007256 G0008892 G0008890 G0008893 G0002873 IMP-116B-04X04 16701-01 G0008267 G0007995 G0008792 G0003493 G0009974 17420-01 8 5 4 3 2 1 Parts List DESCRIPTION ASSEMBLY COMPLETE ENCLOSURE ASSEMBLY DOOR ASSEMBLY STAND ASSEMBLY COMPONENT PANEL (UPPER) COMPONENT PANEL (LOWER) COMPONENT PANEL (BOTTOM) COMPONENT MOUNT ASSEMBLY DISPLAY SCREEN MOUNT AIR CONDITIONER, 12,000 BTU/HR 460/60/3 A/C SUPPORT ANGLE CONTROL MOUSE COVER INLET CONE EXTENSION DRIVE, 150 HP 460VAC 60 HZ DRIVE, 60 HP 460VAC 60 HZ DRIVE, 30 HP 460VAC 60 HZ AIR CONDITIONER COOLING MOTOR FAN WHEEL, 8" BACKWARD CURVED INLET CONE PWR DISTR, BLOCK-4 POLE (1)#4-500MCM POWER DIST. BLOCK, OUTGOING-2/0 AWG-3 POLE POWER DIST. BLOCK, INCOMING (2) 500 MCM -3 POLE POWER DIST. BLOCK COVER 1 POLE GROUND LUG, INCOMING GROUND BUS BAR, INCOMING FUSE BLOCK, 60 AMP 3P CLASS J FUSE, 60 AMP CLASS J FUSE COVER, INDICATING DIN RAIL, 35MM X 5 1/2 TERMINAL BLOCK END BARRIER TERMINAL BLOCK GROUND-YELLOW/GREEN 4 PT TERMINAL BLOCK BARRIER-ORANGE 4 PT FUSE BLOCK, 30 AMP 3P CLASS CC FUSE BLOCK, 200 AMP 1P CLASS J FUSE, 150 AMP CLASS J TYPE HSJ FUSE BLOCK, 400 AMP 3P CLASS T FUSE, 225 AMP CLASS T DIN RAIL, 35MM X 5 BARRIER, INTRINSIC SAFE-VIBR SWITCH BARRIER, INTRINSIC SAFE-RTD SENSOR BARRIER, INTRINSIC SAFE-SPEED SENSOR - PROGRAMMED DIN RAIL, 35MM X 16 ETHERNET SWITCH, 6 PORT PLC, COMPACTLOGIX PROCESSOR POWER SUPPLY, 24VDC, 5 AMP SURGE SUPPRESSOR, 120V 60HZ TRANSFORMER, 500VA, 460V PRI/120V SEC FUSE, TIME DELAY 2.5A 600VAC FUSE, TIME DELAY 7.0A 250VAC OPERATOR INTERFACE- PROGRAMMED INDUSTRIAL MOUSE/POINTER ASSY WIRE DUCT, 1/2 X 2 X 6 WIRE DUCT, 1/2 X 2 X 10 1/2 WIRE DUCT, 1/2 X 2 X 33 1/8 WIRE DUCT, 1/2 X 2 X 30 3/4 WIRE DUCT, 1/2 X 2 X 28 7/8 WIRE DUCT, 1/2 X 2 X 34 3/8 NAMEPLATE, EMERGENCY STOP BUTTON, EMERGENCY STOP DISPLAY SCREEN PROTECTIVE COVER O-RING, PROTECTIVE COVER 1/4-20 SEALING PAN HEAD SCREW CONNECTOR HOUSING INSERT TERMINAL, MALE CONNECTOR HOOD CABLE GLAND CONNECTOR COVER, HOOD CONNECTOR COVER, HOUSING DOOR LATCH INSERT TERMINAL, FEMALE CLOSE OFF PLATE, 10GA X 4 X 9 1/2 CLOSE OFF PLATE, 10GA X 4 X 6 CONDENSER COVER ASSEMBLY TEE HANDLE WIRE DUCT FASTENER MOUNT WIRE SADDLE, SMALL WIRE SADDLE, MEDIUM CABLE ASSEMBLY (USB TO PS2 TO IDC) ETHERNET CABLE X 8 1/2 (ETH SW-PLC) ETHERNET CABLE X 62 (ETH SW-PNL VIEW) ETHERNET CABLE X 84 (ETH SW-60HP) ETHERNET CABLE X 104 (ETH SW-150HP) ETHERNET CABLE X 178 (ETH SW-30HP) HANDLE, COVER LUG, CRIMP #6 AWG LUG, CRIMP #1 AWG LUG, CRIMP #2 AWG POWER DIST BLACK- 2/0 AWG- 1P FINGER SAFE COVER FOR G0008896 FINGER SAFE COVER FOR G0008891 & G0008892 COVER,XFRMR-CLASS 9070 TYPE FSC-2 1/4 90 DEG STREET ELBOW, BRASS 1/4 NPT DRAIN PLUG 1/2 X 1/4 NPT HOSE BARB COMPACT FLASH MEMORY CARD FUSE, TIME DELAY-3 AMP CLASS CC FUSE, TIME DELAY-15 AMP CLASS CC SENSOR, RTD A/C THERMOSTAT MOUNTING BRACKET 7 ITEM QTY DRAWING NUMBER 100 1 G0009291 101 2 G0002535 102 1 CRH-EL296 103 1 G0009972 104 1 G0007229 105 1 G0007230 106 1 G0008349 107 1 G0002874 108 1 G0002967 DESCRIPTION A/C EVAPORATOR FAN (REPLACEMENT ONLY0 CORD FITTING 3/4" ELBOW 90 DEG 3/4" M-F SENSOR CABLE PLC POWER SUPPLY PLC END CAP PLC BATTERY (REPLACEMENT ONLY) COVER/PULLER,FUSE-CLASS 9070 TYPE FP-1 CABLE,GEXOL, 16 AWG- 6C(6FT) 73 D 99 13 46 74 45 02 44 52 84 71 98 58 12 55 59 61 38 63 70 62 64 30 65 60 09 54 50 31 66 32 72 10 57 68 03 11 67 C 06 36 37 34 23 35 22 24 27 25 20 28 07 33 96 04 97 26 89 90 17 41 39 42 43 47 21 18 48 88 69 19 B 51 49 53 05 56 29 REV 1 2 3 4 5 DESCRIPTION ITEM 20 WAS G0007217; ITEM 21 WAS G0007218; ADDED ITEMS 88-94. ITEM 01 WAS 16400-01-001; QUANTITY OF ITEM 69 WAS 5. ADDED ITEMS 95 THRU 97; UPDATED VIEWS. ITEM 50 WAS G0007245. ITEM 13 WAS 15197-01-001 PER DRR# 2563; ADDED ITEMS 98, 99 & 100 ITEM 20 WAS G0008261;21 WAS G0008262;22 WAS G0007210; 23 WAS G0007211;25 WAS G0007610;30 WAS G0007012; 31 WAS G0007216; 32 G0007237 QTY 1; 39 WAS G0007232 QTY 2; 40 WAS G0007233; 41 WAS 6 G0007234 QTY 1; 50 WAS G0008825; 51 WAS G0003466;66 WAS G0007847; 78 WAS 16449-01; 88 WAS G0008263; 89 WAS G0008264 QTY 1; 90 WAS G0008265 QTY 2; 91 WAS G0008266; 96 WAS G0007981; 98 WAS G0009973; ADDED ITEMS 101-108 14 15 GEOMETRIC CHARACTERISTIC SYMBOLS 16 92 FLATNESS c STRAIGHTNESS ROUNDNESS CYLINDRICITY PARALLELISM PERPENDICULARITY ANGULARITY RUNOUT POSITION CONCENTRICITY SYMMETRY TOLERANCES UNLESS SPECIFIED DEC MM (2) PLACE DEC. +/- .0100 +/- .254 (3) PLACE DEC. +/- .0050 +/- .127 (4) PLACE DEC. +/- .0002 +/- .005 94 93 ANGLES.............+/- .1 5 4 3 DMM JWC 7/3/12 THE DESIGNS AND INFORMATION CONTAINED ON THIS DRAWING OR COPIES REMAIN THE EXCLUSIVE PROPERTY OF DERRICK CORPORATION BUFFALO, NEW YORK U.S.A. AND ARE NOT TO BE REPRODUCED WITHOUT THE WRITTEN PERMISSION OF DERRICK CORPORATION. THE INFORMATION CONTAINED ON THIS DRAWING SHALL ONLY BE USED BY CUSTOMERS OR PROSPECTS OR THEIR AGENCIES IN THE ARRANGEMENT OR INSTALLATION OF DERRICK EQUIPMENT, OR BY VENDORS IN QUOTING ON OR IN THE SUPPLY OF PARTS OR ASSEMBLIES TO DERRICK, OR BY OTHERS FOR THE SPECIFIC REASON OUTLINE IN THE TRANSMITTAL WHETHER WRITTEN OR VERBAL. DRAWN fjmonroe R DERRICK CORPORATION 5/15/2007 CHECKED CCSMITH 5/17/2007 QA TITLE A CONTROL ENCLOSURE ASSEMBLY DE-7200 460/480/60/3 MFG APPROVED SIZE D +/- .1 SCALE DO NOT SCALE DRAWING 6 BY CKD DATE CCS 8/14/2007 CCS 9/5/2007 CCS 5/13/2008 CCS 8/24/2010 DJK 5/5/2011 2 REV FILECOPY DWG NO Y 1:10 6 16472-00-005 SHEET 1 1 OF 1 CENT, MAN 8 ITEM QTY 第 9 章:安装和维护记录 目的 本章由操作人员和维护人员用来记录在 Derrick 设备安装和运行期间所收集到的历史信息。如果保 管妥善,该记录将有助于改进维护周期和提示需要修改操作步骤的截距趋势。每次填写记录都应当 注明日期,以备日后参考和查找。如果需要,可以多复印空白页并插入本章后面来增加记录页数。 安装与维护记录: 09 年 10 月 30 日 9-1 DE-7200 VFD 离心机 安装和维护记录 9-2 09 年 10 月 30 日 安装和维护记录 09 年 10 月 30 日 9-3 DE-7200 VFD 离心机 安装和维护记录 9-4 09 年 10 月 30 日 安装和维护记录 09 年 10 月 30 日 9-5 DE-7200 VFD 离心机 安装和维护记录 9-6 09 年 10 月 30 日 第 10 章:供货商资料 概述 本章包括离心机安装部件的制造商手册、专刊、指导和其它技术数据。Derrick 设备总成的图纸、 部件清单和电气图请参见第 8 章内容。 元件 描述 变频驱动器 用户手册第 4 章和 第 1 章第 1-13 和 1-14 页 Marathon 转鼓和传输装置 安装、操作和维护指导 Allen-Bradley PowerFlex 700 20B-UM002B-EN-P 5554E 驱动电机 Johnson 空调装置 资料 安装和操作指导 997-349-7 故障排除 10.99 技术数据和回路图 无编号 安装、操作和维护指导 ML384 MiniPurge 1 型产品手册 ML306 温度控制元件 DTS 空调装置 Expo 技术公司控制柜吹扫系统 Murphy 冲击/振动开关 型号为 VS2EX 09 年 10 月 30 日 安装指导 VS-7037N 10-1 DE-7200VFD 离心机 Chapter 4 Troubleshooting Chapter 4 provides information to guide you in troubleshooting the PowerFlex 700. Included is a listing and description of drive faults (with possible solutions, when applicable) and alarms. For information on… Faults and Alarms Drive Status Manually Clearing Faults Fault Descriptions Clearing Alarms Alarm Descriptions Common Symptoms and Corrective Actions Testpoint Codes and Functions See page… 4-1 4-2 4-4 4-4 4-9 4-10 4-13 4-16 Faults and Alarms A fault is a condition that stops the drive. There are three fault types. Type Fault Description ➀ Auto-Reset Run When this type of fault occurs, and [Auto Rstrt Tries] (see page 3-30) is set to a value greater than “0,” a user-configurable timer, [Auto Rstrt Delay] (see page 3-30) begins. When the timer reaches zero, the drive attempts to automatically reset the fault. If the condition that caused the fault is no longer present, the fault will be reset and the drive will be restarted. Non-Resettable This type of fault normally requires drive or motor repair. The ➁ cause of the fault must be corrected before the fault can be cleared. The fault will be reset on power up after repair. ➂ User Configurable These faults can be enabled/disabled to annunciate or ignore a fault condition. An alarm is a condition that, if left untreated, may stop the drive. There are two alarm types. Type Alarm Description ➀ User Configurable These alarms can be enabled or disabled through [Alarm Config 1] on page 3-44. Non-Configurable These alarms are always enabled. ➁ 4-2 Troubleshooting Drive Status The condition or state of your drive is constantly monitored. Any changes will be indicated through the LEDs and/or the HIM (if present). Front Panel LED Indications Figure 4.1 Typical Drive Status Indicators POWER STS Frames 0&1 S.M.A.R.T. Exit Esc Sel Alt Lang Auto / Man 7 8 9 4 5 6 1 2 3 . 0 POWER STS Remove ➋ Jog +/Param # Exp ➊ S.M.A.R.T. Exit Esc Sel Lang 7 8 4 5 1 2 . 0 Alt Exp PORT PORT MOD MOD NET A NET A NET B NET B Auto / Man Remove 9 6 Jog 3 +/Param # ➌ CAUTION HOT surfaces can cause severe burns # ➊ ➋ Name Color PWR Green (Power) STS Green (Status) Yellow See page 4-10 ➌ PORT MOD NET A NET B Red See page 4-4 Green Yellow Red Red Frames 2&3 CAUTION HOT surfaces can cause severe burns State Steady Description Illuminates when power is applied to the drive. Flashing Steady Flashing, Drive Stopped Flashing, Drive Running Steady, Drive Running Flashing Steady Drive ready, but not running & no faults are present. Drive running, no faults are present. A start inhibit condition exists, the drive cannot be started. Check parameter 214 [Start Inhibits]. An intermittent type 1 alarm condition is occurring. Check parameter 211 [Drive Alarm 1]. A continuous type 1 alarm condition exists. Check parameter 211 [Drive Alarm 1]. Fault has occurred. Check [Fault x Code] or Fault Queue. A non-resettable fault has occurred. – – – – Status of DPI port internal communications (if present). Status of communications module (when installed). Status of network (if connected). Status of secondary network (if connected). Troubleshooting 4-3 Precharge Board LED Indications Precharge Board LED indicators are found on Frame 5 & 6 drives. The LEDs are located above the “Line Type” jumper shown in Figure 1.2. Name Color State Power Green Steady Alarm Yellow Flashing [1] [2] [3] [4] [5] [6] [7] Fault Red Flashing [2] [4] (1) (2) Description Indicates when precharge board power supply is operational Number in “[ ]” indicates flashes and associated alarm (1): Low line voltage (<90%). Very low line voltage (<50%). Low phase (one phase <80% of line voltage). Frequency out of range or asymmetry (line sync failed). Low DC bus voltage (triggers ride-through operation). Input frequency momentarily out of range (40-65 Hz). DC bus short circuit detection active. Number in “[ ]” indicates flashes and associated fault (2): DC bus short (Udc <2% after 20 ms). Line sync failed or low line (Uac <50% Unom). An alarm condition automatically resets when the condition no longer exists A fault indicates a malfunction that must be corrected and can only be reset after cycling power. HIM Indication The LCD HIM also provides visual notification of a fault or alarm condition. Condition Drive is indicating a fault. The LCD HIM immediately reports the fault condition by displaying the following. • “Faulted” appears in the status line • Fault number • Fault name • Time that has passed since fault occurred Press Esc to regain HIM control. Drive is indicating an alarm. The LCD HIM immediately reports the alarm condition by displaying the following. • Alarm name (Type 2 alarms only) • Alarm bell graphic Display F-> Faulted Auto 0.0 Hz Fault — F — 5 Main Menu: OverVoltage Diagnostics Time Since Fault 0000:23:52 Parameter F-> Power Loss 0.0 Hz Main Menu: Diagnostics Parameter Device Select Auto 4-4 Troubleshooting Manually Clearing Faults Step 1. Press Esc to acknowledge the fault. The fault information will be removed so that you can use the HIM. Key(s) Esc 2. Address the condition that caused the fault. The cause must be corrected before the fault can be cleared. 3. After corrective action has been taken, clear the fault by one of these methods. • Press Stop • Cycle drive power • Set parameter 240 [Fault Clear] to “1.” • “Clear Faults” on the HIM Diagnostic menu. Fault Descriptions Type(1) Fault Analog In Loss No. Table 4.A Fault Types, Descriptions and Actions Description An analog input is configured to fault on signal loss. A signal loss has occurred. Configure with [Anlg In 1, 2 Loss] on page 3-52. The checksum read from the analog calibration data does not match the checksum calculated. Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of [Flt RstRun Tries]. Enable/Disable with [Fault Config 1] on page 3-42. Autotune function was canceled by the user or a fault occurred. Auxiliary input interlock is open. Action 1. Check parameters. 2. Check for broken/loose connections at inputs. Cntl Bd Overtemp 55 The temperature sensor on the Main Control Board detected excessive heat. DB Resistance Resistance of the internal DB resistor is out of range. 1. Check Main Control Board fan. 2. Check surrounding air temperature. 3. Verify proper mounting/cooling. Replace resistor. 29 ➀ ➂ Anlg Cal Chksum 108 Auto Rstrt Tries 33 ➂ AutoTune Aborted 80 Auxiliary Input 2 69 ➀ Replace drive. Correct the cause of the fault and manually clear. Restart procedure. Check remote wiring. Fault Decel Inhibit 24 Drive OverLoad 64 Drive Powerup 49 Excessive Load 79 Encoder Loss 91 Type(1) No. Troubleshooting ➂ Encoder Quad Err 90 Faults Cleared 52 Flt QueueCleared 51 FluxAmpsRef Rang 78 Ground Fault 13 Hardware Fault 93 Hardware Fault 130 Hardware Fault 131 Hardware PTC 18 Heatsink OvrTemp 8 ➀ ➀ Description The drive is not following a commanded deceleration because it is attempting to limit bus voltage. 4-5 Action 1. Verify input voltage is within drive specified limits. 2. Verify system ground impedance follows proper grounding techniques. 3. Disable bus regulation and/or add dynamic brake resistor and/or extend deceleration time. Refer to the Attention statement on page P-4 for further info. Drive rating of 110% for 1 minute Reduce load or extend Accel Time. or 150% for 3 seconds has been exceeded. No fault displayed. Used as a Power Up Marker in the Fault Queue indicating that the drive power has been cycled. Motor did not come up to speed in 1. Uncouple load from motor. the allotted time during autotune. 2. Repeat Autotune. Requires differential encoder. 1. Check Wiring. One of the 2 encoder channel 2. Replace encoder. signals is missing. Both encoder channels changed 1. Check for externally induced state within one clock cycle. noise. 2. Replace encoder. No fault displayed. Used as a marker in the Fault Queue indicating that the fault clear function was performed. No fault displayed. Used as a marker in the Fault Queue indicating that the clear queue function was performed. The value for flux amps 1. Reprogram [Motor NP FLA] with determined by the Autotune the correct motor nameplate procedure exceeds the value. programmed [Motor NP FLA]. 2. Repeat Autotune. A current path to earth ground Check the motor and external wiring greater than 25% of drive rating. to the drive output terminals for a grounded condition. Hardware enable is disabled 1. Check jumper. (jumpered high) but logic pin is 2. Replace Main Control Board. still low. Gate array load error. 1. Cycle power. 2. Replace Main Control Board. Dual port failure. 1. Cycle power. 2. Replace Main Control Board. Motor PTC (Positive Temperature Coefficient) Overtemp. Heatsink temperature exceeds 1. Verify that maximum ambient 100% of [Drive Temp]. temperature has not been exceeded. 2. Check fan. 3. Check for excess load. Fault HW OverCurrent 12 Incompat MCB-PB 106 I/O Comm Loss 121 I/O Failure 122 Type(1) Troubleshooting No. 4-6 ➀ ➁ Input Phase Loss 17 IR Volts Range 77 IXo VoltageRange 87 Load Loss 15 Motor Overload 7 Motor Thermistor 16 NVS I/O Checksum 109 NVS I/O Failure 110 Output PhaseLoss 21 ➀ ➂ Description The drive output current has exceeded the hardware current limit. Action Check programming. Check for excess load, improper DC boost setting, DC brake volts set too high or other causes of excess current. Drive rating information stored on Load compatible version files into the power board is incompatible drive. with the main control board. I/O Board lost communications Check connector. Check for induced with the Main Control Board. noise. Replace I/O board or Main Control Board. I/O was detected, but failed the Replace Main Control Board. powerup sequence. The DC bus ripple has exceeded Check incoming power for a missing a preset level. phase/blown fuse. “Calculate” is the autotune default Re-enter motor nameplate data. and the value determined by the autotune procedure for IR Drop Volts is not in the range of acceptable values. Voltage calculated for motor 1. Check for proper motor sizing. inductive impedance exceeds 2. Check for correct programming of 25% of [Motor NP Volts]. [Motor NP Volts], parameter 41. 3. Additional output impedance may be required. Drive output torque current is 1. Verify connections between motor below [Load Loss Level] for a time and load. period greater than [Load Loss 2. Verify level and time time]. requirements. Internal electronic overload trip. An excessive motor load exists. Enable/Disable with [Fault Config Reduce load so drive output current does not exceed the current set by 1] on page 3-42. [Motor NP FLA]. Thermistor output is out of range. 1. Verify that thermistor is connected. 2. Motor is overheated. Reduce load. EEprom checksum error. 1. Cycle power and repeat function. 2. Replace Main Control Board. EEprom I/O error. 1. Cycle power and repeat function. 2. Replace Main Control Board. Current in one or more phases Check the drive and motor wiring. has been lost or remains below a Check for phase-to-phase continuity preset level. at the motor terminals. Check for disconnected motor leads. Type(1) No. Troubleshooting 4-7 Fault OverSpeed Limit 25 ➀ OverVoltage 5 ➀ Parameter Chksum 100 ➁ The checksum read from the board does not match the checksum calculated. The drive was commanded to 1. Clear the fault or cycle power to write default values to EEPROM. the drive. 2. Program the drive parameters as needed. A phase to ground fault has been 1. Check the wiring between the detected between the drive and drive and motor. motor in this phase. 2. Check motor for grounded phase. 3. Replace drive. Excessive current has been 1. Check the motor and drive output detected between these two terminal wiring for a shorted output terminals. condition. 2. Replace drive. ➁ DPI port stopped communicating. 1. If adapter was not intentionally disconnected, check wiring to the A SCANport device was port. Replace wiring, port connected to a drive operating expander, adapters, Main Control DPI devices at 500k baud. Board or complete drive as required. 2. Check HIM connection. 3. If an adapter was intentionally disconnected and the [Logic Mask] bit for that adapter is set to “1”, this fault will occur. To disable this fault, set the [Logic Mask] bit for the adapter to “0.” The communications card has a 1. Check DPI device event queue fault. and corresponding fault information for the device. DC bus voltage remained below Monitor the incoming AC line for low 85% of nominal for longer than voltage or line power interruption. [Power Loss Time]. Enable/ Disable with [Fault Config 1] on page 3-42. Params Defaulted 48 Phase U to Grnd 38 Phase V to Grnd 39 Phase W to Grnd 40 Phase UV Short 41 Phase VW Short 42 Phase UW Short 43 Port 1-5 DPI Loss 8185 Port 1-5 Adapter 7175 Power Loss 3 ➀ ➂ Description Functions such as Slip Compensation or Bus Regulation have attempted to add an output frequency adjustment greater than that programmed in [Overspeed Limit]. DC bus voltage exceeded maximum value. Action Remove excessive load or overhauling conditions or increase [Overspeed Limit]. Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option. 1. Restore defaults. 2. Reload User Set if used. Fault Power Unit 70 Pulse In Loss 92 Type(1) Troubleshooting No. 4-8 Pwr Brd Chksum1 104 Pwr Brd Chksum2 105 ➁ Replaced MCB-PB 107 ➁ See Manual 28 Shear Pin 63 Software Fault Software Fault SW OverCurrent 88 89 36 ➂ ➀ TorqPrv Spd Band 20 Trnsistr OvrTemp 9 ➀ Description One or more of the output transistors were operating in the active region instead of desaturation. This can be caused by excessive transistor current or insufficient base drive voltage. Z Channel is selected as a pulse input and no signal is present. The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data. The checksum read from the board does not match the checksum calculated. Main Control Board was replaced and parameters were not programmed. Encoderless TorqProve has been enabled but user has not read and understood application concerns of encoderless operation. Programmed [Current Lmt Val] has been exceeded. Enable/ Disable with [Fault Config 1] on page 3-42. Microprocessor handshake error. Microprocessor handshake error. Drive output current has exceeded the 1ms current rating. This rating is greater than the 3 second current rating and less than the hardware overcurrent fault level. It is typically 200- 250% of the drive continuous rating Difference between [Commanded Speed] and [Encoder Speed] has exceeded the level set in [Spd Dev Band] for a time period greater than [Spd Band Integrat]. Output transistors have exceeded their maximum operating temperature. Action 1. Check for damaged output transistors. 2. Replace drive. 1. Check wiring. 2. Replace pulse generator. Clear the fault or cycle power to the drive. 1. Cycle power to the drive. 2. If problem persists, replace drive. 1. Restore defaults. 2. Reprogram parameters. 1. Read the “Attention” on page C-5 relating to the use of TorqProve with no encoder. Check load requirements and [Current Lmt Val] setting. Replace Main Control Board. Replace Main Control Board. Check for excess load, improper DC boost setting. DC brake volts set too high. 1. Check wiring between drive and motor. 2. Check release of mechanical brake. 1. Verify that maximum ambient temperature has not been exceeded. 2. Check fan. 3. Check for excess load. 4 UserSet1 Chksum 101 UserSet2 Chksum 102 UserSet3 Chksum 103 (1) Type(1) Fault UnderVoltage No. Troubleshooting ➀ ➂ ➁ ➁ ➁ Description DC bus voltage fell below the minimum value of 407V DC at 400/480V input or 204V DC at 200/240V input. Enable/Disable with [Fault Config 1] (page 3-42). The checksum read from the user set does not match the checksum calculated. 4-9 Action Monitor the incoming AC line for low voltage or power interruption. Re-save user set. See page 4-1 for a description of fault types. Table 4.B Fault Cross Reference No.(1) 2 3 4 5 7 8 9 12 13 15 16 17 20 21 24 25 28 29 33 36 (1) Fault Auxiliary Input Power Loss UnderVoltage OverVoltage Motor Overload Heatsink OvrTemp Trnsistr OvrTemp HW OverCurrent Ground Fault Load Loss Motor Thermistor Input Phase Loss TorqPrv Spd Band Output PhaseLoss Decel Inhibit OverSpeed Limit See Manual Analog In Loss Auto Rstrt Tries SW OverCurrent No. (1) 38 39 40 41 42 43 48 49 51 52 55 63 64 69 70 71- 75 77 78 79 80 Fault Phase U to Grnd Phase V to Grnd Phase W to Grnd Phase UV Short Phase VW Short Phase UW Short Params Defaulted Drive Powerup Flt QueueCleared Faults Cleared Cntl Bd Overtemp Shear Pin Drive OverLoad DB Resistance Power Unit Port 1-5 Adapter IR Volts Range FluxAmpsRef Rang Excessive Load AutoTune Aborted No. (1) 81- 85 87 88 89 90 91 92 93 100 101-103 104 105 106 107 108 120 121 122 130 131 Fault Port 1-5 DPI Loss IXo VoltageRange Software Fault Software Fault Encoder Quad Err Encoder Loss Pulse In Loss Hardware Fault Parameter Chksum UserSet Chksum Pwr Brd Chksum1 Pwr Brd Chksum2 Incompat MCB-PB Replaced MCB-PB Anlg Cal Chksum I/O Mismatch I/O Comm Loss I/O Failure Hardware Fault Hardware Fault Fault numbers not listed are reserved for future use. Clearing Alarms Alarms are automatically cleared when the condition that caused the alarm is no longer present. 4-10 Troubleshooting Alarm Descriptions Type(1) Alarm AdjVoltRef Cflct Analog In Loss Bipolar Conflict No. Table 4.C Alarm Descriptions and Actions 33 ➀ 5 ➀ 20 ➁ Brake Slipped 32 ➁ Decel Inhibt 10 Dig In ConflictA 17 ➀ ➁ Description Invalid adjustable voltage reference selection conflict. An analog input is configured for “Alarm” on signal loss and signal loss has occurred. Parameter 190 [Direction Mode] is set to “Bipolar” or “Reverse Dis” and one or more of the following digital input functions is configured: “Fwd/Reverse,” “Run Forward,” “Run Reverse,” “Jog Forward” or “Jog Reverse.” Encoder movement has exceeded the level in [BrkSlipCount] after the brake was set. Drive is being inhibited from decelerating. Digital input functions are in conflict. Combinations marked with a “ ” will cause an alarm. Acc2/Dec2 Accel 2 Decel 2 Jog 1/2 Jog Fwd Jog Rev Fwd/Rev Acc2/Dec2 Accel 2 Decel 2 Jog 1/2 Jog Fwd Jog Rev Fwd/Rev Dig In ConflictB 18 ➁ A digital Start input has been configured without a Stop input or other functions are in conflict. Combinations that conflict are marked with a “ ” and will cause an alarm. Start StopJog Fwd/ CF Run Run Fwd Run Rev 1/2 Jog Fwd Jog Rev Rev Start Stop-CF Run Run Fwd Run Rev Jog 1/2 Jog Fwd Jog Rev Fwd/Rev Dig In ConflictC 19 ➁ More than one physical input has been configured to the same input function. Multiple configurations are not allowed for the following input functions. Forward/Reverse Speed Select 1 Speed Select 2 Speed Select 3 Run Forward Run Reverse Jog Forward Jog Reverse Run Stop Mode B Bus Regulation Mode B Acc2 / Dec2 Accel 2 Decel 2 Drive OL Level 2 Type(1) Alarm Drive OL Level 1 No. Troubleshooting 8 ➀ 9 ➀ FluxAmpsRef 26 Rang Ground Warn 15 Home Not Set 34 ➁ ➀ ➀ In Phase Loss IntDBRes OvrHeat IR Volts Range 13 ➀ 6 ➀ 25 ➁ Ixo Vlt Rang 28 ➁ Load Loss 14 MaxFreq Conflict 23 Motor Thermistor Motor Type Cflct 12 21 ➁ NP Hz Conflict PI Config Conflict 22 ➁ 52 ➁ ➁ 4-11 Description The calculated IGBT temperature requires a reduction in PWM frequency. If [Drive OL Mode] is disabled and the load is not reduced, an overload fault will eventually occur. The calculated IGBT temperature requires a reduction in Current Limit. If [Drive OL Mode] is disabled and the load is not reduced, an overload fault will eventually occur. The calculated or measured Flux Amps value is not within the expected range. Verify motor data and rerun motor tests. Ground current has exceeded the level set in [Gnd Warn Level]. Configurable alarm set in parameter 259, bit 17. When set to “1,” this alarm is displayed when any of the following occur: • parameter 88 is set to “7” (Pos/Spd Prof) • on power up and parameter 88 = “7” • recall user sets and parameter 88 = “7” Alarm is cleared when: • setting parameter 88 to a value other than “7” • reset defaults • parameter 259, bit 17 is cleared • a digital input is configured as “Set Home” and input is True • parameter 705, bit 9 is “Enabled” • parameter 700, bit 13 (At Home) is “Enabled” - position regulator will set this bit if device is “home” The DC bus ripple has exceeded the level in [Phase Loss Level]. The drive has temporarily disabled the DB regulator because the resistor temperature has exceeded a predetermined value. The drive auto tuning default is “Calculate” and the value calculated for IR Drop Volts is not in the range of acceptable values. This alarm should clear when all motor nameplate data is properly entered. Motor leakage inductance is out of range. Output torque current is below [Load Loss Level] for a time period greater than [Load Loss time]. The sum of [Maximum Speed] and [Overspeed Limit] exceeds [Maximum Freq]. Raise [Maximum Freq] or lower [Maximum Speed] and/or [Overspeed Limit] so that the sum is less than or equal to [Maximum Freq]. The value at the thermistor terminals has been exceeded. [Motor Type] has been set to “Synchr Reluc” or “Synchr PM” and one or more of the following exist: • [Torque Perf Mode] = “Sensrls Vect,” “SV Economize” or “Fan/Pmp V/Hz.” • [Flux Up Time] is greater than 0.0 Secs. • [Speed Mode] is set to “Slip Comp.” • [Autotune] = “Static Tune” or “Rotate Tune.” Fan/pump mode is selected in [Torq Perf Mode] and the ratio of [Motor NP Hertz] to [Maximum Freq] is greater than 26. Check [PI Configuration], both “AdjVoltTrim” & “Torque Trim” are selected. Alarm Power Loss 3 Type(1) Troubleshooting No. 4-12 ➀ ➀ Precharge Active Prof Step Cflct 1 50 ➁ PTC Conflict 31 ➁ Sleep Config 29 ➁ Speed Ref Cflct Start At PowerUp TB Man Ref Cflct 27 ➁ 4 ➀ 30 ➁ Description Drive has sensed a power line loss. Drive is in the initial DC bus precharge state. An error is detected in trend step(s). • Set if Sleep Mode is enabled. • Set if: any profile step uses “Encoder Incr” and/or “Enc Absolute” and [Motor Cntl Sel], parameter 53 is not set to “FVC Vector” and [Feedback Select], parameter 80 is not set to “Encoder” or “Simulator” and [Speed/Torque Mod], parameter 88 = “7” (Pos/Spd Prof). • a Step Type is configured for “Dig Input” and the Step Value is greater than 6, less than –6, or zero or the digital input selected with [Digital Inx Sel] is not set to “57, Prof Input.” • Cleared if none of the above occur. PTC is enabled for Analog In 1, which is configured as a 0-20 mA current source in [Anlg In Config]. Sleep/Wake configuration error. With [Sleep-Wake Mode] = “Direct,” possible causes include: drive is stopped and [Wake Level] < [Sleep Level].“Stop=CF,” “Run,” “Run Forward,” or “Run Reverse.” is not configured in [Digital Inx Sel]. [Speed Ref x Sel] or [PI Reference Sel] is set to “Reserved”. [Start At PowerUp] is enabled. Drive may start at any time within 10 seconds of drive powerup. Occurs when: • “Auto/Manual” is selected (default) for [Digital In3 Sel], parameter 363 and • [TB Man Ref Sel], parameter 96 has been reprogrammed. No other use for the selected analog input may be programmed. Example: If [TB Man Ref Sel] is reprogrammed to “Analog In 2,” all of the factory default uses for “Analog In 2” must be reprogramed (such as parameters 90, 117, 128 and 179). See also Auto/Manual Examples on page 1-22. TorqProve 49 Cflct UnderVoltage 2 VHz Neg Slope 24 Waking (1) 11 ➁ ➀ ➁ ➀ To correct: • Verify/reprogram the parameters that reference an analog input or • Reprogram [Digital In3] to another function or “Unused.” When [TorqProve Cnfg] is enabled, [Motor Cntl Sel], [Feedback Select] and [Motor Fdbk Type] must be properly set (refer to page C-7). The bus voltage has dropped below a predetermined value. [Torq Perf Mode] = “Custom V/Hz” & the V/Hz slope is negative. The Wake timer is counting toward a value that will start the drive. See page 4-1 for a description of alarm types. Troubleshooting 4-13 Table 4.D Alarm Cross Reference No. (1) 1 2 3 4 5 6 8 9 10 11 12 13 (1) Alarm Precharge Active UnderVoltage Power Loss Start At PowerUp Analog in Loss IntDBRes OvrHeat Drive OL Level 1 Drive OL Level 2 Decel Inhibt Waking Motor Thermistor In Phase Loss No. (1) 14 15 17 18 19 20 21 22 23 24 25 26 Alarm Load Loss Ground Warn Dig In ConflictA Dig In ConflictB Dig In ConflictC Bipolar Conflict Motor Type Cflct NP Hz Conflict MaxFreq Conflict VHz Neg Slope IR Volts Range FluxAmpsRef Rang No. (1) 27 28 29 30 31 32 33 34 49 50 52 Alarm Speed Ref Cflct Ixo Vlt Rang Sleep Config TB Man Ref Cflct PTC Conflict Brake Slipped AdjVoltRef Cflct Home Not Set Torq Prove Cflct Prof Step Cflct PI Config Conflict Alarm numbers not listed are reserved for future use. Common Symptoms and Corrective Actions Drive does not Start from Start or Run Inputs wired to the terminal block. Cause(s) Drive is Faulted Indication Flashing red status light Incorrect input wiring. See pages 1-19 & 1-20 for wiring examples. • 2 wire control requires Run, Run Forward, Run Reverse or Jog input. • 3 wire control requires Start and Stop inputs. • Jumper from terminal 25 to 26 is required. Incorrect digital input programming. • Mutually exclusive choices have been made (i.e., Jog and Jog Forward). • 2 wire and 3 wire programming may be conflicting. • Exclusive functions (i.e, direction control) may have multiple inputs configured. • Stop is factory default and is not wired. None None Corrective Action Clear fault. • Press Stop • Cycle power • Set [Fault Clear] to 1 (See page 3-42) • “Clear Faults” on the HIM Diagnostic menu. Wire inputs correctly and/or install jumper. Program [Digital Inx Sel] for correct inputs. (See page 3-55) Start or Run programming may be missing. Flashing yellow Program [Digital Inx Sel] to resolve status light and conflicts. (See page 3-55) “DigIn CflctB” Remove multiple selections for the indication on same function. LCD HIM. Install stop button to apply a signal at [Drive Status 2] stop terminal. shows type 2 alarm(s). 4-14 Troubleshooting Drive does not Start from HIM. Cause(s) Drive is programmed for 2 wire control. HIM Start button is disabled for 2 wire control. Indication None Corrective Action If 2 wire control is required, no action needed. See [Save HIM Ref] on page 3-34. If 3 wire control is required, program [Digital Inx Sel] for correct inputs. (See page 3-55) Drive does not respond to changes in speed command. Cause(s) Indication Corrective Action No value is coming from the source LCD HIM Status 1. If the source is an analog input, check of the command. Line indicates wiring and use a meter to check for “At Speed” and presence of signal. output is 0 Hz. 2. Check [Commanded Speed] for correct source. (See page 3-7) Incorrect reference source has None 3. Check [Speed Ref Source] for the source of been programmed. the speed reference. (See page 3-39) 4. Reprogram [Speed Ref A Sel] for correct source. (See page 3-19) Incorrect Reference source is None 5. Check [Drive Status 1], page 3-37, bits 12 being selected via remote device or and 13 for unexpected source selections. digital inputs. 6. Check [Dig In Status], page 3-40 to see if inputs are selecting an alternate source. 7. Reprogram digital inputs to correct “Speed Sel x” option. (See page 3-55) Motor and/or drive will not accelerate to commanded speed. Cause(s) Acceleration time is excessive. Excess load or short acceleration times force the drive into current limit, slowing or stopping acceleration. Indication None None Speed command source or value is None not as expected. Programming is preventing the None drive output from exceeding limiting values. Corrective Action Reprogram [Accel Time x]. (See page 3-26) Check [Drive Status 2], bit 10 to see if the drive is in Current Limit. (See page 3-37) Remove excess load or reprogram [Accel Time x].(See page 3-26) Check for the proper Speed Command using Steps 1 through 7 above. Check [Maximum Speed] (See page 3-17) and [Maximum Freq] (See page 3-10) to assure that speed is not limited by programming. Motor operation is unstable. Cause(s) Indication Motor data was incorrectly entered None or Autotune was not performed. Corrective Action 1. Correctly enter motor nameplate data. 2. Perform “Static” or “Rotate” Autotune procedure. (Param #061, page 3-12) Troubleshooting 4-15 Drive will not reverse motor direction. Cause(s) Digital input is not selected for reversing control. Digital input is incorrectly wired. Direction mode parameter is incorrectly programmed. Motor wiring is improperly phased for reverse. A bipolar analog speed command input is incorrectly wired or signal is absent. Indication None None None None None Corrective Action Check [Digital Inx Sel], page 3-55. Choose correct input and program for reversing mode. Check input wiring. (See page 1-15) Reprogram [Direction Mode], page 3-33 for analog “Bipolar” or digital “Unipolar” control. Switch two motor leads. 1. Use meter to check that an analog input voltage is present. 2. Check wiring. (See page 1-15) Positive voltage commands forward direction. Negative voltage commands reverse direction. Stopping the drive results in a Decel Inhibit fault. Cause(s) The bus regulation feature is enabled and is halting deceleration due to excessive bus voltage. Excess bus voltage is normally due to excessive regenerated energy or unstable AC line input voltages. Internal timer has halted drive operation. Indication Decel Inhibit fault screen. LCD Status Line indicates “Faulted”. Corrective Action 1. See Attention statement on page P-4. 2. Reprogram parameters 161/162 to eliminate any “Adjust Freq” selection. 3. Disable bus regulation (parameters 161 & 162) and add a dynamic brake. 4. Correct AC input line instability or add an isolation transformer. 5. Reset drive. 4-16 Troubleshooting Testpoint Codes and Functions Select testpoint with [Testpoint x Sel], parameters 234/236. Values can be viewed with [Testpoint x Data], parameters 235/237. No. (1) 01 02 03 04 05 06 07 08 09 10 11 12 13 16 17 18 19 22 23 24-29 30 31 32 33 34 35 36 37 (1) (2) Description DPI Error Status Heatsink Temp Active Cur Limit Active PWM Freq Life MegaWatt Hr(2) Life Run Time Life Pwr Up Time Life Pwr Cycles Life MW-HR Fract (2) MW-HR Frac Unit (2) MCB Life Time Raw Analog In 1 Raw Analog In 2 CS Msg Rx Cnt CS Msg Tx Cnt CS Timeout Cnt CS Msg Bad Cnt PC Msg Rx Cnt PC Msg Tx Cnt PC1-6 Timeout Cnt CAN BusOff Cnt No. of Analog Inputs Raw Temperature MTO Norm Mtr Amp DTO-Cmd Frequency DTO-Cmd Cur Lim DTO-Cmd DC Hold Control Bd Temp Units 1 0.1 degC 1 1 Hz 0.0001 MWh 0.0001 Hrs 0.0001 Hrs 1 1 1 0.0001 Hrs 1 1 1 1 1 1 1 1 1 1 1 1 0.1 Amps 1 0.1 1 0.1 Values Minimum 0 –100.0 0 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.0 Maximum 255 100.0 32767 10 214748.3647 214748.3647 214748.3647 4294967295 4294967295 4294967295 214748.3647 65535 65535 255 255 65535 65535 255 65535 x 65535 65535 420 32767 60.0 Default 0 0 0 4 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.0 Enter in [Testpoint x Sel]. Use the equation below to calculate total Lifetime MegaWatt Hours. Value of Code 9 --------------------------------× 0.1 + Value of Code 5 = Total Lifetime MegaWatt Hours Value of Code 10 Installation/Wiring 1-13 Bypass Contactor Precaution ! ATTENTION: An incorrectly applied or installed bypass system can result in component damage or reduction in product life. The most common causes are: • Wiring AC line to drive output or control terminals. • Improper bypass or output circuits not approved by Allen-Bradley. • Output circuits which do not connect directly to the motor. Contact Allen-Bradley for assistance with application or wiring. Disconnecting MOVs and Common Mode Capacitors PowerFlex 700 drives contain protective MOVs and common mode capacitors that are referenced to ground. To guard against drive damage, these devices must be disconnected if the drive is installed on a resistive grounded distribution system or an ungrounded distribution system where the line-to-ground voltages on any phase could exceed 125% of the nominal line-to-line voltage. To disconnect these devices, remove the jumper(s) listed in Table 1.D. Jumpers can be removed by carefully pulling the jumper straight out. See Wiring and Grounding Guidelines for PWM AC Drives, publication DRIVES-IN001 for more information on ungrounded systems. ! ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before removing/installing jumpers. Measure the DC bus voltage at the +DC & –DC terminals of the Power Terminal Block. The voltage must be zero. Table 1.D Jumper Removal (1) Frame Jumper Component Jumper Location No. 0, 1 PEA Common Mode Cap. Remove the I/O Cassette (page 1-16). Jumpers located ➊ on the Power Board (Figure 1.5). PEB MOV’s 2-4 PEA PEB 5 6 Wire Wire (1) ➋ ➌ ➍ Common Mode Cap. Remove the I/O Cassette as described on page 1-16. ➎ Common Mode Cap. Jumpers are located above the Power Terminal Block (see Figure 1.5). MOV’s The green/yellow jumper is located on the back of chassis (see Figure 1.5 for location). Disconnect, insulate and secure the wire to guard against unintentional contact with chassis or components. MOV’s Note location of the two green/yellow jumper wires next to the Power Terminal Block (Figure 1.5). Disconnect, Input Filter Cap. insulate and secure the wires to guard against unintentional contact with chassis or components. Common Mode Cap. Remove the wire guard from the Power Terminal Block. Disconnect the three green/yellow wires from the two MOV’s “PE” terminals shown in Figure 1.4. Insulate/secure the Input Filter Cap. wires to guard against unintentional contact with chassis or components. Important: Do Not remove jumpers if the distribution system is grounded. ➏ 1-14 Installation/Wiring Figure 1.5 Typical Jumper Locations (see Table 1.D for description) ➍ ➌ PE 1 PE 2 MOV-PE JMPR PE 4 PE 3 DC FILTER CAP-PE JMPR ire CW G e 75 Us #14 AW lbs #10- 7 into ue Torq BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 POWER 75C Cu Wire 2 6 AWG [10MM ] Max. 12 IN. LBS. 1.4 N-M } TORQUE ly On CONTROL WIRE STRIP ER NG DA ! PE R/L1 S/L2 T/L3 AUX IN+ AUX OUT– BR1 BR2 DC+ DC– PE ➋ SHLD U/T1 V/T2 3 W/T R/L1 S/L2 T/L3 ➊ Frame 2 Frames 0 & 1 (I/O Cassette Removed) ➌ SHLD ➍ ➎ PE B PE A Optional Communications Module 12 IN. LBS. 1.4 N-M } TORQUE AUX IN + – 75C Cu Wire 3 AWG [25MM2] Max. 16 IN. LBS. 1.8 N-M } TORQUE POWER BR1 BR2 75C Cu Wire 6 AWG [10MM2] Max. CONTROL WIRE STRIP BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 R/L1 S/L2 T/L3 300 VDC EXT PWR SPLY TERM (PS+, PS-) POWER TERMINAL RATINGS WIRE RANGE: 14-1/0 AWG (2.5-35 MM2) TORQUE: 32 IN-LB (3.6 N-M) STRIP LENGTH: 0.67 IN (17 MM) USE 75° C CU WIRE ONLY GROUND TERMINAL RATINGS (PE) WIRE RANGE: 22-10 AWG (0.5-4 MM2) TORQUE: 5.3 IN-LB (0.6 N-M) STRIP LENGTH: 0.35 IN (9 MM) 9 17 WIRE RANGE: 6-1/0 AWG (16-35 MM2) TORQUE: 44 IN-LB (5 N-M) STRIP LENGTH: 0.83 IN (21 MM) PE 21 OUTPUT INPUT AC SHLD SHLD Important: Do Not discard or replace grounding hardware. Frames 3 & 4 ➏ Frame 5 Installation, Operation and Maintenance Instructions for AC Induction Motors 56- 6800 Frames (NEMA) 63 – 280 Frames (IEC) MARATHON ELECTRIC Contact Motor Customer Service at: Phone: (715) 675-3311 www.marathonelectric.com Form 5554E INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE OWNER: READ AND SAVE THESE INSTRUCTIONS SAFETY INSTRUCTIONS This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING Before installing, using, or servicing this product, carefully read and fully understand the instructions including all warnings, cautions, & safety notice statements. To reduce risk of personal injury, death and/or property damage, follow all instructions for proper motor installation, operation and maintenance. These instructions are not intended as a complete listing of all details for installation, operation, and maintenance. If you have any questions concerning any of the procedures, STOP, and call the appropriate Regal-Beloit motor company. Table of Contents 1.0 INSTALLER / OWNER / OPERATOR RESPONSIBILITY 1.1 Electrical Safety 1.2 Mechanical Safety Environmental Safety 1.3 2.0 RECEIVING & INSPECTION 2.1 Initial Inspection 2.1.1 Packing List & Inspect 2.1.2 Turn Motor Shaft 2.1.3 Check Nameplate 2.2 Handling 2.2.1 Correct Lifting Angles 2.3 Storage 2.3.1 Bearing Lubrication 2.3.2 Shaft Rotation 2.3.3 Damp or Humid Storage Locations 3.0 INSTALLATION AND OPERATION 3.1 Location 3.1.1 Selecting a Location 3.1.2 Ambient Temperature Limits 3.1.3 Construction Selection per Location 3.1.3.1 Dripproof 3.1.3.2 Totally Enclosed 3.1.3.3 Hazardous Locations Motors 3.2 Mounting Motor 3.2.1 Rigid Base (Footed) 3.2.2 Rigid Base Hole Selection -6 or 8 Hole Bases 3.2.3 Vertical 3.3 Application Assembly to Motor 3.3.1 General: Proper Alignment 3.3.2 Direct Coupling 3.3.3 Direct Connected 3.3.4 Belted 3.3.5 VFD Operation 3.3.6 Accessories 3.3.6.1 General 3.3.6.2 Brake Motors 3.3.6.3 Space Heaters 3.3.6.4 Thermal Protection General, Thermostats, Thermisters & RTDs 3.3.6.5 RTD Alarm & Trip Settings 3.3.7 Guards 3.4 Electrical Connections 3.4.1 Power Supply / Branch Circuit 3.4.1.1 Branch Circuit Supply 3.4.1.2 Fuses, Breakers, Overload Relays 3.4.1.3 AC Power Supply Limits 3.4.2 Terminal Box 3.4.2.1 Conduit opening 3.4.2.2 Hazardous Locations 3.4.3 Lead Connections 3.4.3.1 Wire Size Requirements (Single Phase) 3.4.3.2 Extension Cords (Single Phase) 3.4.4 Ground Connections 3.4.5 Start Up 3.4.5.1 Start Up – No Load Procedure 3.4.5.2 Start Up – Load Connected Procedure 3.4.5.3 Jogging and/or repeated starts 4.0 MAINTENANCE 4.1 General Inspection 4.1.1 Ventilation 4.2.3 Lubrication Interval 4.1.2 Insulation 4.2.4 Lubrication Procedure 4.1.3 Electrical Connections 4.2.5 Lubrication Example 4.2 Lubrication and Bearings 4.3 Trouble Shooting 4.2.1 Grease Type 4.3.1 General Trouble-Shooting Warnings 4.2.2 Bearing Operating Temperature 4.3.2 Trouble-Shooting Cause / Corrective Action _________________________________________________________________________________________________________________________ motor is suitable for use on Pulse Width Modulated (PWM) type VFD power. In addition, the nameplate must be marked with the inverter rating; for example, “2:1 CT”, “2 to 1 Constant Torque”, etc. 1.0 INSTALLER/OWNER/OPERATOR RESPONSIBILITY: 1.1 ELECTRICAL SAFETY WARNING: ELECTRICAL SHOCK HAZARD Electrical connections shall be made by a qualified electrical personnel in accordance with all applicable codes, ordinances and sound practices. Failure to follow these instructions could result in serious personal injury, death and/or property damage. Only qualified personnel who are familiar with the applicable National Code (USA = NEC) and local codes should install or repair electrical motors and their accessories. WARNING: ELECTRICAL LIVE CIRCUIT HAZARD Do not touch electrically live parts. Disconnect, lockout and tag input power supply before installing or servicing motor (includes accessory devices). Use a voltmeter to verify that power is off before contacting conductors. WARNING: ELECTRICAL GROUNDING HAZARD Failure to properly ground motors, per the National Electrical Code (NEC) Article 430 and local codes may cause serious injury or death to personnel. For general information on grounding refer to NEC Article 250. (Also see “Ground Connections section 3.4.4“). WARNING: AUTOMATIC RESET PROTECTOR HAZARD Do not use automatic reset protectors if automatically restarting the motor will place personnel or equipment at risk. . Failure to follow this instruction could result in serious personal injury, death and/or property damage WARNING: MANUAL RESET PROTECTOR HAZARD If a tripped manual reset thermal protector is exposed to a temperature less than –7°C (20°F) it may reset and restart the motor automatically. If an application requires a motor with a manual reset thermal protector that will be operated at temperatures less than –7°C (20°F) contact the manufacturer to review the application / motor requirements. Failure to follow this instruction could result in serious personal injury, death and/or property damage 1.2 MECHANICAL SAFETY WARNING: LOOSE PARTS HAZARD Before starting the motor, remove all unused shaft keys and loose rotating parts to prevent them from flying off. Failure to follow these instructions could result in serious personal injury, death and/or property damage. 2.0 RECEIVING AND INSPECTION 2.1 INITIAL INSPECTIONS 2.1.1 CHECK PACKING LIST AND INSPECT the packaging to make certain no damage has occurred in shipment. If there is visible damage to the packaging, unpack and inspect the motor immediately. Claims for any damage done in shipment must be made by the purchaser against the transportation company. 2.1.2 TURN MOTOR SHAFT by hand to be certain that it rotates freely. Note: Shaft seals and bearing seals may add drag. 2.1.3 CHECK NAMEPLATE for conformance with purchase order requirements and compliance with power supply and control equipment requirements. 2.2 HANDLING: WARNING: FALLING OBJECT HAZARD Eyebolts or lifting lugs, where provided, are intended for lifting only the motor and accessories mounted by the motor manufacturer (unless specifically stated otherwise on the motor). Utilizing the motor lifting provision to lift other components such as pumps and gear boxes could result in serious personal injury, death and/or property damage. WARNING: FALLING OBJECT HAZARD Before using the lifting provision, check the eyebolts and/or other lifting means to assure they are not bent or damaged and are completely threaded, seated & secured to the motor. Equipment to lift motor must have adequate lifting capacity. While lifting the motor DO NOT stand under or in the vicinity of the motor. Failure to follow these instructions could result in serious personal injury, death and/or property damage. 2.2.1 LIFTING ANGLE LIMITATIONS WARNING: ROTATING PARTS HAZARD Keep extremities, hair, jewelry and clothing away from moving parts. Failure to follow these instructions could result in serious personal injury, death and/or property damage. 1.3 ENVIRONMENTAL SAFETY WARNING: HAZARDOUS LOCATIONS (1) The NEC and the local authority having jurisdiction must be consulted concerning the installation and suitability of motors for use in Hazardous Locations. The local authority having jurisdiction must make the final determination of what type of motor is required. The application and operation is beyond the control of the motor manufacturer. (2) Division 1 Hazardous Locations motors can only be modified or reworked by the manufacturer or a facility that is Listed under UL’s category “Motors and Generators, Rebuilt for use in Hazardous Locations”. Failure to follow these instructions could result in serious personal injury, death and/or property damage. (3) Do not use a Hazardous Locations motor with a Variable Frequency Drive (VFD) unless the motor nameplate specifically states that the 2.3 STORAGE: Motors, not put into service immediately, must be stored indoors in a clean, dry location. Avoid locations with large temperature swings that will result in condensation. Motors must be covered to eliminate airborne dust and dirt. If the storage location exhibits high vibration, place isolation pads under motor to minimize damage to motor bearings. 2.3.1 BEARING LUBRICATION: Bearings are grease packed at the factory; relubrication upon receipt of motor or while in storage is not necessary. If stored more than one year, add grease per lubrication instructions (Table 4-4) before start-up. 2.3.2 SHAFT ROTATION: It is recommended that the motor shaft be rotated 5 to 10 rotations every three months to distribute the grease in the bearings. This will reduce the chance for corrosion to form on the bearing rolling elements and raceways. Note: Shaft seals and bearing seals may add drag. 2.3.3 DAMP OR HUMID STORAGE LOCATIONS: Treat unpainted flanges, shafts, and fittings with a rust inhibitor. Apply appropriate power to the motor’s space heaters (if so equipped) 3.0 INSTALLATION AND OPERATION WARNING: Only qualified personnel who are familiar with the appropriate national code, local codes and sound practices should install or repair electrical motors and their accessories. Installation should conform to the appropriate national code as well as local codes and sound practices. Failure to follow these instructions could result in serious personal injury, death and/or property damage. WARNING: ELECTRICAL LIVE CIRCUIT HAZARD Do not touch electrically live parts. Disconnect, Lockout and Tag input power supply before installing or servicing motor (includes accessory devices). Use a voltmeter to verify that power is off before contacting conductors. 3.1 LOCATION 3.1.1 SELECTING A LOCATION: Consideration should be given to environment and ventilation. Motors should be installed in an area that is protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and vibration. A motor with the proper enclosure for the expected operating condition should be selected. Provide accessible clearance for cleaning, repair, service, and inspections (See section 3.1.3 for construction clearances). The location should be considered for possible future motor removal / handling. The free flow of air around the motor should not be obstructed. 3.1.2 AMBIENT TEMPERATURE LIMITS: The ambient temperatures of the air inlet to the motor should not exceed 40°C (104°F) or be less than -30°C (-22°F) unless the motor nameplate specifically states an ambient temperature outside of these limits. The ambient inside an enclosure built around the motor shall not exceed the nameplate ambient. For ambient temperatures outside of these limits consult the motor manufacturer. TEFC (Totally Enclosed Fan Cooled) motors must meet a minimum distance of ½ the shaft height between the fan guard grill openings and the nearest obstruction. 3.1.3.3 HAZARDOUS LOCATIONS MOTORS: Hazardous Locations motors are intended for installations in accordance with NEC Article 500. For all installations involving Hazardous Locations motors, consult the applicable national codes, local codes, and the authority having jurisdiction. Division 1 Installations – includes Class I & II: Use only motors that are UL Listed and CSA Certified or UL Listed and UL Certified for Canada. These motors bear a separate nameplate that includes the UL Listing Mark and CSA Certification Mark or includes the UL Listing Mark and the UL Mark for Canada. This plate also bears the phrase: “ Electric motor for Hazardous Locations” and is marked with the Class, Group and Operating Temperature Code. Division 2 Installations – Class I only: Use only motors that are CSA Certified and bear the CSA Certification Mark. These motors include a phrase on the main motor nameplate that indicates the motor is CSA Certified for Class I, Division 2 / Zone 2 locations. Division 2 Installation – Class II only: Use only Class II motors as described above under “Division I Installations”. WARNING: EXPLOSION HAZARD A motor should never be placed in an area with a hazardous process or where flammable gases or combustible materials may be present unless it is specifically designed and nameplated for this type of service. Hazardous Locations motors are intended for installations in accordance with NEC Article 500. For all installations involving Hazardous Locations motors, consult the NEC, local codes, and the authority having jurisdiction. Failure to follow these instructions could result in serious personal injury, death and/or property damage. (For other limitations see section 1.3) 3.2 MOUNTING MOTOR: 3.2.1 RIGID BASE (FOOTED): The motor must be securely installed to a rigid foundation or a mounting surface to minimize vibration and maintain alignment between the motor shaft and the load’s shaft. The mounting surfaces of the four mounting pads must be flat within 0.01 inches for 210 frame & smaller; 0.015 inches for 250 frame & larger. [IEC 0.25 mm for 130 frame & smaller, 0.38 mm for 160 frame & larger]. This may be accomplished by shims under the motor feet. For special isolation mounting, contact manufacturer for assistance 3.2.2 RIGID BASE HOLE SELECTION -6 OR 8 HOLES CAUTION: INSULATION DEGRADATION WARNING Insulation at high temperatures ages at an accelerated rate. Each 10°C increase in temperature reduces the insulation life by one half. WARNING: HAZARDOUS LOCATIONS AMBIENT LIMIT: Division 1 Hazardous Locations motors shall NOT be operated below –25°C (-13°F) ambient. (Low temperatures reduce the component mechanical properties.) 3.1.3 CONSTRUCTION SELECTION per LOCATION: 3.1.3.1 DRIPPROOF (OPEN) MOTORS are intended for use indoors where the atmosphere is relatively clean, dry, and non-corrosive. Recommended a minimum clearance of ½ the shaft height between vent openings and the nearest obstruction. 3.2.3 VERTICAL MOUNTING: CAUTION: 3.1.3.2 TOTALLY ENCLOSED MOTORS are suitable for ENCLOSURE PROTECTION CAUTION: Most Dripproof rigid base (footed) motors do NOT meet “Dripproof” requirements when mounted vertically. If the motor is located in unprotected environments, the addition of a drip cover may be available. Drip covers not available for cast iron rigid base motors. indoor or outdoor standard service applications. TEAO or AOM (Totally Enclosed Air Over) motors must be mounted in the air stream. When the motor nameplate states a minimum airflow the motor must be mounted in an air stream meeting this minimum value. WARNING: FALLING OBJECT HAZARD The lifting provision on standard horizontal footed motors is not designed for lifting the motor in a vertical shaft up or shaft down position. (see 2.2.1 lifting angles). Lifting method / provisions for mounting a rigid base (footed) motor vertically is the responsibility of the installer. VERTICAL SHAFT DOWN: Most standard horizontal motors thru 449 Fr. (excluding brake motors) can be mounted in a vertical shaft down orientation. For vertical brake motors see section 3.3.6.2. VERTICAL SHAFT UP: WARNING: HAZARDOUS LOCATIONS VERTICAL MOUNT: Hazardous locations motors must NOT be mounted vertically shaft up without approval by the motor manufacturer. Without proper retaining provisions the rotor may move axially and contact components, creating a spark hazard. Belted or Radial Load when mounted vertically: The following frame sizes / constructions with applied (axial) down loads within the limit stated are acceptable when mounted vertical shaft up. Table 3-1 Belted or Radial Load Applications (All speeds) Max Frame Shaft Up Applied Enclosure Construction Down Size OK 3 Load TEFC & 56 Steel Yes 25 lbs ODP Steel & Cast TEFC Yes 25 lbs 140 Iron ODP Steel Yes 25 lbs TEFC All Yes 35 lbs 180 ODP Steel Yes 35 lbs TEFC All Yes 40 lbs 210 ODP Steel Yes 40 lbs TEFC All Yes 40 lbs 250 Steel Yes 40 lbs ODP 2 Cast Iron N/A No 320 TTFC 1 N/A Cast Iron Eng models All Other Cast Iron & Yes 30 lbs TEFC Aluminum 280-320 2 ODP Cast Iron N/A No TEFC & Build Up N/A Steel ODP Only4 Build Up TEFC Cast Iron N/A Only4 360 & 2 ODP Cast Iron No N/A Up TEFC & Build Up N/A Steel 4 ODP Only Notes: 1 For TEFC model numbers beginning with 324TTFC or 326TTFC consult the motor manufacturer to determine if a build up motor is required. 2 The max applied down load is any applied load external to the motor, including such things as sheave weight, fan loads, axial belt force, pump load, etc. If the application is direct drive with no applied radial load, consult the motor manufacturer. 3 ”Build-up only”, refers to motors that are specifically ordered and built for shaft up applications. It does not imply that all buildup motors are suitable for shaft up applications. 3.3 APPLICATION ASSEMBLY TO MOTOR: CAUTION: EQUIPMENT DAMAGE: Do not connect or couple motor to load until correct rotational direction is established. 3.3.1 GENERAL: PROPER ALIGNMENT of the motor and driven equipment minimizes vibration levels, maximizes bearing life, and extends the overall life of the machinery. Consult the drive or equipment manufacturer for more information. CAUTION: BEARING FAILURE During assembly do NOT force components onto the shaft. Striking or hammering the component may result in bearing damage. 3.3.2 DIRECT COUPLING: Use flexible couplings if possible. For applications that apply radial, axial or moment loading on the motor shaft see section 3.3.3. CAUTION: BEARING FAILURE Unless approved by the motor manufacturer do NOT direct couple a vertical shaft up or roller bearing motor. Direct coupling a vertical shaft up motor or a motor with a roller bearing may result in bearing damage. 3.3.3 DIRECT CONNECTED: Radial loading for direct connected equipment (gears, fans etc.) must be approved by the motor manufacturer unless within the maximum overhung load limits (Table 3-2). Combined loading (axial, radial and/or moments) must be approved by motor manufacturer. For belted loads see section 3.3.4. Table 3-2 Maximum Radial Load (lbf) @ Middle of the Shaft Extension Length Motor Rated RPM Frame Number 3600 1800 1200 900 143T 106 166 193 210 145T 109 170 199 218 182T 187 230 261 287 184T 193 237 273 301 213T 319 317 470 510 215T 327 320 480 533 254T 500 631 729 793 256T 510 631 736 820 284T - 866 990 1100 286T - 871 1005 1107 324T - 950 1100 1215 326T - 950 1113 1230 364T - 1078 1365 1515 365T - 1078 1380 1540 404T - 1388 1590 1762 405T - 1400 1610 1780 444T - 1580 1795 2005 445T - 1520 1795 1985 447T - 1455 1765 1985 449T - 1640 1885 2130 Values based on 26,280 hrs B-10 Life For “End of Shaft” Load multiply value by 0.88 To convert from lbf to N multiply value by 4.4482. 3.3.4 BELTED: The goal of any belted system is to efficiently transmit the required torque while minimizing the loads on the bearings and shafts of the motor and driven equipment. This can be accomplished by following four basic guidelines: 1. Use the largest practical sheave diameter. 2. Use the fewest number of belts possible. 3. Keep sheaves as close as possible to support bearings. 4. Tension the belts to the lowest tension that will still transmit the required torque without slipping. It is normal for V-belts to squeal initially when line starting a motor 3.3.4.1 Sheave Diameter Guidelines: In general, smaller sheaves produce greater shaft stress and shaft deflection due to increased belt tension. See Table 3-3 for recommended minimum sheave diameters. Using larger sheaves increases the contact with belts which reduces the number of belts required. It also increases the belt speed, resulting in higher system efficiencies. When selecting sheaves, do not exceed the manufacturer's recommended maximum belt speed, typically 6,500 feet per minute for cast iron sheaves. Determine belt speed by the following formula: Figure 1 3.3.4.4 Belt Tension CAUTION: Equipment Failure Caution Belt tensioning by feel is NOT acceptable. Tensioning by "feel" can be very misleading, and can damage motor and equipment. It is normal for V-belts to squeal initially when line starting a motor. In general, belt tensions should be kept as loose as possible while still transmitting the required torque without slipping. Belt tensions must be measured with a belt tension gage. These inexpensive gages may be obtained through belt manufacturers, or distributors. BELT SPEED (Ft/min) = Shaft RPM x 3.14 x Sheave Dia ( inches ) 12 3.3.4.2 Number of Belts In general, use the fewest number of belts that will transmit the required torque without slipping. See Table 3-3 for recommended maximum number of belts. Each belt adds to the tension in the system, which increases load on the shafts and bearings. Belts are most efficient when operated at or near their rated horsepower. If the sheaves have more grooves than the number of belts required, use the grooves closest to the motor. 3.3.4.3 Sheave Location Install sheaves as close to the housing as possible to increase the bearing life of the motor and driven equipment Figure 2 Proper belt tension is determined by measuring the force required to deflect the center of the belt a given distance. The proper deflection (in inches) is determined by dividing the belt span in inches by 64. Calculate the proper deflection and then see Table 3-3 for the required “Deflected Force” to achieve that deflection. After tensioning the belt, rotate the sheaves for several rotations or operate the system for a few minutes to seat belts into the grooves, then re-tension the belts. New belts will stretch during use, and should be retensioned after the first eight hours of use. Table 3-3 Motor Hp Recommended Min Sheave Dia (in) Minimum 1200 rpm Max # Belt of Type Belts 3VX 1 3VX 1 3VX 2 3VX 3 3VX 2 3VX 3 3VX 4 3VX 4 3VX 5 3VX 6 3VX 7 3VX 7 5VX 4 5VX 4 5VX 5 5VX 5 5VX 6 5V 7 5V 7 5V 8 8V 6 8V 7 8V 7 8V 8 8V 8 8V 9 Sheave Avg. Deflected Force (lbs) 3.4 4.0 3.1 2.8 3.3 4.0 4.7 5.4 5.4 6.0 5.6 5.9 11.6 14.6 14.1 14.5 16.0 14.1 15.4 16.0 27.6 27.1 30.3 29.1 31.6 30.7 Diameters, Min Sheave Dia (in) Belt Type, 1800 rpm Max # Belt of Type Belts 3VX 1 3VX 1 3VX 2 3VX 2 3VX 3 3VX 3 3VX 4 3VX 4 3VX 4 3VX 6 3VX 7 3VX 7 3VX 7 3VX 8 5VX 4 5VX 4 5VX 6 5V 6 5V 7 5V 8 5V 9 5V/8V 11 / 7 5V/8V 12 / 7 5V/8V 13 / 8 5V/8V 14 / 9 5V/8V 15 / 9 8V 11 8V 12 8V 13 Number Avg. Deflected Force (lbs) 2.2 3.1 2.1 2.9 2.9 3.7 4.1 4.3 5.4 4.8 5.2 5.3 6.0 5.9 13.3 14.3 13 13.1 13.4 13.1 13.8 23.4 26.0 25.7 25.2 26.9 26.3 27.3 28.2 of Belts Min Sheave Dia (in) and Deflected 3600 rpm Max # Belt of Type Belts 3VX 1 3VX 1 3VX 1 3VX 1 3VX 2 3VX 3 3VX 2 3VX 3 3VX 3 3VX 3 3VX 4 Force Avg. Deflected Force (lbs) 1.3 1.6 2.5 2.7 2.3 2.5 4.2 3.8 4.4 5.0 4.7 0.75 2.2 2.2 2.2 1 2.4 2.2 2.2 1.5 2.4 2.4 2.2 2 2.4 2.4 2.4 3 3.0 2.4 2.4 5 3.0 3.0 2.4 7.5 3.8 3.0 3.0 10 4.4 3.8 3.0 15 4.4 4.4 3.8 20 5.2 4.4 4.4 25 6.0 4.4 4.4 30 6.8 5.2 40 6.8 6.0 50 8.2 6.8 60 8.2 7.4 75 10.0 8.6 100 10.0 8.6 125 12.0 10.5 150 13.2 10.5 200 15.0 13.2 250 15.0 14.0 300 16.0 14.0 350 16.5 14.5 400 17.5 15.0 450 18 16.0 500 18.5 16.5 600 17.5 700 19.0 800 20.0 Notes: 1. Horsepower is the nameplate motor horsepower, and RPM is the motor (driver) speed. 2. Minimum sheave diameters are from NEMA standards where applicable. 3. For variable speed applications or values outside these recommendations, consult motor manufacturer. 4. Selections are based on a 1.4 service factor, 5 to 1 speed ratio and various Power Transmission Manufacturers’ catalogs. 5. These selections are for Narrow V-belt sections only. Consult manufacturer for details on conventional V-belt sections (A, B, C, D and E), or other belt types. 6. “Average Deflected Force is per section 3.3.4.4 of this document and is the force required to deflect the center of a belt 1/64 of the belt span distance. Tolerance on this force is ±1 lbf for forces ≤10 lbs, and ±2 lbs for forces >10 lbs as measured utilizing a belt tension gage. 7. When more than one belt is required the belts must be a matched set (matched for length). 8. If possible, the lower side of the belt should be the driving side to increase the length of wrap on the sheave). 9. For belted loads do not exceed 125% of 60 Hz operating RPM. Contact Motor Manufacturer when Belting 3600 rpm Motors Greater than 25 HP _________________________________________________________________________________________________________________________ 3.3.5 VFD (Variable Frequency Drives) OPERATION: WARNING: VFD Motors with Reset Thermal Protectors UL Recognition, UL Listing, or CSA certification does not apply to motors that are equipped with a manual or automatic reset thermal protector when the motor is operated on VFD power. WARNING: Power Factor Correction Capacitors: Power factor correction capacitors should never be installed between the drive and the motor. CAUTION: VFD / Motor Setup: It is the responsibility of the startup personnel during set up of the VFD / motor system to properly tune the drive to the motor for the specific application per the VFD user manual. The correct voltage boost and volts per hertz settings are application dependent and unique to each motor design. Failure to connect over temperature devices (when provided) will void the warranty. 3.3.5.1 Overspeed Capability: Belted loads: Do not exceed 125% of 60 Hz operating RPM. Table 3-4 Maximum Safe Continuous Speed (RPM) For Coupled and Direct Connected Loads NEMA / [IEC] Frame Size 2-Pole 4, 6, or 8 Pole 7200 * 5400 * 210-250 [130-160] 5400 * 4200* 280 [180] 5400 * 3600 320 [200] 4500 * 3600 360 [225] 4500 * 2700 3600 2700 56-180 [80-110] 400-440 [250-280] >440 [>280] 3600 1800 * = Fan cooled motors (Totally Enclosed & Hazardous Locations Motors) are limited to a maximum safe continuous speed of 4000 RPM For higher speeds or shortened duty cycle contact motor manufacturer 3.3.5.2 Cable Lengths: For optimum insulation life, limit VFD to motor cable lengths of general purpose motors to Table 3-5 values. Definite purpose VFD motors may accommodate longer cable lengths. For additional information contact motor manufacturer. Table 3-5 Max Cable Lengths General Purpose Motors These values are based on 3 kHz carrier frequency. Add suitable VFD output-side filters when exceeding the listed values. Frame Size 230V 460 V 575 V NEMA 56-320 600 ft. 125 ft. 40 ft. NEMA 360-5011 1000 ft. 225 ft. 60 ft. IEC 80-200 180 m. 40 m. 12 m. IEC 225-280. 300 m. 70 m. 18 m. General Information: When thermal protection is provided, one of the following will be stamped on the nameplate: 1. “THERMALLY PROTECTED” This motor has built in thermal protection. Thermal protectors open the motor circuit electrically when the motor overheats or is overloaded. The protector cannot be reset until the motor cools. If the protector is automatic, it will reset itself. If the protector is manual, disconnect motor from power supply. After protector cools (five minutes or more) press the reset button and reapply power to the motor. In some cases a motor is marked “Auto” and the connection diagram on the motor will identify T’Stat leads – see “2 ” below. (See warnings on Manual and Automatic reset protectors - section 1.1) 2. “WITH OVERHEAT PROTECTIVE DEVICE”: This motor is 3.3.5.3 VFD Grounding: Equipment grounding conductors may be run in the same conduit as the AC motor power leads. This wire must be used as the equipment ground for the motor and not as the fourth current carrying wire of a “WYE” motor circuit. The grounded metal conduit carrying the output power conductors can provide EMI shielding, but the conduit does not provide an adequate ground for the motor; a separate grounding conductor must be used. Grounding the motor neutral (WYE) of a VFD powered motor may result in a VFD ground fault trip. Improper grounding of an inverter fed motor may result in frame voltages in excess of 500 Volts. Refer to Grounding section 3.4.4 3.3.5.4 VFD – Single Phase: CAUTION: SINGLE PHASE MOTOR FAILURE: Single Phase motors are NOT suitable for use on VFD power. Connecting a Single Phase Motor to a VFD voids the warranty. 3.3.5.5 Stray Voltage on Accessory Leads: VFD’s will couple stray (common-mode) voltage to motormounted RTDs, thermistors, thermostats and space heaters. The leads of these elements must be properly insulated and control input circuits must be designed to withstand this common-mode voltage. 3.3.6 ACCESSORIES / PROVISIONS: 3.3.6.1 General: Carefully read and understand the accessory manufacturer’s instructions, supplied with motor. Contact the manufacturer for additional information. 3.3.6.2 Brake Motors: CAUTION: Vertical Motor Premature Brake Failure Motors with brakes that are designed for vertical applications are equipped with springs to support the brake pressure plate. Mounting a horizontal brake motor vertically shaft up or down may require a pressure plate spring modification. Failure to modify the brake for the vertical application may result in premature brake failure. If in question, consult brake literature or brake manufacturer. Brake Solenoid Wiring: Do NOT connect the brake solenoid to the output of a VFD. The brake solenoids must be wired to 50/60 Hz line power 3.3.6.3 Space Heaters: Motors provided with space heaters have two leads that are brought into the conduit box or into an auxiliary box. These leads are marked ”H1”, “H2” (”H3”, “H4” if a second space heater is supplied). See the space heater nameplate on motor for heater rating. WARNING: DIVISION 2 EXPLOSION HAZARD The space heater temperature rating when used in Class I, Division 2 motors shall NOT exceed 80% of the auto ignition temperature of the hazardous gas or vapor. See the space heater nameplate on motor for heater Temperature Code and heater rating. Failure to follow this instruction could result in serious personal injury, death and/or property damage 3.3.6.4 Thermal Protection: provided with an overheat protective device that does not directly open the motor circuit. Motors nameplated with this phrase have either thermostats, thermisters or RTD’s. The leads to these devices are routed into the motor conduit box or into an auxiliary box. The lead markings are defined on the nameplate (normally “P1”, “P2”) . The circuit controlled by the overheat protection device must be limited to a maximum of 600 volts and 360 volt-amps. See connection decal provided inside the terminal box cover. Failure to connect these over temperature devices (when provided) will void the warranty. WARNING: EXPLOSION HAZARD For Hazardous Locations motors provided with thermostats UL and the NEC require connection of thermostat leads into the control portion of a manual reset start circuit. Failure to follow this instruction could result in serious personal injury, death and/or property damage Resistance Temperature Detectors (RTD): When winding and/or bearing RTDs are provided the RTD lead markings are defined on the nameplate. (Normally “R1”, “R2”, “R3” etc.) 3.3.6.5 RTD Alarm & Trip Settings: Tables 3-6 & 3-7 are suggested initial RTD alarm and trip settings. For motors found to operate significantly below these values the settings may be reduced accordingly. Table 3-6 Winding RTD – Temperature Limit (C) 40 C Max Ambient Motor Load Class B Temp Rise≤ ≤ 80C Class F Temp Rise≤ ≤ 105C Alarm Trip Alarm Trip Up to 1.0 SF 130 140 155 165 >1.0 to 1.15 SF 140 150 160 165 Table 3-7 Bearing RTD – Temperature Limit (C) 40 C Max Ambient Alarm Trip Ambient Up to 40C 95 100 > 40C Bearings that are Heat Stabilized to 150 C 110 115 130 135 3.3.7 GUARDS: WARNING: ROTATING PARTS HAZARD When devices are assembled to the motor shaft, be sure to install protective devices such as belt guards, chain guards, and shaft covers. These devices must protect against accidental contact with extremities, hair, and clothing. Consider the application and provide guarding to protect personnel. Remove all unused shaft keys and loose rotating parts to prevent them from flying off and causing bodily injury. Failure to follow this warning could result in serious personal injury, death and/or property damage. 3.4 ELECTRICAL CONNECTIONS: WARNING: ELECTRICAL HAZARDS Before proceeding read Section 1-1 on Electrical Safety. Failure to follow the instructions in Section 1-1 could result in serious personal injury, death and/or property damage 3.4.1 POWER SUPPLY / BRANCH CIRCUIT WARNING: POWER SUPPLY INCOMPATIBILITY HAZARD Check power supply to make certain that voltage, frequency and current carrying capacity are in accordance with the motor nameplate. Failure to match motor nameplate values could result in serious personal injury, death and/or property damage WARNING: BRANCH CIRCUIT SUPPLY HAZARD Motor and control wiring, fusing, overload protection, disconnects, accessories and grounding must always conform to the applicable electrical codes as well as local codes and sound practices. 3.4.1.1 Branch Circuit Supply to a motor should include a disconnect switch, short circuit current fuse or breaker protection, motor starter (controller) and correctly sized thermal elements or overload relay protection. 3.4.1.2 Fuses, Breakers, Overload Relays Short Circuit Current Fuses or Breakers are for the protection of the branch circuit. Starter or motor controller overload relays are for the protection of the motor. Each of these should be properly sized and installed per the applicable electrical codes as well as local codes and practices. WARNING: PROTECTIVE DEVICE DISABLED HAZARD DO NOT bypass or disable protective devices. Protection removal could result in serious personal injury, death and/or property damage 3.4.1.3 AC Power Supply Limits Motors are designed to operate within the following limits at the motor terminals: 1- AC power is within +/- 10 % of rated voltage with rated frequency applied. (Verify with nameplate ratings) OR 2- AC power is within +/- 5% of rated frequency with rated voltage OR 3- A combined variation in voltage and frequency of +/- 10% (sum of absolute values) of rated values, provided the frequency variation does not exceed +/-5% of rated frequency. 4- For 3 phase motors the line to line full load voltage must be balanced within 1%. 5If the motor is rated 208-230V, the voltage deviations must be calculated from 230V. CAUTION: Reduced Motor Performance Operation outside of these limits will degrade motor performance and increase operating temperature. 3.4.2 TERMINAL BOX: 3.4.2.1 Conduit Opening: For ease of connections, motors are typically provided with large terminal boxes. Most motors have conduit access in 90 degree increments, the terminal box conduit opening is typically provided via knockouts, holes with covers, or the terminal box is rotate-able. Fabricated conduit boxes may have a removable plate for the installer to provide correctly sized hole(s). 3.4.2.2 Hazardous Locations Motors: WARNING: EXPLOSION HAZARDS (1) Terminal Boxes mounted to motor with a pipe nipple: If a pipe nipple mounted terminal box is removed or rotated it must be reassembled with a minimum of five full threads of engagement. (2) Component Removal: Do not set a terminal box component on its machined surfaces. Prior to component reassembly wipe clean all machined surfaces. (3) Machined Surface Gap (Hazardous Locations Terminal Boxes): The gap between mating surfaces with the machined terminal box MUST BE LESS THAN 0.002 inches. This gap must be checked with a feeler gage along the entire perimeter. If there is visible damage to the mating surfaces, or if the gap between these surfaces exceeds 0.002 inches, DO NOT complete the installation and contact the motor manufacturer. Failure to follow these instructions could result in serious personal injury, death and/or property damage 3.4.3 LEAD CONNECTIONS Electrical connections to be made per nameplate connection diagram or separate connection plate. In making connections follow the applicable electrical code as well as local codes and practices. WARNING: ELECTRICAL CONNECTION HAZARD Failure to correctly connect the motor leads and grounding conductor can result in injury or death. Motor lead connections can short and cause damage or injury if not well secured and insulated. 3.4.3.1 Wire Size (Single Phase) Requirements The minimum wire size for Single Phase, 115 & 230 Volt Circuits must meet table 3-8 for a given distance between motor and either Fuse or Meter Box. Table 3-8 Minimum Wire Gage Size Single Phase 115 & 230 Volt Circuits Distance (Feet) - Motor to Fuse or Meter Box Motor HP 1/4 1/3 1/2 3/4 1 1 1/2 2 3 5 100 Ft. 200 Ft. 300 Ft. 500 Ft. 115 230 115 230 115 230 115 230 14 12 10 10 8 4 14 14 12 12 10 10 8 8 6 10 10 8 6 6 0 12 12 10 10 8 8 6 6 4 8 6 6 4 4 10 10 8 8 6 6 4 4 2 6 4 4 2 8 8 6 6 4 4 2 2 0 3.4.3.2 Extension Cords (Single Phase Motors): Where an extension cord(s) is utilized to provide power to the motor the extension cord(s) must be…(1) the proper gauge size per table 3-8, (2) in good working condition (3) properly grounded. 3.4.4 GROUND CONNECTION(S): WARNING: ELECTRICAL GROUNDING HAZARD For general information on grounding (USA) refer to NEC Article 250. Improper grounding of an inverter fed motor may result in frame voltages in excess of 500 Volts. In making the ground connection, the installer must make certain that a good electrical connection is obtained between motor and grounding lead. Failure to properly ground motors, per the applicable national code (such as NEC Article 430) and local codes may cause serious injury or death to personnel. Primary “Internal” Ground: A grounding conductor must be connected to the grounding terminal provided in the terminal housing. This grounding terminal is either a ground screw, ground lug, or a tapped hole to be used with a separately provided ground screw. The internal grounding feature is accessible inside the terminal housing and must be used as the primary grounding connection. Secondary “External” Ground: Some motors are provided with a supplemental grounding terminal located on the external surface of the motor frame or feet. This external terminal is for supplemental bonding connections where local codes permit or require such connection 3.4.5 START UP: WARNING: ELECTRICAL SHOCK HAZARD: Be certain that all connections are secure and the conduit box cover is fastened in place before electrical power is connected. Failure to follow these instructions could result in serious personal injury, death, and/or property damage. WARNING: LOOSE & ROTATING PARTS HAZARD Before proceeding read Section 1-2 on Mechanical Safety. Failure to follow the instructions in Section 1-2 could result in serious personal injury, death and/or property damage WARNING: EXCESSIVE SURFACE TEMPERATURE HAZARD Motors with the temperature code stated on the nameplate are designed to operate within this limit. Improper application or operation can cause the maximum surface temperature to be exceeded. A motor operated in a Hazardous Location that exceeds this surface temperature limit increases the potential of igniting hazardous materials. Therefore, motor selection, installation, operation, and maintenance must be carefully considered to ensure against the following conditions: (1) Motor load exceeds service factor value, (2) Ambient temperature above nameplate value, (3) Voltages outside of limits (3.4.1.3), (4) Loss of proper ventilation, (5) VFD operation exceeding motor nameplate rating, (6) Altitude above 3300 feet / 1000 meters, (7) Severe duty cycles, (8) Repeated starts, (9) Motor stall, (10) Motor reversing, and (10) Single phase operation. Failure to follow these instructions could result in serious personal injury, death and/or property damage. CAUTION: HOT SURFACE Normal motor surface temperatures may exceed 90 ° C (194° F). Touching the motor frame may cause discomfort or injury. Surface temperatures should only be measured with suitable instruments and not estimated by hand touch. 3.4.5.1 Start Up - No Load Procedure 1. Check Instructions: Before startup carefully read and fully understand these instructions including all warnings, cautions, and safety notice statements. 2. Motor out of storage after more than three months: Check winding insulation integrity with a Megger. If winding resistance to ground is less than 1.5 Meg-ohms consult the local authorized service shop before energizing the motor. 3. Check Installation: Mechanical - Check tightness of all bolts and nuts. Manually rotate the motor shaft to ensure motor shaft rotates freely. Note: Shaft & bearing seals will add drag. Electrical - Inspect all electrical connections for proper terminations, clearance, mechanical tightness and electrical continuity. Be sure to verify connections are made per the nameplate connection diagram or separate connection plate. Replace all panels and covers that were removed during installation before energizing the motor. 4. Energize Motor: Check Rotation If practical check motor rotation before coupling to the load. Unlock the electrical system. Momentarily provide power to motor to verify direction of rotation. If opposite rotation is required, lock out power before reconnecting motor. If motor has a rotational arrow only operate the motor in the rotation identified. Reapply power to ensure proper operation. 5. Record No Load Amps, Watts & Voltage: Recommend - To establish a baseline value check and record the no load amps, watts, and voltage. 3.4.5.2 Start Up – Load Connected Procedure 1. Check Instructions: Before startup carefully read and fully understand these instructions including all warnings, cautions, & safety notice statements. 2. Coupling Installation: Check that the connected equipment is properly aligned and not binding. Check that all guards and protective devices are properly installed. 3. Energize Motor: When all personnel are clear of the machine, apply power and verify that the load is not transmitting excessive vibration back to the motor though the shaft or the foundation. Verify that motor amps are within nameplate rating. For repeated starts see 3.4.5.3. The equipment can now be fully loaded and operated within specified limits as stated on the nameplate. 3.4.5.3 Jogging and/or Repeated Starts Do not start more than twice in succession under full load. Repeated starts and/or jogs of induction motors can cause overheating and immediate failure. Contact the motor manufacturer if it is necessary to repeatedly start or jog the motor. 4.0 MAINTENANCE: WARNING: Hazardous Locations Motor Repair HAZARD: Division 1 Hazardous Locations motors can only be modified or repaired by the manufacturer or a facility that is Listed under UL’s category “Motors and Generators, Rebuilt for use in Hazardous Locations”. Failure to follow these instructions could result in serious personal injury, death and/or property damage. WARNING: ELECTRICAL SHOCK HAZARD Electrical connections are to be made by qualified electrical personnel in accordance with all applicable codes, ordinances and sound practices. Failure to follow these instructions could result in serious personal injury, death and/or property damage. Only qualified personnel who are familiar with the applicable national codes, local codes and sound practices should install or repair electric motors and their accessories. WARNING: ELECTRICAL LIVE CIRCUIT HAZARD Do not touch electrically live parts. Disconnect, lockout and tag input power supply before installing or servicing motor (includes accessory devices). 4.1 GENERAL INSPECTION Inspect the motor approximately every 500 hours of operation or every three months, whichever occurs first. Keep the motor clean and the ventilation and fin openings clear. The following steps should be performed at each inspection: 4.1.1 VENTILATION: Check that the ventilation openings and/or exterior of the motor is free of dirt, oil, grease, water, etc, which can accumulate and block motor ventilation. If the motor is not properly ventilated, overheating can occur and cause early motor failure. 4.1.2 INSULATION: Use a “Megger” periodically to ensure that the integrity of the winding insulation has been maintained. Record the Megger readings. If winding resistance to ground is less than 1.5 Meg-ohms consult the local authorized service shop before reenergizing the motor. 4.1.3 ELECTRICAL CONNECTIONS: Check all electrical connectors to be sure that they are tight. 4.2 LUBRICATION & BEARINGS: The lubricating ability of grease (over time) depends primarily on the type of grease, the size of the bearing, the speed at which the bearing operates and the severity of the operating conditions. Longer bearing life can be obtained if the listed recommendations are followed: NOTE: If lubrication instructions are provided on the motor nameplate, the nameplate instructions will supersede these instructions. Motors marked “Permanently Lubricated” do not require additional service. CAUTION: BEARING / MOTOR DAMAGE WARNING Lubricant should be added at a steady moderate pressure. If added under heavy pressure bearing shield(s) may collapse. Over greasing bearings greatly increases bearing friction and can cause premature bearing and/or motor failure. 4.2.1 GREASE TYPE (unless nameplate states otherwise): Nameplate Ambient Temperature between -30°C (-22°F) to 65°C (150°F) inclusive: Recommended grease for standard service conditions is Mobil Polyrex ® EM. Equivalent and compatible greases include: Texaco Polystar RB, Rykon Premium #2, Pennzoil Pen 2 Lube, Chevron SRI & Mobil SHC 100. Nameplate Ambient Temperature below -30°C (-22°F): Special low temperature grease is recommended, such as Aeroshell 7 or Beacon 325 for ball bearings and Mobil SHC 100 for roller bearings. Nameplate Ambient Temperature above 65°C (150°F): Dow Corning DC44 or equivalent, a special high temperature grease is required. Note that Dow Corning DC44 grease does not mix with other grease types. For RTD settings see Table 3-7. 4.2.2 BEARING OPERATING TEMPERATURE: CAUTION: HOT SURFACE The external surface temperature of the end shield (bracket) bearing hub may reach 100° C (212° F) during normal operation. Touching this surface may cause discomfort or injury. Surface temperatures should only be measured with suitable instruments and not estimated by hand touch. _________________________________________________________________________________________________________________________ 4.2.3 LUBRICATION INTERVALS: (For motors with regreasing provisions) Eq. 4.2 Lubrication Interval = [(Table 4-1) hrs] x [Interval Multiplier (Table 4-2)] x [Construction Multiplier (Table 4-3)] Table 4-1 Lubrication Intervals (Hours) These values are based on average use. Operating Speed – RPM (See Table 3.4 for Maximum Operating Speed) NEMA / [IEC] Frame Size <7200 <5400 <4500 <3600 <1800 <1200 56-180 [80-110] 2500 Hrs. 210-250 [130-160] 4000 Hrs 5000 Hrs 6000 Hrs. 17000 Hrs. 20000 Hrs. 2500 Hrs 4000 Hrs 5000 Hrs. 12000 Hrs. 16000 Hrs. 2000 Hrs 3000 Hrs 4000 Hrs. 10000 Hrs. 14000 Hrs. 280 [180] 320 [200] 2000 Hrs 3000 Hrs. 9000 Hrs. 12000 Hrs. 360 [225] 1500 Hrs 2000 Hrs. 8000 Hrs. 10000 Hrs. 1500 Hrs. 1000 Hrs. 4000 Hrs. 3000 Hrs. 7000 Hrs. 5000 Hrs. 400-440 [250 – 280] >440 [>280] Seasonal Service: If motor remains idle for more than six months, Lubricate at the beginning of the season, then follow lubrication interval. Do not exceed maximum safe operating speed Table 3-4 without manufacturer’s approval Table 4-2 Service Conditions Use highest level Multiplier: Maximum Ambient Temperature and Contamination are independent factors Severity of Service Maximum Ambient Temperature Atmospheric Contamination Standard Less than 40° C (104° F) Clean, Slight Corrosion, indoors, less than 16 hrs per day Severe Above 40° C (104° F) to 50° C Moderate dirt or Corrosion or outdoors or more than 16 hrs per day 0.5 Extreme Greater than 50° C or Class H Insulation Severe dirt or Abrasive dust or Corrosion 0.2 Multiplier 1.0 ________________________________________________________________________________________________________________________ Table 4-3 Construction Multiplier Construction Angular Contact or Roller Bearing Multiplier 0.5 Vertical Motor 0.5 All others 1.0 Table 4-4 Relubrication Amounts Frame Size Volume NEMA 48-56 143-145 182-184 213-215 254-256 284-286 324-326 364-365 404-405 444-449 >449 IEC 80 90 110 130 160 180 200 225 250 280 >280 Cu. In. 0.25 0.25 0.50 0.75 1.00 1.50 2.00 3.00 3.80 4.10 4.50 Fluid oz 0.14 0.14 0.28 0.42 0.55 0.83 1.11 1.66 2.11 2.27 2.50 ml 4.0 4.0 8.0 12.5 16.0 25.0 33.0 50.0 62.0 67.0 74.0 For regreasing while operating multiply volume by 125%. ________________________________________________________________________________________________________________________ 1. 2. 4.2.4 LUBRICATION PROCEDURE: 3. 4. (For Motors with Regreasing Provisions) Table 4-1 list 10,000 hours for standard conditions. Table 4-2 classifies severity of service as “Severe” with a multiplier of 0.5. Table 4-3 lists a multiplier value of 0.5 for “Vertical” (Eq. 4.2) Interval = 10,000 hrs x 0.5 x 0.5 = 2500 hrs 3 CAUTION: BEARING DAMAGE WARNING Added grease must be compatible with the original equipment’s grease. If a grease other than those stated in 4.2.1 is to be utilized contact the motor manufacturer. Nameplate information supersedes section 4.2.1 (GREASE TYPE). New grease must be free of dirt. Failure to follow these instructions and procedure below may result in bearing and/or motor damage. For an extremely dirty environment, manufacturer for additional information. contact the motor LUBRICATION PROCEDURE: 1. Clean the grease inlet plug or zerk fittings prior to regreasing. 2. (If present) Remove grease drain plug and clear outlet hole blockage. CAUTION: GREASE DRAIN PLUGGED: Old grease may completely block the drain opening and must be mechanically removed prior to regreasing. Forcing a blocked drain open by increased greasing pressure may collapse bearing shields and / or force excess grease through the bearings and into the motor. 3. Add grease per Table 4-4 4. Re-install grease inlet and drain plugs (if removed). WARNING: EXPLOSION HAZARD Do NOT energize a Hazardous Locations motor without all grease fittings properly installed. 4.2.5 EXAMPLE: LUBRICATION Assume - NEMA 286T (IEC 180), 1750 RPM Vertical motor driving an exhaust fan in an ambient temperature of 43° C and the atmosphere is moderately corrosive. Table 4-4 shows that 1.5 in of grease is to be added. 3 Relubricate every 2,500 hrs of service with 1.5 in of recommended grease. 4.3 TROUBLE-SHOOTING WARNING: READ INSTRUCTIONS: Before trouble-shooting a motor, carefully read and fully understand the warnings, cautions, & safety notice statements in this manual. WARNING: Hazardous Locations Motor Repair: Motors nameplated for use in Division 1 Hazardous Locations can only be disassembled, modified or repaired by the plant of manufacturer or a facility that is Listed under UL’s category “Motors and Generators, Rebuilt for use in Hazardous Locations”. Failure to follow these instructions could result in serious personal injury, death and/or property damage CAUTION: DISASSEMBLY APPROVAL REQUIRED: Motor disassembly must be performed by a party approved by the motor manufacturer. To disassemble the motor without approval voids the warranty. 4.3.1 GENERAL TROUBLE-SHOOTING WARNINGS 1. 2. 3. 4. 5. DISCONNECT POWER TO THE MOTOR BEFORE PERFORMING SERVICE OR MAINTENANCE. Discharge all capacitors before servicing motor. Always keep hands and clothing away from moving parts. Be sure required safety guards are in place before starting equipment. If the problem persists contact the manufacturer. 4.3.2 Motor Trouble-shooting Cause / Corrective Action - Table 4-5 Issue: Likely Cause: Corrective Action: Motor fails to start upon initial installation: B.) Supply voltage is too low or is severely unbalanced (one (1) Check power supply fuses (2) Match motor lead wiring to nameplate connection diagram and supply voltage (3) Ensure that steady state supply voltage at motor terminals is within limits (see section 3.4.1.3). Correct as needed (4) Obtain correct Motor leads are miswired at conduit box. motor to match actual supply voltage. C.) Driven load exceeds motor capacity A.) phase is low or missing). D.) Load is jammed. (1) Verify that motor & load turn freely (2) Disconnect motor from load & ensure motor turns freely. Note: Roller bearings make noise when motor is uncoupled and shaft is rotated (3) Verify that motor starts when disconnected from load (4) Remove excessive / binding load if present. E.) Fan guard is bent and making contact with fan Replace fan guard & fan (if blades are damaged) F.) Remove power factor correction capacitors if equipped VFD with power factor capacitors installed G.) VFD with motor neutral lead grounded Ensure that motor neutral lead is ungrounded H.) VFD programmed incorrectly (1) Repeat checks listed above (2) Verify that VFD current limit and starting boost are set correctly (5) Double-check motor and feedback parameter settings and VFD permissives (6) Repeat autotune (for vector drives) procedure (7) Consult VFD supplier. Motor has been running, then slow down, stalls, or fails to restart: A.) (1) Replace fuse or reset circuit breaker. Allow motor to cool down before resetting manual protector on motor. Warnings - See section 1.1 for automatic and manual Supply voltage has drooped or has become severely reset protector warnings (2) Verify that rated and balanced supply voltage has unbalanced been restored before restarting motor. Measure voltage during restart. Ensure that steady state supply voltage at motor terminals is within limits (see section 3.4.1.3). B.) Motor is overloaded C.) Motor bearings are seized D.) Load Is jammed. (1) Verify that motor & load turn freely. Repair binding components as needed (2) Reduce driven load to match motor capacity or increase motor size to match load requirements. E.) VFD will not restart motor after tripping (1) Check fault codes on VFD and follow VFD troubleshooting procedures (2) Verify that VFD input voltage is balanced and within limits (3) Remove excessive mechanical load if present. F.) Capacitor failure on single phase motor (if equipped) Warning: Potential Shock Hazard: Contact service shop to check capacitor. Motor takes too long to accelerate: A.) Motor leads are not connected correctly Match motor lead wiring to nameplate diagram. C.) Load exceeds motor capability (1) Ensure that steady state supply voltage at motor terminals is within limits (see section 3.4.1.3). Correct as needed (2) Obtain correct motor to match actual supply voltage. Determine correct motor size and contact motor representative to obtain replacement motor. D.) Faulty start capacitor (Single Phase) Motor may be too small for load. Record acceleration time. Start capacitors may fail if acceleration time exceeds 3 seconds. E.) Mechanical Failure (1) Check to make sure motor & load turn freely (2) Disconnect motor from load & ensure motor turns freely Supply voltage has drooped or become severely B.) unbalanced. Motor rotates in the wrong direction: A.) Incorrect wiring connection at motor [Single Phase] Reconnect motor according to wiring schematic provided. Some motors are non-reversible Note: [Three Phase] Interchange any two power supply (phase) leads. Motor overheats or overload protector repeatedly trips A.) Driven Load is excessive (1) If motor current exceeds nameplate value, ensure that driven load has not increased. Correct as needed. (2) If new motor is a replacement, verify that the rating is the same as the old motor. If previous motor was a special design, a general purpose motor may not have the correct performance. B.) Ambient temperature too high Most motors are designed to operate in an ambient up to 40 C. (See section 4.2.2 Hot Surface Caution) C.) Motor cooling fins and/or vent openings blocked Remove foreign materials – clear vent openings, fan guard air inlets and frame fins (TEFC motors) D.) Insufficient Air Flow TEAO (Totally Enclosed Air Over) motors: Measure airflow next to motor surface and obtain minimum requirements from motor manufacturer. E.) Motor is started too frequently See section 3.4.5.3 F.) Supply voltage too low, too high, or unbalanced (1) Ensure that steady state supply voltage at motor terminals is within limits (see section 3.4.1.3) Correct as needed (2) Reconnect motor per input voltage (3) Obtain correct motor to match power supply. Motor Vibrates A.) Motor misaligned to load. Realign load B.) Load out of balance (Direct drive application) (1) Ensure that load is dynamically balanced: (2) Remove motor from load and inspect motor by itself. Verify that motor shaft is not bent. Rule of thumb is 0.002” runout for shafts extension lengths up to 3.00”. Add 0.0005” per every additional inch of shaft length beyond 3.00”. C.) Uneven tension on multiple belts Mixing new with used belts. Replace multiple belt applications with a complete set of matched belts. D.) (1) De-energize motor and record vibration as load coasts from 100% speed to 0 RPM. If vibration drops immediately, vibration source is electrical. If levels do not Driven load operating at resonant point / natural drop immediately, source is mechanical (2) Redesign system to operate below the frequency. resonant point (3) On VFD-driven loads, program skip frequencies to bypass resonant points (4) Increase carrier frequency to obtain <3% THD current (5) On variable torque loads reduce volts/hertz below base speed. E.) VFD torque pulsations (1) Adjust VFD to obtain <3% THD current @ rated motor current (2) Adjust VFD stability for smooth operation. Vector drives may be unstable at light load. F.) Motor miswired at terminal box Match motor lead wiring to nameplate connection diagram. G.) Uneven, weak or loose mounting support. Shim, strengthen or tighten where required. H.) Motor bearings defective Test motor by itself. If bearings are bad, you will hear noise or feel roughness. Roller bearings are normally noisy when operated without load. If sleeve bearing, add oil per nameplate instructions. For motors with regreasing provisions, add grease per relubricating instructions (see section 4.2.3). If noise persists contact warranty service. I.) Disconnect from load. Set motor on rubber pads on solid floor. Secure a ½ height key in shaft keyway and energize from balanced power supply @ rated voltage. Record vibration levels and compare with appropriate standards. If excessive vibration persists contact motor manufacturer. Motor out of balance Bearings repeatedly fail. A.) Load to motor may be excessive or unbalanced (1) If belt drive check system per section 3.3.4. (2) Other than belting, check loading on motor shaft. An unbalanced load will also cause the bearings to fail. (3) Check runouts of mating components, such as a C-face and pump flange. B.) Bearings contaminated. Motor enclosure not suitable for environment. Replace with correct enclosure construction C.) Incorrect grease or bearings for ambient extremes. See section 4.2.1 D.) VFD bearing damage Ground brush, common mode filter, or insulated bearings must be added. Contact motor manufacturer. Motor, at start up, makes a loud rubbing, grinding, or squealing noise. A.) Contact between rotating and stationary components Belt squeal during across the line starting is normal: (1) Verify that supply voltage is within limits (see section 3.4.1.3). (2) Ensure that motor lead wiring matches nameplate connection diagram: (3) Isolate motor from load. (4) To locate point of contact turn motor shaft by hand. (5) If point of contact is not located contact motor service shop. Start capacitors repeatedly fail. A.) The motor acceleration time is too long Motor may be too small for load. Record acceleration time. Start capacitors may fail if acceleration time exceeds 3 seconds. B.) Motor is being started too frequently Excessive starting will damage motor capacitors. Contact motor manufacturer if motor is started more than 20 times/hour or if acceleration time exceeds 3 seconds. C.) Motor voltage low Verify that voltage at the motor terminals is within limits (see section 3.4.1.3). D.) Defective start switch inside motor Motor internal switch failure overheats start capacitor. Contact service shop or motor manufacturer. Run capacitor fails. A.) High ambient temperature Verify that the ambient does not exceed motor’s nameplate value B.) Input voltage exceeds limit Power surge to motor (caused by lightning strike or other C.) high transient voltage). Verify that voltage to the motor terminals is within limits (see section 3.4.1.3). If a common problem, install surge protector. Document No.: PE-S-069-03-03 ® CERTIFICATE OF ORIGIN Equipment: Centrifuge Model: DE-1000™ GBD, DE-1000™ FHD, DE-1000™ VFD Characteristics: 0-600VAC, 50/60Hz, 3PH Derrick Corporation acknowledges that the above set-forth product is manufactured in the United States of America as of the data of this certificate. This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporation’s original shipment of the referenced product. Date: 29-December-2011 http://dmc-sps/qc/Certificates/Origin Standard/PE-S-069-03-03.doc Revison Number 2 Revision Date: 29-December-2011 Signature: Jennifer J. Polanowski Derrick Corporation Document No.: PE-S-073-04-00 ® SHIPPING FINAL INSPECTION AND RUN TEST CERTIFICATE Equipment: Centrifuges Model: DE-1000™ GBD, DE-1000™ FHD, DE-1000™ VFD, DE-7200 VFD Characteristics: 0-600VAC, 50/60Hz, 3PH The product listed above was inspected and found to be in conformance with Derrick Corporation’s internal coating, run test, and assembly inspection documents that were required for the type of equipment manufactured in accordance with the Derrick quality system. This certificate is governed by the applicable purchase order terms in effect at the time of Derrick Corporation’s original shipment of the referenced product. Date: 29-December-2011 Signature: Jennifer J. Polanowski Derrick Corporation http://dmc-sps/qc/Certificates/Shipping Final Inspection and Run Test/PE-S-073-04-00.doc Revison Number 2 Revision Date: 29-December-2011
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